Maintenance Costing / Biaya Pemeliharaan

1. MAINTENANCE LABOR COST ESTIMATION

The cost of labor is an important component of the maintenance cost. Labor costs are
made up of payroll information that is usually obtained from labor distribution reports prepared
by the accounting department. The information is required for four key areas:

1. Total number of hours worked annually on a per-employee basis

2. Hourly cost of employee benefits on a per-employee basis

3. Ratio of cost of annual benefits to yearly wages

4. Base pay rates per hour by labor grade

The cost per employee is expressed by :

Cem = LR(1 + BR)TAH..Eq(1.1)

Where :

Cem = cost per employee,

LR = hourly labor rate,

BR = benefit ratio,

TAH = total number of annual hours.

The total labor cost is given by :

TLC = CemN.Eq(1.2)

Where :

TLC = total labor cost,

N = number of employees

Example :

Assume that in a maintenance organization we have the following data:

TAH = 2000 h
BR = 0.2

LR = $15 per hour

N = 40

Calculating the total labor cost associated with the maintenance activity by

inserting the above values into Eqs. (1.1) and (1.2), we get :

Cem = 15 (1 + 0.2) 2,000 = $36,000

And

TLC = 36,000 40 = $1,440,000

Thus, the total labor cost associated with the maintenance activity will be $1.44 million.

2. CORRECTIVE M AINTENANCE LABOR COST ESTIMATION

In this case corrective maintenance labor cost is estimated when the item/system mean
time between failures (MTBF) and mean time to repair (MTTR) are known. Consequently, the
annual labor cost of corrective maintenance is expressed by :

..Eq(2.1)

Where :

CMal = annual corrective maintenance labor cost,

LCH = corrective maintenance labor cost per hour,
SOH = annual scheduled operating hours.

Example :

A system is scheduled to operate for 2000 hours per year. The systems MTBF and MTTR are
400 h and 20 h, respectively. Calculate the annual labor cost of corrective maintenance if the
maintenance labor cost is $20 per hour. By substituting the specified data into Eq. (2.1), we get :

The annual labor cost of corrective maintenance is $2000.

3. EQUIPMENT OWNERSHIP CYCLE MAINTENANCE COST ESTIMATION

This section is concerned with estimating the maintenance cost of the entire ownership
cycle of equipment, so that its present value can be added to acquisition cost to obtain equipment
life cycle cost. The following two formulas are often used to find present value of a sum of
money. They can equally be used to obtain present values of equipment ownership cycle
maintenance costs :

FORMULA I
This formula is used to estimate the present value of a single amount of money after k periods
and is expressed by :

.Eq(3.1)
Where :
PV = present value,
AM = single amount,
k = number of interest or conversion periods (normally taken as years),
i = interest rate per period.

FORMULA II
This formula is concerned with obtaining the present value of equal amounts of, say,
maintenance costs occurring at the end of each of k conversion periods (usually years). The
present value is given by :

Eq(3.2)
Where :
MC = maintenance cost occurring at the end of each (interest) conversion period.

Example :
A maintenance department considers procuring an engineering system. Two manufacturers are
bidding to provide the system and their corrective maintenance costrelated data are given in
Table 3.1. Determine which of the two systems will be less costly with respect to present
values of corrective maintenance and by how much :
 Tabel 3.1 Maintenance Cost-Related Data

Manufacturer A System
The annual expected cost, MC, of a corrective maintenance action is :

MCa = 1000 2.5 = $2500

The present value, PVA, of the engineering system life cycle corrective maintenance
cost using Eq. (3.2) and the specified and calculated values is :

Manufacturer B System
The annual expected cost, MC, of a corrective maintenance action is :

MCb = 1400 2 = $2800

The present value, PVB, of the engineering system life cycle corrective maintenance
cost using Eq. (3.2) and the specified and calculated values is :

Manufacturer As engineering system will be less costly with respect to present

values of corrective maintenance by $2,260.81.

4. ACTIVITY EXPECTED DURATION TIME ESTIMATION

The PERT scheme calls for three estimates of activity duration time using the following
formula to calculate the final time:

Eq(4.1)
Where :
Ta = activity expected duration time,
OT = optimistic or minimum time an activity will require for completion,
PT = pessimistic or maximum time an activity will require for completion,
MT = most likely time an activity will require for completion. This is the time
used for CPM activities.

Example 3.1
Assume that we have the following time estimates to accomplish an activity:
OT = 55 days
PT = 80 days
MT = 60 days
Calculate the activity expected duration time. Substituting the given data into Eq. (4.1), we get :

The expected duration time for the activity is 62.5 days.

5. MAINTAINABILITY MEASURES AND FUNCTIONS

Various measures are used in maintainability analysis: for example, mean time to repair
(MTTR), mean preventive maintenance time, and mean maintenance downtime. Maintainability
functions are used to predict the probability that a repair, starting at time t= 0, will be completed
in a time. Some maintainability measures and functions are presented below.

MEAN TIME TO R EPAIR

Mean time to repair (MTTR) is probably the most widely used maintainability measure.
It measures the elapsed time required to perform a given maintenance activity. MTTR
is expressed by :
 ..Eq(5.1)

Where :
k number of units or parts,
i failure rate of unit/part, for i 1, 2, 3, k
CMTi corrective maintenance/repair time required to repair unit/part i,
for i 1, 2, 3..,k

Usually, times to repair follow exponential, lognormal, and normal probability

distributions.

Example :

MAIN TIME BETWEEN FAILURE

Mean time between failure (MTBF) is probably the most time between the occurring of failure
in maintainability measure.
It measures the elapsed time required to perform a given maintenance activity.
EXAMPLE :
Data historical of machine in industry :
a. Hour ( 0 to 200) = up-time
b. Hour ( 200 to 280 ) = down-time
c. Hour ( 280 to 420 ) = up-time
d. Hour ( 420 to 490) = down-time
e. Hour ( 490 to 590 ) = up-time
f. Hour ( 590 to 650 ) = down-time
g. Hour (650 to 780 ) = up-time
To calculate of :
the mean time to between failure (MTBF ) and mean downtime (MDT) ?

MTBF ( Main time between Failure ) =

MDT ( Main down time ) =

Tugas 2 - Perawatan Mesin
Tanggal : 4 April 2017
Materi : ( Maintenance Costing ) / Biaya Pemeliharaan 3IC09
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Kerjakanlah soal soal maintenance costing berikut ini !!

1. To Calculate the mean time to repair (MTTR ) ?

a. Eight Subsytem : a, b, c, d, e, f, g, h form an electronic system.
b. The constants failure rates of these subsystems are :
a = 0.002 , b = 0.004 , c = 0.006 , d = 0.008 , e = 0.010 , f = 0.012 , g =
0.014 , h = 0.016 failures per hour.
c. The corresponding estimate corrective maintenance time are :
Ta = 2 hour, Tb = 3 hour, Tc = 4 hour, Td = 5 hour, Te = 6 hour, Tf = 7 hour, Tg = 8
hour, Th = 9 hour.

2. Data historical of machine in industry :

h. Hour ( 0 to 200) = up-time
i. Hour ( 200 to 210 ) = down-time
j. Hour ( 210 to 400 ) = up-time
k. Hour ( 400 to 415) = down-time
l. Hour ( 415 to 590 ) = up-time
m. Hour ( 590 to 600 ) = down-time
n. Hour (600 to 750 ) = up-time
To calculate of :
the mean time to between failure (MTBF ) and mean downtime (MDT) ?
the annual labor cost of corrective maintenance (CMal) ?
Whereas : SOH = 3500 hour, MTTR = 30 h, LCH = $ 40.

3. Maintenance Cost-Related Data :

Description Manufacture A Manufacture B Manufacture C

system system System

Expected Life 15 years 15 years 15 years

Expected cost of $2000 $2500 $3500

 a corrective
maintenance
action

Annual failure 3 failures per year 3.5 failures per year 2.5 failures per year
rate

Annual interest 4% 4% 4%
rate

Determine which of the three system will be less costly with present value of corrective
maintenance ( Find the value of (PV)?
NB : Using the Formula II.

4. Assume that we have the following time estimates to accomplish an activity :

OT = 85 days
PT = 105 days
MT = 90 days
To Calculate the activity expected duration time ( Ta )?

5. Assume that in maintenance organization we have the following data :

TAH = 2500 hour
BR = 0.2
LR = $25
N = 50
To Calculate the cost per employee (Cem)and The total labor cost ( TLC )?