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Assignment 5

This document discusses corrective maintenance. It defines corrective maintenance and describes types including overhaul, rebuild, and servicing. It discusses sequential steps in corrective maintenance including fault recognition, localization, diagnosis, repair, and checkout. It defines components of active repair time and discusses strategies to reduce corrective maintenance time like efficiency in fault identification, effective interchangeability, redundancy, accessibility, and human factors. It also defines median corrective maintenance time and includes examples of calculations for system availability and failure rates.

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John Carlo Carillo
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44 views

Assignment 5

This document discusses corrective maintenance. It defines corrective maintenance and describes types including overhaul, rebuild, and servicing. It discusses sequential steps in corrective maintenance including fault recognition, localization, diagnosis, repair, and checkout. It defines components of active repair time and discusses strategies to reduce corrective maintenance time like efficiency in fault identification, effective interchangeability, redundancy, accessibility, and human factors. It also defines median corrective maintenance time and includes examples of calculations for system availability and failure rates.

Uploaded by

John Carlo Carillo
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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CARILLO, JOHN CARLO B.

MAINTENANCE ENGINEERING AND TRIBOLOGY


BSME – 3A

ASSIGNMENT 5
PROBLEMS:
1. Define corrective maintenance.
 Corrective maintenance may be defined as the remedial action carried out due to failure
or deficiencies discovered during preventive maintenance, to repair an equipment/item to
its operational state.

2. Describe the following types of corrective maintenance:


• Overhaul
• Rebuild
• Servicing

Overhaul: Restoring an item to its total serviceable state as per maintenance serviceability
standards, using the “inspect and repair only as appropriate” approach.

Rebuild: This is concerned with restoring an item to a standard as close as possible to original
state in performance, life expectancy, and appearance. This is achieved through complete
disassembly, examination of all components, repair and replacement of worn/unserviceable
parts as per original specifications and manufacturing tolerances, and reassembly and testing
to original production guidelines.

Servicing: Servicing may be needed because of the corrective maintenance action, for
example, engine repair can lead to crankcase refill, welding on, etc. Another example could
be that the replacement of an air bottle may require system recharging.

3. Discuss sequential steps associated with corrective maintenance.


 Different authors have laid down different sequential steps for performing
corrective maintenance. For example, Reference 2 presents nine steps (as applicable):
localize, isolate, adjust, disassemble, repair, interchange, reassemble, align, and checkout.
Reference 3 presents seven steps (as applicable): localization, isolation, disassembly,
interchange, reassemble, alignment, and checkout.
For our purpose, we assume that corrective maintenance is composed of five
major sequential steps, as shown in Fig. 5.2. These steps are: fault recognition,
localization, diagnosis, repair, and checkout.

4. Define main components of active repair time.


Preparation time
Fault location time
Spare item obtainment time
Fault correction time
Adjustment and calibration time
Checkout time
CARILLO, JOHN CARLO B. MAINTENANCE ENGINEERING AND TRIBOLOGY
BSME – 3A

5. Discuss at least four strategies for reducing the system-level corrective maintenance
time.
 Efficiency in fault recognition, location, and isolation: Past experience indicates that in
electronic equipment, fault isolation and location consume the most time within a
corrective maintenance activity. In the case of mechanical items, often the largest
contributor is repair time. Factors such as well-designed fault indicators, good
maintenance procedures, well-trained maintenance personnel, and an unambiguous fault
isolation capability are helpful in lowering corrective maintenance time.
 Effective interchangeability: Good physical and functional interchangeability is useful in
removing and replacing parts/items, reducing maintenance downtime, and creating a
positive impact on spares and inventory needs.
 Redundancy: This is concerned with designing in redundant parts that can be switched in
at the moment of need so the equipment/system continues to operate while the faulty part
is being repaired. In this case the overall maintenance workload may not be reduced, but
the equipment/system downtime could be impacted significantly.
 Effective accessibility: Often a significant amount of time is spent accessing the failed
part. Proper attention to accessibility during design can help reduce part accessibility time
and, in turn, the corrective maintenance time.
 Human factor considerations: Attention paid to human factors during design in areas
such as readability of instructions, size, shape, and weight of components, selection and
placement of dials and indicators, size and placement of access, gates, and readability,
and information processing aids can help reduce corrective maintenance time
significantly.

6. Define median corrective maintenance time.


 MEDIAN ACTIVE CORRECTIVE MAINTENANCE TIME
This normally provides the best average location of the sample data and is the 50 th
percentile of all values of repair time. It may be said that median corrective maintenance
time is a measure of the time within which 50% of all corrective maintenance can be
accomplished. The computation of this measure depends on the distribution representing
corrective maintenance times. Consequently, the median of the lognormally distributed
corrective maintenance times is given by
CARILLO, JOHN CARLO B. MAINTENANCE ENGINEERING AND TRIBOLOGY
BSME – 3A

7. Assume that exponential mean time to failure and mean corrective maintenance time of
a system are 2500 h and 4 h, respectively. Calculate the system steady-state availability.

8. A system can fail in two mutually exclusive failure modes. Failure mode I constant
failure and corrective maintenance rates are 0.005 failures per hour and 0.02 repairs
per hour, respectively. Similarly, failure mode II constant failure and corrective
maintenance rates are 0.001 failures per hour and 0.03 repairs per hour, respectively.
Calculate the system steady-state availability.
CARILLO, JOHN CARLO B. MAINTENANCE ENGINEERING AND TRIBOLOGY
BSME – 3A

9. A system is composed of two independent and identical units in parallel. Although a


failed unit is repaired immediately, the failed system is never repaired. The unit times to
failure and corrective maintenance times are exponentially distributed. Thus, the unit
mean time to failure and mean corrective maintenance time are 200 h and 2 h,
respectively. Calculate the system mean time to failure.

10. Assume that a system is composed of two independent and identical units in parallel and
at least one unit must operate normally for system success. The unit failure and repair
rates are 0.002 failures per hour and 0.01 repairs per hour, respectively. The failed
system is never repaired. Calculate the value of the system approximate effective failure
rate.

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