What is the link between reliability and maintenance? ANSWER -

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 MAINTENANCE MANAGEMENT
N.B. : 1) Please read the cases carefully
2) All questions are compulsory
3) Figures in the right margin indicate full marks
4) Total marks : 80
CASE 1 :
Somalu Industries in Andhra Pradesh, is facing frequent break down. Its
managing director, Mr D V K Soma Reddy is quite perturbed about these
breakdowns. He was in the United States and worked there in sophisticated
plants and also worked in Gulf countries, but never faced so many break
downs. From Somalu Industries, internal records, the number of
Breakdowns of Equipments, over the past 2 years are as furnished below :
No. of
Breakdowns
0 1 2 3 4 Total
No. of
months of
occurrence
3 7 1 3 2 24
AN ISO 9001 : 2008 CERTIFIED INTERNATIONAL B-SCHOOL
It has been worked out that each break down costs are average of Rs 3,000/-
preventive maintenance services can be hired at a cost of Rs 1500 per
month, and is expected that preventive maintenance service, will limit the
break downs to an average of one break down per month only.
In this case, you are required to find out i) which maintenance arrangement
is preferable; ii) the current break down maintenance policy or a preventive
service contact; iii) Please give elaborate reasons for your comments on
this case.
(25 Marks)
CASE 2 :
In Noida, the work shop of Mr Jagadhry has twenty identical machines.
Senior Maintainance Supervisor, Mr B N Singh has recorded the failure
pattern of the machines in Yagerdhry Industries.
Mr B N Singh, did his B E(Mechanical), from Roorkee and after working
for BHEL, a stint of 5 years, he went to Africa on deputation. After
returning from Africa, Mr B N Singh opted for Jagudhry Industries, since
Mr Jagudhry was personally known to him and Mr Jagudhry has an
analytical bent of mind and always encouraged research/analysis. B N
Singh has recorded the failure pattern of the machines in the following
manner :
Esimated Time (In months)
After Maintenance Attention
Probability of Failure
1 0.20
2 0.15
3 0.15
4 0.15
5 0.15
6 0.20
Mr B N Singh, observed that it gots Rs 1500 to attend a failed machine and
rectify the same. He also computed the cost of servicing the broken down
machines.
1) In this case, you are required to find expected value of elapsed time (in
month), i.e. the internal between two successfive break downs in months.
2) Expected no. of break downs per machine per year.
3) Total number of expected break downs for 20 machines per year.
4) Cost of servicing the driven down machine per year.
5) Give your elaborate comments on the findings, it’s interpretation and
you suggestions for improved method or alternative method.
(25 Marks)
CASE 3 :
The dramatic success of the Japanese had been attributed to a large extent to
the quality of their manufacturing goes “quality is multi-dimensional but
reliability is a key component of quality. In fact, product reliability was the
top priority of the Japanese firms. Japanese automobile and other products
have been highly successful in the US market and also gained a high market
share. In fact, product quality are exceptional reliability of Japanese
products, is the key reason for this.
Reliability considers the performance of a product for long time. The
random of interest concern the amount of elapsed time between failures
after a product is placed into service. Thus, reliability is time based concept
of quality. It is the probability that a product will operate adequately for or
given period in the intended application.
Sony, as an electronics manufacturer has gone above what many other
electronic companies as such. Sony has brought great many inventions
which have benefited mankind. Sony continues to innovate and has become
a world class leader in reliable electronics.
In this case, you are required to answer the following :
1) What is the link between reliability and maintenance, please elaborate.
2) List the aspects of from producers point of view.
3) What are the risks of poor reliability borne by the consumer.
4) What are the needs for Total Productive Maintenance.
5) What do you mean by Reliability Engineering and Reliability
Quantification.
6) How `Failure Rate’ is computed.
(30 Marks)