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Agenda
Maintenance Techniques Evolution Maintenance Program Goals and Objectives Maintenance Perspective on the SDLC Maintenance Strategies
Maintenance For ORT/Express/High Speed Toll Lanes
September 12, 2007
Goals of Maintenance Program Extend the availability of the systems intended functionality Avoid the consequences due to the failure of the system components operational failures: result in revenue loss and cost of repair Increased traffic congestion safety failures: endanger personnel and equipment non-operational failures: result in cost of repair
1930-1950
Fix it when it breaks
1950-1980
Scheduled Maintenance (PM) Planning Systems Computerization
1980-2000
2000-Present
MTBF Predictive Condition Maintenance Monitoring Failure Modes & Effects Applications Diagnostics Proactive Maintenance TPM/RCM
9/12/2007
SDLC Project Definition and Feasibility Maintenance Strategy The appropriate maintenance strategy determined by a complete understanding and analysis of the following, The failure pattern that applies to ORT/Express Lanes Mean Time between Failures (MTBF): the number of installed components multiplied by the total operational hours for the period, divided by the failures in that period FMEA (Failure Mode and Effects Analysis): identify all the events which are reasonably likely to cause each failed state, most importantly, their effect on the operation of the system
SDLC Project Definition and Feasibility Maintenance Strategy The failure pattern that applies to ORT/Express Lanes
Failure Rates
A (bathtub curve)
Starting with system tuning, manufacturing and installation defects, going to constant operating conditions (high availability), ending in normal component failures rates
SDLC System Analysis and Requirements Definitions Gantry/Canopy Design Tremendous influence on Maintenance requirements and resulting maintenance performance
SDLC System Analysis and Requirements Definitions Open Road/Express Lanes Susceptible to Lightning
9/12/2007
SDLC System Analysis and Requirements Definitions Software Reliability Usually measured in the number of anomalies (bugs) per line of code, metric development still in its infancy Conduct a series of tests including, Factory Tests Performance Tests Operational Tests
Reliability The probability that equipment will not fail in a given time period A measure of the frequency of downtime Measured in Mean Time Between Failures (MTBF) Sometimes confused with system accuracy Availability time available for production - downtime
time available for production A measure of the equipment uptime
Maintainability The required time in which a specified component or subsystem will be restored to a specified condition A characteristics of design and installation
Maintenance Procedures Emergency Maintenance Definition - maintenance work requiring immediate response from maintenance employees due to unforeseen component failures Corrective Maintenance Definition restoring a component or subsystem to a prescribed state, within design tolerance or specifications, i.e. recalibration or realignment of components
Maintenance Procedures Emergency Maintenance/Corrective Maintenance Traditional or Low speed Lanes Response/Repair Times priority based
Typically - 2hr response, 2hr repair for highest priority
Lane Closures
Single barrier vehicle
9/12/2007
Maintenance Procedures Emergency Maintenance/Corrective Maintenance Open Road/Express Tolling Response/Repair Times priority based Typically - 2hr response, Repairs times dependent on failure, or failed component
Lane Accessibility or component accessibility
Maintenance Procedures Preventive Maintenance Traditional Definition scheduled maintenance activities such as, inspections, lubrications, realignments, calibrations conducted on a prescribed frequency Open Road/Express Tolling Shifts from the physical performance tasks to more of system analysis. Review and interpret system log files, trends analysis, image quality, etc Maintenance technician skill sets shifts to accommodate this evolution in preventive maintenance
Lane Closures Full MOT requirements Modify lane closure request procedures, Immediate versus week(s) notice 1-2 hours setup and take down
Maintenance Procedures Predictive Maintenance Traditional Predictive Maintenance definition monitoring and tracking the run-rate or accumulated metrics such as operating hours, axle counts, flash counts, etc against the designed life of the components Open Road/Express Lanes Uses a combination of time based (MTBF) or runrate described above for predictive maintenance and condition monitoring
100%
Operating Condition
Environmental Testing Reliability/Maintainability Demonstration Tests QA/QC Maintenance Procedure and Techniques MOMS/CMMS notifications
9/12/2007