AEREN FOUNDATIONS

Maharashtra Govt. Reg. No.: F-11724

AN ISO 9001 : 2008 CERTIFIED INTERNATIONAL B-SCHOOL

MARKS:80

SUB:MAINTENANCEMANAGEMENT

N.B. : 1) Please read the cases carefully 2) All questions are compulsory 3) Figures in the right margin indicate full marks 4) Total marks : 80 CASE 1 : Somalu Industries in Andhra Pradesh, is facing frequent break down. Its managing director, Mr D V K Soma Reddy is quite perturbed about these breakdowns. He was in the United States and worked there in sophisticated plants and also worked in Gulf countries, but never faced so many break downs. From Somalu Industries, internal records, the number of Breakdowns of Equipments, over the past 2 years are as furnished below : No. of Breakdowns No. of months of occurrence 0 3 1 7 2 1 3 3 4 2 Total 24

It has been worked out that each break down costs are average of Rs 3,000/preventive maintenance services can be hired at a cost of Rs 1500 per month, and is expected that preventive maintenance service, will limit the break downs to an average of one break down per month only. In this case, you are required to find out i) which maintenance arrangement is preferable; ii) the current break down maintenance policy or a preventive service contact; iii) Please give elaborate reasons for your comments on this case. (25 Marks)

CASE 2 : In Noida, the work shop of Mr Jagadhry has twenty identical machines. Senior Maintainance Supervisor, Mr B N Singh has recorded the failure pattern of the machines in Yagerdhry Industries. Mr B N Singh, did his B E(Mechanical), from Roorkee and after working for BHEL, a stint of 5 years, he went to Africa on deputation. After returning from Africa, Mr B N Singh opted for Jagudhry Industries, since Mr Jagudhry was personally known to him and Mr Jagudhry has an analytical bent of mind and always encouraged research/analysis. B N Singh has recorded the failure pattern of the machines in the following manner : Esimated Time (In months) After Maintenance Attention 1 2 3 4 5 6 Probability of Failure 0.20 0.15 0.15 0.15 0.15 0.20

Mr B N Singh, observed that it gots Rs 1500 to attend a failed machine and rectify the same. He also computed the cost of servicing the broken down machines. 1) In this case, you are required to find expected value of elapsed time (in month), i.e. the internal between two successfive break downs in months.

2) Expected no. of break downs per machine per year. 3) Total number of expected break downs for 20 machines per year. 4) Cost of servicing the driven down machine per year. 5) Give your elaborate comments on the findings, its interpretation and you suggestions for improved method or alternative method. (25 Marks)

CASE 3 : The dramatic success of the Japanese had been attributed to a large extent to the quality of their manufacturing goes quality is multi-dimensional but reliability is a key component of quality. In fact, product reliability was the top priority of the Japanese firms. Japanese automobile and other products have been highly successful in the US market and also gained a high market share. In fact, product quality are exceptional reliability of Japanese products, is the key reason for this. Reliability considers the performance of a product for long time. The random of interest concern the amount of elapsed time between failures after a product is placed into service. Thus, reliability is time based concept of quality. It is the probability that a product will operate adequately for or given period in the intended application. Sony, as an electronics manufacturer has gone above what many other electronic companies as such. Sony has brought great many inventions which have benefited mankind. Sony continues to innovate and has become a world class leader in reliable electronics. In this case, you are required to answer the following : 1) What is the link between reliability and maintenance, please elaborate. 2) List the aspects of from producers point of view. 3) What are the risks of poor reliability borne by the consumer. 4) What are the needs for Total Productive Maintenance. 5) What do you mean by Reliability Engineering and Reliability Quantification.

6) How `Failure Rate is computed. (30 Marks)