Integrated Reliability

Reliability
The ability of a system to perform its

required function under stated condition for

a specific period of time.

Role of maintenance
Increase the life of the product
Increase the Reliability of the product
Increase Durability
Lowering the cost
Increasing the productivity
Reducing the breakdown

Maintenance
Breakdown
Preventive
Periodic
Predictive
Corrective

TPM

Total productive maintenance

It is a system of maintaining and improving

the integrity of production and quality

systems through the machines,
equipments, processes and employees.
Definition:
a philosophy to permeate throughout an

operating company touching people of all

levels
a collection of techniques and practices
aimed at maximizing the effectiveness (best
possible return) of business facilities and
processes

Pillars of TPM

Elements of TPM
Maximize the OEE
PM for entire life span of equipment
Implemented by various departments
Involves every single employee
Promotion of PM(preventive maintenance)

through motivation.

Activities of TPM
1.
2.
3.
4.
5.

Autonomous maintenance
Equipment improvement
Quality maintenance
MP(Maintenance Prevention) systembuilding
Education and training

losses
Down time
Breakdown
Setup and adjustment

Speed losses
Idling and minor stoppages
Reduced speed

Defects
Process defects
Reduced yield

Meaning for total in TPM

Total effectiveness
Total maintenance system = MP & MI -> PM
Total participation

Overall Equipment Effectiveness

OEE = Availability X Performance Efficiency X

Rate of quality products

Availability
It is the ratio of operating time to the

loading time.
Operating time = loading time downtime
Loading time = working hours

Performance Efficiency
PE = operating speed rate X net operating

rate
Operating speed rate
time /
Net operating rate =
time /

= theoretical cycle
actual cycle time
actual processing
operation time

Actual processing time = processed amount

actual cycle time

Rate of quality products

It is the ratio of the no of product produced

without to the total no of products

produced.
Rate of quality = no of products without
defects/ no of
products
produced
No of products without defects = total no of

products no of
defects no of product reworked

Down time
Time of equipment when it is not producing

any products (breakdown and failures,

accident)
There are two types of downtime can be
occurred,
Equipment failures
Setup and adjustments

Example 1
A medium volume manufacturing facility with a capacity of
producing 2 parts/minute actually produced 800 parts in a
planned running 2 shifts of 8 hours each. It had breaks
and scheduled maintenance for 40 minutes and also
faced 40 minutes breakdowns and 1 hour 20 minutes for
changeover and adjustment. Number of rejects and reworks were 10 and 6 parts respectively. Calculate its
overall effectiveness
Planned production time = 2x8 hrs. = 960 minutes
Loading time = 960-40 (breaks & scheduled maintenance) = 920 min.
Down-time
=40 (Breakdowns) + 80(Changeover & adjustment)= 120

Example 1 (Contd.)
Loading time Down time
920 - 120
%Availability = -------------------------------x100 = ----------------x100 = 87%
Loading time
920

Quantity produced
800
%Performance = --------------------------------x100 = -------------x100
= 50%
Time run x Capacity/given time (920-120)x2
Amount produced Amount defects Amount re-work
%Quality = ----------------------------------------------------------------------- x
100
Amount produced
800 10 6
= -------------------- x 100 = 98%
800

Benefits
Increased decision making
Operators becomes more valuable
Operators receive additional training
More cooperative work environment
Higher lever of expertise
Increased self esteem for better

performance
Multi skilled operators are in demand
Ability to address issue that plagued
operations

MTTF
Mean Time To Failure (MTTF) is the mean time

expected until the first failure of a piece of

equipment.
MTTF= T/N
T = total time N = no of items under test
MTTR
Mean Time To Repair (MTTR) is the time needed to

repair a failed hardware module.

MTBF
Mean Time Between Failure (MTBF) is a reliability

term used to provide the amount of failures per

million hours for a product.
MTBF = 1/(sum of all the part failure rates)
Failure rate = no of failure / total time

Example
Suppose 10 devices are tested for 500 hours.
During the test 2 failures occur.
The estimate of the MTBF is:
MTBF= (10*500)/2 = 2,500 hours
/ failure.
Whereas for MTTF
MTTF= (10*500)/10 = 500
hours / failure.

A system has 4000 components with a

failure rate of 0.02% per 1000 hours.

Calculate and MTBF.
= (0.02 / 100) * (1 / 1000) * 4000
= 8 * 10-4 failures/hour
MTBF = 1 / (8 * 10-4 ) = 1250 hours