MAINTENANCE CONTROL

Maintenance Control can be of three

types as follows:-

1. Work Control
2. Equipment Control
3. Cost Control

Work Control is done through periodic

reporting of the progress of various
maintenance activities.

Equipment Control is the process of

carrying out Failure Analysis and
Downtime Analysis and of taking
corrective measures such as Design-out
Maintenance and Design-for
Maintenance.

Cost control is exercised by the

identification of high-cost areas through
periodic reporting of PM Costs & CM
Costs department/section/equipmentwise and initiating necessary action to
reduce the same

Maintainability
It is the probability that a unit or system
will be restored to specific conditions
within a given period when maintenance
action is taken in accordance with
prescribed procedures and resources. It is a
characteristic of the design and installation
of the unit or system

 Failure density :-This is the ratio of number

of failures during a given unit interval of
time to the total number of items at the very
beginning of the test (also called as initial
population).
Failure rate :-This is the ratio of number of
failures during a particular unit time
interval to the average population during
that interval.

Mean time to repair(MTTR)

Let N number of items are undergoing
repair and n1 items repaired in first t time
interval and n2 items repaired in next t
time interval and all the N were repaired at
lth t interval then n1 = N
MTTR = 1/N (n1 t + n2 2t+ .. nk k t + ..nl l t)
MTTR = 1 /N nk (kt)

 MTTF is the mean time to first failure and is used in

case of components that are not repaired when they
fail, but are replaced by new components.
MTBF: mean time between failures :- system
unavailable due to breakdown and put back to use
after proper repair . Mean time between such
breakdowns is defined as MTBF (Repairable)
MTBM: mean time between maintenance ( includes
break down time and preventive maintenance time.)
If preventive maintenance down time is zero
MTBF=MTBM

Bathtub Curve

Early-life Period
Also called infant mortality phase or reliability
growth phase or the burn in period
The decreasing but greater failure rate early in life
of the system is due to one or more of several
potential causes.
The causes include inadequate testing or screening
of components during selection or acceptance,
damage to components during production,
assembly, or testing, and choice of components
which have too great a failure variability.

Steady-state Period
service failures
Failure rate much lower than in early-life
period
Either constant (age independent) or slowly
varying failure rate
it represents the effective life of the product.

Wear out Period

The incidence of failure in this zone is high
since most of the components will have
exceeded their service life, and
consequently would have deteriorated.