Introduction to Maintenance Engineering

Preface xxxi Acknowledgments xxxv Abbreviations xxxvii 1 An Overview 1 1.1 Introduction 2 1.2 Classification of Engineered Objects 4 1.3 Performance of Engineered Objects 10 1.4 Maintenance 12 1.5 Evolution of Maintenance 15 1.6 Focus of the Book 17 1.7 Structure and Outline of the Book 18 Review Questions 20 Exercises 21 References 22 Part A Maintenance Engineering and Technology 23 2 Basics of Reliability Theory 25 2.1 Introduction 26 2.2 Decomposition of an Engineered Object 26 2.3 Functions, Failures, and Faults 27 2.4 Characterization of Degradation 31 2.5 Reliability Concept and Characterization 33 2.6 Linking System and Component Failures 36 2.7 Reliability Theory 45 2.8 Summary 45 Review Questions 46 Exercises 47 References 50 3 System Degradation and Failure 51 3.1 Introduction 52 3.2 Failure Mechanisms 52 3.3 Classification of Failure Mechanisms 54 3.4 Dynamic Nature of Stress and Strength 61 3.5 Degradation of Products and Plants 62 3.6 Degradation of Infrastructures 64 Review Questions 69 Exercises 69 References 71 4 Maintenance – Basic Concepts 73 4.1 Introduction 74 4.2 Types of Maintenance Actions 74 4.3 Preventive Maintenance Actions 77 4.4 Corrective Maintenance Actions 83 4.5 Design Out Maintenance 85 4.6 Uptime and Downtime 86 4.7 Warranty and Maintenance 88 4.8 Maintenance of Products 90 4.9 Maintenance of Plants and Facilities 95 4.10 Maintenance of Infrastructures 100 4.11 Effective Maintenance 102 4.12 Summary 103 Review Questions 104 Exercises 104 References 105 5 Life Cycle of Engineered Objects 107 5.1 Introduction 108 5.2 Life Cycle Concept and Classification 108 5.3 Standard Objects 109 5.4 Custom-Built Objects 113 5.5 Reliability: Product Life Cycle Perspective 115 5.6 Life Cycle Cost 118 5.7 Summary 120 Review Questions 120 Exercises 121 References 122 6 Technologies for Maintenance 123 6.1 Introduction 124 6.2 Technology – An Overview 124 6.3 Assessing the State (Condition) of an Item 125 6.4 Sensors 129 6.5 Testing Technologies 137 6.6 Data-Related Technologies 142 6.7 Technologies for Maintenance of Products 144 6.8 Technologies for Maintenance of Plants 144 6.9 Technologies for Maintenance of Infrastructures 148 6.10 Summary 151 Review Questions 152 Exercises 153 References 154 7 Maintainability and Availability 155 7.1 Introduction 156 7.2 Maintainability – An Overview 156 7.3 Elements of Maintainability 158 7.4 Availability 161 7.5 Maintainability Process 163 7.6 Maintainability Standards 165 7.7 Relationship with Other Disciplines 166 7.8 Summary 167 Review Questions 168 Exercises 168 References 169 Part B Reliability and Maintenance Modeling 171 8 Models and the Modeling Process 173 8.1 Introduction 174 8.2 Models 174 8.3 Mathematical Modeling 178 8.4 Approaches to Modeling 182 8.5 Mathematical Modeling Process 185 8.6 Statistics versus Probability Perspectives 189 8.7 Modeling of Maintenance Decision Problems 190 8.8 Summary 191 Review Questions 191 Exercises 192 Reference 193 9 Collection and Analysis of Maintenance Data 195 9.1 Introduction 196 9.2 Data, Information, and Knowledge 196 9.3 Maintenance Data 199 9.4 Data Analysis 201 9.5 Descriptive Statistics 202 9.6 Inferential Statistics 212 9.7 Collection of Maintenance Data for Products 213 9.8 Collection of Maintenance Data for Plants 215 9.9 Collection of Maintenance Data for Infrastructures 218 9.10 Summary 220 Review Questions 221 Exercises 222 References 223 10 Modeling First Failure 225 10.1 Introduction 226 10.2 One-Dimensional Formulations 227 10.3 Two-Dimensional Formulations 230 10.4 Properties of Distribution Functions 232 10.5 Preliminary Data Analysis and Plots 236 10.6 Selection of a Mathematical Formulation 241 10.7 Parameter Estimation 242 10.8 Model Validation 246 10.9 Examples 247 10.10 Summary 253 Review Questions 254 Exercises 254 References 255 11 Modeling CM and PM Actions 257 11.1 Introduction 258 11.2 Modeling CM Actions 258 11.3 Modeling PM Actions 262 11.4 Repair Times and Downtimes 266 11.5 Maintenance Costs 269 11.6 Repair–Replace Decisions 272 11.7 Modeling Fleet and Infrastructure Maintenance 273 11.8 Summary 273 Review Questions 274 Exercises 275 References 276 12 Modeling Subsequent Failures 277 12.1 Introduction 278 12.2 System Characterization for Modeling 278 12.3 Mathematical Formulations for Modeling 280 12.4 Subsequent Failures with Only CM Actions 283 12.5 Subsequent Failures with Both CM and PM Actions 285 12.6 Data-Based Modeling 287 12.7 Summary 295 Review Questions 296 Exercises 296 References 298 Part C Maintenance Decision Models and Optimization 299 13 Optimal Maintenance 301 13.1 Introduction 302 13.2 Framework for Optimal Maintenance Decisions 302 13.3 Maintenance Policy 303 13.4 Decision Parameters 304 13.5 Objective Function 305 13.6 Optimization Model 306 13.7 Information 306 13.8 Optimization 307 13.9 Summary 308 Review Questions 308 Exercises 308 Reference 309 14 Maintenance Optimization for Non-Repairable Items 311 14.1 Introduction 312 14.2 Preliminaries 312 14.3 Infinite Time Horizon 314 14.4 Group Replacement 322 14.5 Finite Time Horizon 323 14.6 Inspection Policies 325 14.7 Summary 327 Review Questions 327 Exercises 328 Reference 329 15 Maintenance Optimization for Repairable Items 331 15.1 Introduction 332 15.2 Preliminaries 332 15.3 Group I Scenarios 334 15.4 Group II Scenarios 338 15.5 Group III Scenarios 344 15.6 Multi-Item Policies 350 15.7 Summary 351 Review Questions 352 Exercises 352 References 354 16 Condition-Based Maintenance 355 16.1 Introduction 356 16.2 Characterization of Degradation 357 16.3 Approach to CBM 359 16.4 Diagnostics, Prognostics, and CBM 364 16.5 Summary 382 Review Questions 384 Exercises 384 References 386 Part D Maintenance Management 389 17 Maintenance Management 391 17.1 Introduction 392 17.2 Management 393 17.3 Maintenance Management 401 17.4 Maintenance Organization 403 17.5 Approaches to Maintenance 407 17.6 Risk and Maintenance 410 17.7 Maintenance Management System 415 17.8 Summary 417 Review Questions 418 Exercises 418 References 419 18 Maintenance Outsourcing and Leasing 421 18.1 Introduction 422 18.2 Outsourcing 422 18.3 Maintenance Outsourcing 424 18.4 Framework for Maintenance Outsourcing Decision Making 426 18.5 Optimal Decisions 429 18.6 Leasing 436 18.7 MSCs for Products and Plants 438 18.8 Infrastructures 444 18.9 Summary 447 Review Questions 448 Exercises 449 References 450 19 Maintenance Planning, Scheduling, and Control 451 19.1 Introduction 452 19.2 Maintenance Planning 452 19.3 Tactical-Level Maintenance Planning 454 19.4 Operational-Level Maintenance Planning 458 19.5 Maintenance Control 462 19.6 Maintenance Control System 464 19.7 Maintenance of Products 465 19.8 Maintenance of Plants 468 19.9 Maintenance of Infrastructures 470 19.10 Summary 471 Review Questions 472 Exercises 472 Reference 473 20 Maintenance Logistics 475 20.1 Introduction 476 20.2 Logistics 476 20.3 Key Elements of Maintenance Logistics 478 20.4 Service Facilities 479 20.5 Human Resources 480 20.6 Inventories 480 20.7 New Item Inventory Management 484 20.8 Repairable Items Inventory Management 487 20.9 Maintenance Logistics for Products 488 20.10 Maintenance Logistics for Plants 491 20.11 Maintenance Logistics for Infrastructures 492 20.12 Summary 493 Review Questions 494 Exercises 494 References 495 21 Maintenance Economics 497 21.1 Introduction 498 21.2 Basic Concepts and Terms 498 21.3 Capital Investment 502 21.4 Cost Elements of Capital Investment 505 21.5 Life Cycle Cost 506 21.6 Capital Equipment Replacement 509 21.7 Buy versus Lease Decisions 515 21.8 LCCA for Products and Plants 519 21.9 LCCA for Infrastructures 520 21.10 Summary 522 Review Questions 523 Exercises 523 References 525 22 Computerized Maintenance Management Systems and e-Maintenance 527 22.1 Introduction 528 22.2 Role of Technology in Maintenance Management 528 22.3 Computerized Maintenance Management Systems (CMMSs) 530 22.4 e-Maintenance 534 22.5 Applications of e-Maintenance 538 22.6 Summary 543 Review Questions 544 Exercises 545 References 546 Part E Case Studies 547 23 Case Studies 549 23.1 Introduction 549 23.2 Case Study 1 – Hydraulic Pump Maintenance 549 23.3 Case Study 2 – Maintenance of Rail Track 559 Part F Appendices 575 Appendix A: Introduction to Probability Theory 577 A.1 Basics of Probability 577 A.2 Random Variables 578 A.3 Characterization of a Univariate Random Variable 579 A.4 Some Basic Univariate Discrete Distribution Functions 580 A.5 Some Basic Univariate Continuous Distribution Functions 581 A.6 Bivariate Random Variables 587 A.7 Sums of Independent Random Variables 590 References 591 Appendix B: Introduction to Stochastic Processes 593 B.1 Basic Concept 593 B.2 Characterization of a Stochastic Process 593 B.3 Classification of Markov Processes 594 B.4 Point Processes 596 B.5 Poisson Processes 597 B.6 Renewal Processes 599 B.7 Marked Point Processes 603 References 604 Appendix C: Introduction to the Theory of Statistics 605 C.1 Introduction 605 C.2 Descriptive Statistics 605 C.3 Inferential Statistics 609 References 612 Appendix D: Introduction to Optimization 613 D.1 Introduction 613 D.2 Case A 615 D.3 Case B 617 D.4 Case C 619 D.5 Case D 622 References 623 Appendix E: Data Sets 625 Data Set E.1 Battery (Component of a Bus) 625 Data Set E.2 Automobile (Repair Costs) 625 Data Set E.3 Photocopier 625 Data Set E.4 Throttle Valve (Automobile Component) 628 Data Set E.5 Valve Seat Replacement for Diesel Engines 628 Data Set E.6 Heavy Vehicle 628 Data Set E.7 Buses 628 Data Set E.8 Buses 629 Data Set E.9 Hydraulic Pumps 631 Data Set E.10 Shock Absorber 634 References 634 Index 635