Introduction to Maintenance Engineering

Mohamed Ben-Daya is a Professor in the Department of Systems Engineering at King Fahd University of Petroleum and Minerals, Dhahran, Saudi Arabia. He received his PhD in Operations Research from Georgia Institute of Technology, USA. His research interests are in the areas of production planning and scheduling, maintenance, quality control, supply chain management, and risk management in product development. He teaches course in the areas of facilities planning, Production and inventory control, scheduling, Quality control, Maintenance and reliability engineering and supply chain management. Dr. Ben-Daya is the Associate Editor of the Journal of Quality in Maintenance Engineering and on the Editorial Board of the Journal of Logistics. He has published over eighty papers in refereed journals and conference proceedings and co-edited five books.Pra Murthy obtained B.E. and M.E. degrees from Jabalpur University and the Indian Institute of Science in India and M.S. and Ph.D. degrees from Harvard University. At The University of Queensland he was responsible for setting up the Technology Management Centre (offering master's program in technology management) and Reliability Engineering and Risk Management Group (offering postgraduate programs in reliability and maintenance). He has held visiting appointments at fifteen universities in the USA, Europe and Asia. His current research interests include various aspects of reliability, maintenance, warranties and service contracts. He has authored or co-authored 20 book chapters, 165 journal papers and 150 conference papers. He is a co-author of 7, and co-editor of 3, books. He has run short courses for industry on various topics in technology management, operations management and post-sale support in Australia, Asia, Europe and the USA.Uday Kumar obtained his B. Tech from IIT BHU, India and worked 7 years in industry before joining the postgraduate program of Luleå University of Technology, Luleå, Sweden to obtain a PhD degree in field of Reliability and Maintenance Engineering during 1990. He worked as a Senior Lecturer and Associate Professor at Luleå University and joined University of Stavanger, Norway as a Professor of Mechanical Engineering (Maintenance) in 1997. In July 2001, he was appointed as a Professor of Operation and Maintenance Engineering at Luleå University of Technology, Luleå, Sweden. He has been guest faculty at Helsinki University of Technology, Helsinki, Imperial College London and Stavanger University, University of Tromsö, Norway, University of Cincinnati, USA. His research interests are equipment maintenance, reliability and maintainability analysis, etc. He has published more than 275 papers in International Journals and Conference Proceedings.

• Preface xxxiAcknowledgments xxxvAbbreviations xxxvii1 An Overview 11.1 Introduction 21.2 Classification of Engineered Objects 41.3 Performance of Engineered Objects 101.4 Maintenance 121.5 Evolution of Maintenance 151.6 Focus of the Book 171.7 Structure and Outline of the Book 18Review Questions 20Exercises 21References 22Part A Maintenance Engineering and Technology 232 Basics of Reliability Theory 252.1 Introduction 262.2 Decomposition of an Engineered Object 262.3 Functions, Failures, and Faults 272.4 Characterization of Degradation 312.5 Reliability Concept and Characterization 332.6 Linking System and Component Failures 362.7 Reliability Theory 452.8 Summary 45Review Questions 46Exercises 47References 503 System Degradation and Failure 513.1 Introduction 523.2 Failure Mechanisms 523.3 Classification of Failure Mechanisms 543.4 Dynamic Nature of Stress and Strength 613.5 Degradation of Products and Plants 623.6 Degradation of Infrastructures 64Review Questions 69Exercises 69References 714 Maintenance – Basic Concepts 734.1 Introduction 744.2 Types of Maintenance Actions 744.3 Preventive Maintenance Actions 774.4 Corrective Maintenance Actions 834.5 Design Out Maintenance 854.6 Uptime and Downtime 864.7 Warranty and Maintenance 884.8 Maintenance of Products 904.9 Maintenance of Plants and Facilities 954.10 Maintenance of Infrastructures 1004.11 Effective Maintenance 1024.12 Summary 103Review Questions 104Exercises 104References 1055 Life Cycle of Engineered Objects 1075.1 Introduction 1085.2 Life Cycle Concept and Classification 1085.3 Standard Objects 1095.4 Custom-Built Objects 1135.5 Reliability: Product Life Cycle Perspective 1155.6 Life Cycle Cost 1185.7 Summary 120Review Questions 120Exercises 121References 1226 Technologies for Maintenance 1236.1 Introduction 1246.2 Technology – An Overview 1246.3 Assessing the State (Condition) of an Item 1256.4 Sensors 1296.5 Testing Technologies 1376.6 Data-Related Technologies 1426.7 Technologies for Maintenance of Products 1446.8 Technologies for Maintenance of Plants 1446.9 Technologies for Maintenance of Infrastructures 1486.10 Summary 151Review Questions 152Exercises 153References 1547 Maintainability and Availability 1557.1 Introduction 1567.2 Maintainability – An Overview 1567.3 Elements of Maintainability 1587.4 Availability 1617.5 Maintainability Process 1637.6 Maintainability Standards 1657.7 Relationship with Other Disciplines 1667.8 Summary 167Review Questions 168Exercises 168References 169Part B Reliability and Maintenance Modeling 1718 Models and the Modeling Process 1738.1 Introduction 1748.2 Models 1748.3 Mathematical Modeling 1788.4 Approaches to Modeling 1828.5 Mathematical Modeling Process 1858.6 Statistics versus Probability Perspectives 1898.7 Modeling of Maintenance Decision Problems 1908.8 Summary 191Review Questions 191Exercises 192Reference 1939 Collection and Analysis of Maintenance Data 1959.1 Introduction 1969.2 Data, Information, and Knowledge 1969.3 Maintenance Data 1999.4 Data Analysis 2019.5 Descriptive Statistics 2029.6 Inferential Statistics 2129.7 Collection of Maintenance Data for Products 2139.8 Collection of Maintenance Data for Plants 2159.9 Collection of Maintenance Data for Infrastructures 2189.10 Summary 220Review Questions 221Exercises 222References 22310 Modeling First Failure 22510.1 Introduction 22610.2 One-Dimensional Formulations 22710.3 Two-Dimensional Formulations 23010.4 Properties of Distribution Functions 23210.5 Preliminary Data Analysis and Plots 23610.6 Selection of a Mathematical Formulation 24110.7 Parameter Estimation 24210.8 Model Validation 24610.9 Examples 24710.10 Summary 253Review Questions 254Exercises 254References 25511 Modeling CM and PM Actions 25711.1 Introduction 25811.2 Modeling CM Actions 25811.3 Modeling PM Actions 26211.4 Repair Times and Downtimes 26611.5 Maintenance Costs 26911.6 Repair–Replace Decisions 27211.7 Modeling Fleet and Infrastructure Maintenance 27311.8 Summary 273Review Questions 274Exercises 275References 27612 Modeling Subsequent Failures 27712.1 Introduction 27812.2 System Characterization for Modeling 27812.3 Mathematical Formulations for Modeling 28012.4 Subsequent Failures with Only CM Actions 28312.5 Subsequent Failures with Both CM and PM Actions 28512.6 Data-Based Modeling 28712.7 Summary 295Review Questions 296Exercises 296References 298Part C Maintenance Decision Models and Optimization 29913 Optimal Maintenance 30113.1 Introduction 30213.2 Framework for Optimal Maintenance Decisions 30213.3 Maintenance Policy 30313.4 Decision Parameters 30413.5 Objective Function 30513.6 Optimization Model 30613.7 Information 30613.8 Optimization 30713.9 Summary 308Review Questions 308Exercises 308Reference 30914 Maintenance Optimization for Non-Repairable Items 31114.1 Introduction 31214.2 Preliminaries 31214.3 Infinite Time Horizon 31414.4 Group Replacement 32214.5 Finite Time Horizon 32314.6 Inspection Policies 32514.7 Summary 327Review Questions 327Exercises 328Reference 32915 Maintenance Optimization for Repairable Items 33115.1 Introduction 33215.2 Preliminaries 33215.3 Group I Scenarios 33415.4 Group II Scenarios 33815.5 Group III Scenarios 34415.6 Multi-Item Policies 35015.7 Summary 351Review Questions 352Exercises 352References 35416 Condition-Based Maintenance 35516.1 Introduction 35616.2 Characterization of Degradation 35716.3 Approach to CBM 35916.4 Diagnostics, Prognostics, and CBM 36416.5 Summary 382Review Questions 384Exercises 384References 386Part D Maintenance Management 38917 Maintenance Management 39117.1 Introduction 39217.2 Management 39317.3 Maintenance Management 40117.4 Maintenance Organization 40317.5 Approaches to Maintenance 40717.6 Risk and Maintenance 41017.7 Maintenance Management System 41517.8 Summary 417Review Questions 418Exercises 418References 41918 Maintenance Outsourcing and Leasing 42118.1 Introduction 42218.2 Outsourcing 42218.3 Maintenance Outsourcing 42418.4 Framework for Maintenance Outsourcing Decision Making 42618.5 Optimal Decisions 42918.6 Leasing 43618.7 MSCs for Products and Plants 43818.8 Infrastructures 44418.9 Summary 447Review Questions 448Exercises 449References 45019 Maintenance Planning, Scheduling, and Control 45119.1 Introduction 45219.2 Maintenance Planning 45219.3 Tactical-Level Maintenance Planning 45419.4 Operational-Level Maintenance Planning 45819.5 Maintenance Control 46219.6 Maintenance Control System 46419.7 Maintenance of Products 46519.8 Maintenance of Plants 46819.9 Maintenance of Infrastructures 47019.10 Summary 471Review Questions 472Exercises 472Reference 47320 Maintenance Logistics 47520.1 Introduction 47620.2 Logistics 47620.3 Key Elements of Maintenance Logistics 47820.4 Service Facilities 47920.5 Human Resources 48020.6 Inventories 48020.7 New Item Inventory Management 48420.8 Repairable Items Inventory Management 48720.9 Maintenance Logistics for Products 48820.10 Maintenance Logistics for Plants 49120.11 Maintenance Logistics for Infrastructures 49220.12 Summary 493Review Questions 494Exercises 494References 49521 Maintenance Economics 49721.1 Introduction 49821.2 Basic Concepts and Terms 49821.3 Capital Investment 50221.4 Cost Elements of Capital Investment 50521.5 Life Cycle Cost 50621.6 Capital Equipment Replacement 50921.7 Buy versus Lease Decisions 51521.8 LCCA for Products and Plants 51921.9 LCCA for Infrastructures 52021.10 Summary 522Review Questions 523Exercises 523References 52522 Computerized Maintenance Management Systems and e-Maintenance 52722.1 Introduction 52822.2 Role of Technology in Maintenance Management 52822.3 Computerized Maintenance Management Systems (CMMSs) 53022.4 e-Maintenance 53422.5 Applications of e-Maintenance 53822.6 Summary 543Review Questions 544Exercises 545References 546Part E Case Studies 54723 Case Studies 54923.1 Introduction 54923.2 Case Study 1 – Hydraulic Pump Maintenance 54923.3 Case Study 2 – Maintenance of Rail Track 559Part F Appendices 575Appendix A: Introduction to Probability Theory 577A.1 Basics of Probability 577A.2 Random Variables 578A.3 Characterization of a Univariate Random Variable 579A.4 Some Basic Univariate Discrete Distribution Functions 580A.5 Some Basic Univariate Continuous Distribution Functions 581A.6 Bivariate Random Variables 587A.7 Sums of Independent Random Variables 590References 591Appendix B: Introduction to Stochastic Processes 593B.1 Basic Concept 593B.2 Characterization of a Stochastic Process 593B.3 Classification of Markov Processes 594B.4 Point Processes 596B.5 Poisson Processes 597B.6 Renewal Processes 599B.7 Marked Point Processes 603References 604Appendix C: Introduction to the Theory of Statistics 605C.1 Introduction 605C.2 Descriptive Statistics 605C.3 Inferential Statistics 609References 612Appendix D: Introduction to Optimization 613D.1 Introduction 613D.2 Case A 615D.3 Case B 617D.4 Case C 619D.5 Case D 622References 623Appendix E: Data Sets 625Data Set E.1 Battery (Component of a Bus) 625Data Set E.2 Automobile (Repair Costs) 625Data Set E.3 Photocopier 625Data Set E.4 Throttle Valve (Automobile Component) 628Data Set E.5 Valve Seat Replacement for Diesel Engines 628Data Set E.6 Heavy Vehicle 628Data Set E.7 Buses 628Data Set E.8 Buses 629Data Set E.9 Hydraulic Pumps 631Data Set E.10 Shock Absorber 634References 634Index 635