Design for Maintainability

Maintainability
Definition
Maintainability, as a characteristic of design, can be defined on the basis of a combination of the following factors:
Maintenance times Maintenance frequency Maintenance cost
The above three factors are dependant on the fact that the system is operated and maintained in accordance with prescribed procedures and resources.

Maintainability

Maintainability
Measures of Maintainability
From a systems perspective
Corrective maintenance Preventive maintenance

From a software perspective

Adaptive maintenance Perfective maintenance

Maintainability

Maintenance Elapsed -Time Factors

Corrective and preventive active maintenance times Administrative and logistic delay times Total maintenance downtime

Maintainability

Mean corrective maintenance time(Mct)

Mean corrective time is a composite value representing the arithmetic average of the individual maintenance cycle times(Mcti) Mean time to repair(MTTR) Basic measure of maintainability Sum of corrective maintenance times divided by the total number of failures within an item Average time it takes to fully repair a failed system Includes fault isolation,replacements of failed item(s) and check out Its also called the mean corrective maintenance time,Mct

Maintainability

Detection Preparation for Maintenance Localization And Isolation Disassembly (Access)

Failure Occurs Failure Confirmed (Notification) Active Maintenance Commences Reassembly Reassembly completed Alignment And Adjustment

Faulty Item Identified

Condition Verification (Checkout) Repair Completed

OR
Removal of Faulty Item Installation of Spare/Repair Part

Disassembly Completed

Repair of Equipment

Corrective Maintenance Cycle

Maintainability

Frequency of Occurrence 14 12 10 8 6 4 2 0 29.5 39.5 49.5 5 7 10

12 9

4 3

59.5

69.5

79.5 89.5 99.5

Time(min)

Histogram of maintenance times

Maintainability

Arithmetic Mean
n Mct i i 1 Mct n

Maintainability

Mean Preventive Maintenance Time (M pt )

Preventive Maintenance refers to the actions required to retain a system at a specified level of performance fpt i Mpt i Mpt= fpt i Includes active maintenance time Does not include logistic delay and administrative delay time

Maintainability

Logistics Delay Time (LDT)

Refers to maintenance downtime, which is expended as a result of waiting for spare part to become available Waiting for availability of an item of test equipment in order to perform maintenance, waiting for transportation and so on LDT does not include active maintenance time It does constitute a major element of total maintenance downtime (MDT)
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ADT & MDT

Administrative Delay Time (ADT)
That portion of downtime when maintenance time is delayed for administrative reasons. Examples:
Personnel Assignment Issues Labor Strike

Maintenance Down Time (MDT)

Total elapsed time required to repair or restore a system to full operational status or to retain a system in that condition MDT includes:
Mean active maintenance time Logistics delay time (LDT) Administrative delay time (ADT)
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Uptime/Downtime Factors
Time Uptime Downtime Standby/ Ready Time System Operating Time Active Maintenance Time Logistics Delay Time Administrative Delay Time

Corrective Maintenance

Preventive Maintenance Preventive Maintenance Cycle Inspection Servicing Checkout Time Time Time

Fault Detection

Preparation Time

Corrective Maintenance Preparation for Maintenance Localization and Fault Isolation Disassembly (Gain Access) or

Repair of Item in Place Reassembly (Buildup) Removal of Faulty Item and Replace with Spare

Adjustment, Alignment, or Calibration

Condition Verification (Checkout)

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Maintenance Labor Hours

Elapsed time vs. labor hours Elapsed time reduction via more personnel Can be expensive Maintainability is primarily concerned with ease and economy of maintainability

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Maintenance Labor Hours

Important factors in the labor-time element
Maintenance labor-hours per system operating hour (MLH/OH) Maintenance labor-hours per cycle of system operation (MLH/cycle) Maintenance labor-hours per month (MLH/month) Maintenance labor-hours per maintenance action (MLH/MA)

Note: Any of these factors can be specified in terms of mean values.

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Maintenance Frequency Factors

The reliability factors MTBF and are the basis for determining the frequency of corrective maintenance. Maintainability deals with the design characteristics necessary to minimize corrective and preventive maintenance In this area reliability and maintainability factors should be compatible and mutually supportive.

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Some Definitions
MTBF = Mean time between failure = Rate of breakdown = 1/MTBF

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Maintenance Frequency Factors

(Continued)
MTBM:Mean time between maintenance is the mean average time between all maintenance actions
MTBM=

1
1 1 + MTBMs MTBM

where:

MTBM: Unscheduled (corrective maintenance) MTBMs: Scheduled (preventive maintenance) MTBM should be equivalent to the MTBF if all failures are considered MTBM is crucial to determine the achieved and operational availability.
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Maintenance Frequency Factors

(Continued)
Example : Consider a communication equipment with an MTBF (where all failures are considered) of 20 years and has a schedule of maintenance every 6 months, what is the MTBM ?

If all failures were measured to determine the MTBF is safe to assume that MTBF=MTBM
With a MTBMs= 0.5 years

MTBM=

1 1 1 + MTBM MTBMs

1 1 1 + 0.5 years 20 years

= 0.55 years

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Maintenance Frequency Factors

(Continued)
MTBR:Mean time between replacement a factor of MTBM refers to all item replacement.

In corrective and schedule maintenance a replacement of a spare part is not always necessary.
A low MTBR will mean a higher frequency of replacement which in turn will required higher levels of maintenance support. A maintainability objective in system design is to maximize the MTBR

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Maintenance Cost Factors

Important factor in the total life-cycle cost Make design decisions in the early stages of System Development Life-cycle must be considered when defining the system requirements
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Maintenance Cost Factors

Cost-related indices appropriate in system design
Cost per maintenance action ($/month) Maintenance cost per system operating hour ($/OH) Maintenance cost per month ($/month) Maintenance cost per mission or mission segment ($/mission) Ratio of maintenance cost to total life-cycle cost

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Related Maintenance Factors

Various logistics factors based from the System Supply Responsiveness
Test and Support Effectiveness Maintenance facility availability and use Transportation modes Maintenance organizational effectiveness

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Related Maintenance Factors

Cost-effectiveness Total system cost (Live cycle) System effectiveness

Availability

Dependability

Capability

Uptime (Operating/standby)

Downtime (Non-use)

Active maintenance time Logistic support resource consumption

Logistic delay time

Administrative delay time

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Maintainability Requirements in the System Life-Cycle

Conceptual Design
======================== Feasibility study Operational requirements Maintenance Concept Functional requirements Technical performance measures Advance system planning ----------------------------------------Maintenance concept, quantitative and qualitative maintainability requirements for system (MTBM, MTBR, Mct, Mpt, MLH/OH, cost/MA, etc.), maintainability planning.

Preliminary System Design

======================== System functional analysis Preliminary synthesis and allocation of design criteria System optimization System synthesis and definition ----------------------------------------Allocation of maintainability requirements, maintainability analysis and trade-offs, maintenance engineering analysis, design support, maintainability predictions, formal design review and approval.

Detail Design & Development ======================== System / product detail design System prototype development System prototype test and evaluation System modification ----------------------------------------Maintainability analysis and trade-offs, maintenance engineering analysis, design support, maintainability predictions, maintainability demonstration, formal design review and approval.

Feedback Loop System Utilization & Life-Cycle Support System Retirement and Phaseout
================================ Consumer use of system and its components Life-cycle system support -----------------------------------------------------Maintainability data collection, analysis, and evaluation; system modification (as required)

Production / Construction
============================== Fabrication, assembly, and test of system and its components System construction --------------------------------------------------Maintainability test and evaluation; maintainability data collection, analysis, and corrective action

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Maintainability in the System Life Cycle

Maintainability is considered early in the process During the conceptual design phase. Requirements developed from feasibility study
Qualitative Requirements Quantitative Requirements

Maintainability testing is included as part of the overall system test and evaluation activity
After the physical models are developed and evaluation process is established.
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Maintainability in the System Life Cycle

System Requirements Definition of system performance factors, the mission profile, and system use requirements. Definition of the operational life cycle. Definition of the basic system maintenance. Definition of the environment in which system is expected to operate and be maintained.

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Component Selection and Application

Select standardized components and materials. Select items with built-in self-test features and diagnostics. Select items that do not require highly specialized skills.

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Component Selection and Application

Ensure appropriate accessibility to subsystems for maintenance. Incorporate modularized functional-package approach. Avoid selection of short-life components. Incorporate proper identification of components.
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Maintainability Analysis Method

Maintainability Analysis: Iterative process of system synthesis, analysis and evaluation Tools/Methods Used for Maintainability analysis 1, Reliability-Maintainability Trade-off Evaluation 2, Reliability-Centered Maintenance 3, Repair versus Discard Analysis 4, Maintenance Prediction 5, Maintenance Task Analysis (MTA)

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Maintainability Analysis Method

Reliability- maintainability trade off Evaluation:
Reliability = The probability that a system will perform in a satisfactory manner for a given period when used under specified operating conditions. E.g.; Equipment A MTBF = 100 hrs Equipment B , MTBF = 125 hrs >> Reliability of equipment B is higher. Maintainability = It is the ability of a product to be maintained E.g.; Equipment A Mct = 2 hrs, Equipment B Mct = 3 hrs >> maintainability of the equipment A is higher
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Maintainability Analysis Method

Example: Requirement: To replace an existing equipment item with a new item for the purpose of improving operational effectiveness. Alternatives: 3 different design configurations are available Evaluation: Reliability-Maintainability-Cost>>decision

Result: Configuration A satisfies reliability maintainability with least cost.

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Maintainability Analysis Method

Reliability- Centered Maintenance(RCM)
Cost-effective preventive maintenance program
Best initiated during the early process RCM analysis leads to specification for preventive maintenance or recommendation for redesign

Repair Versus Discard Analysis:

It is economically feasible to repair certain items and/or to discard certain when failure occur.

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Maintainability Prediction
Maintainability Predictions are done periodically at different stages in the design process. Predictions of the MTBM, Mct, Mpt, MLH/OH, and so on, are made and compared against the requirements identified earlier in the Maintainability Allocation Process.

Areas of noncompliance are evaluated for possible design improvement.

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Prediction of Mct
The Prediction covers subsystems, units, assemblies, subassemblies and parts. Maintainability Characteristics such as localization, isolation, accessibility, repair, and checkout are evaluated. Times applicable to each part are combined to provide factors for the next-higher level (subassemblies, assemblies, etc.).
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Design Review and Evaluation

The characteristics of the system and its elements are evaluated in terms of the initially specified maintainability requirements for the system. A check list may be developed to facilitate the review process. Ex:
Have servicing and lubrication requirements been held to a minimum (if not eliminated)? Have adjustment, alignment, and calibration requirements been minimized (if not eliminated)? Have all system maintainability requirements been met?
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Maintainability Demonstration
It is conducted as part of the system test and evaluation effort It is usually accomplished during the latter part of detail design. It should be conducted in an environment that simulates, as closely as practical, the operational and maintenance environment planned for the item.
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Checklist for review cont

Standardization; Minimize spares? Modular packaging achieved? Are modules interchangeable? Diagnostic testing provisions? Quick disassembly possible? Accessibility to parts requiring replacement? Is alignment, adjustment and calibration in field minimized? Are the parts labeled? Servicing and lubrication minimized? Handling of heavy items designed?
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Design Review & Evaluation

Done at various stages of design and development Create a formal checklist for the reviews
Maintainability requirements adequately defined and specified? Compatible with other requirements ? Realistic ? Compatible with maintenance concept?
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Maintainability Demonstration
It is usually accomplished during the latter part of detail design. It should be conducted in an environment that simulates, as closely as practical, the operational and maintenance environment planned for the item

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