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Rajiv Nandan Rai - Repairable Systems Reliability Analysis

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Название:
Repairable Systems Reliability Analysis
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Rajiv Nandan Rai
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unrecognised / на английском языке
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Most of the reliability literature is directed towards non repairable systems, that is, systems that fail are discarded. This book is mainly dedicated towards providing coverage to the reliability modeling and analysis of repairable systems that are repaired and not replaced when they fail. Most of the equipment – mechanical or otherwise -are repairable and are subjected to maintenance actions- reactive or proactive- at various levels. Maintenance actions are carried out either to preserve a system or to renovate it to a specified functionable state. Maintenance actions are also characterized by the degree (perfect or imperfect) to which a system can be restored, i.e., to an ‘as good as new condition’ (AGAN), or ‘as bad as old condition’ (ABAO). Mathematically perfect repair is modeled using a renewal process (RP). Since it represents much idealized situation, this model has restricted applications in the analysis of repairable systems. At the other extreme, the ABAO repair is mathematically modelled using a Non-Homogenous Poisson Process (NHPP). These assumptions are very unrealistic for probabilistic modeling and leads to major distortions in statistical analysis.
This unique book provides a comprehensive framework for the modeling and analysis of repairable systems considering both the non- parametric and parametric approaches to deal with the failure data. The book presents MCF based non-parametric approach with several illustrative examples and the generalized renewal process (GRP) based arithmetic reduction of age (ARA) models along with its applications to the systems failure data from aviation industry. The book also covers various multi-criteria decision-making (MCDM), integrated with repairable systems reliability analysis models to provide a much better insight into imperfect repair and maintenance data analysis. A complete chapter on an integrated framework for procurement process is added which will of a great assistance to the readers in enhancing the potential of their respective organization. This book also presents FMEA methods tailored for GRP based repairs.
This text has primarily emerged from the industrial experience and research work of the authors. A number of illustrations have been included to make the subject lucid and vivid even to the readers who are relatively new to this area. Besides, various examples have been provided to display the applicability of presented models and methodologies to assist the readers in applying the concepts presented in this book.

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This book presents modified failure modes and analysis (FMEA) model in Chapter 6. This model is based on the concept of REI propounded by Kijima and is best applicable to the repairable systems reliability analysis.

Chapter 7provides an integrated approach for weapon procurement systems for military aviation. The combined applications of MCDM tools like AHP, ANP, and optimization techniques can be seen in this chapter. This model can be used for other industries procurement policy as well.

Chapter 8is aimed at reducing the overhaul time of a repairable equipment to enhance the availability. Various concepts of throughput analysis have been utilized in this chapter.

The book makes an honest attempt to provide a comprehensive coverage to various models and methodologies that can be used for modeling and analysis of repairable systems reliability analysis. However, there is always a scope for improvement and we are looking forward to receiving critical reviews and/or comments of the book from students, teachers, and practitioners. We hope that the readers will all gain as much knowledge, understanding, and pleasure from reading this book as we have from writing it.

Rajiv Nandan Rai Sanjay Kumar Chaturvedi Nomesh BoliaAugust 2020

List of Tables

Table 2.1	Rotating machine failure data of Example 2.2
Table 2.2	MCF and confidence calculations
Table 2.3	Example 2.3—Burn-in period determination
Table 2.4	Data for Example 2.4
Table 2.5	List of failure categories and counts for all 53 ROVs
Table 2.6	Failure Counts in Months Corresponding their Failure Modes
Table 2.7	MCF calculation by combining all failure modes
Table 2.8	MCF calculation for individual category at 24 months
Table 2.9	A sample of collected data
Table 2.10	Exercise 1: Failure data of three systems
Table 3.1	Time to failure data (hours) of aero engines of Example 3.2
Table 3.2	Virtual age–based reliability metrics
Table 3.3	Time to failure data (hours) of Example 3.4
Table 3.4	Time to failure data (hours) of Example 3.5
Table 3.5	Time between failures for a compressor
Table 4.1	Hypothesis tests
Table 5.1	Maintenance modeling in repairable systems
Table 5.2	Relative outcome of the two overhaul cycles
Table 5.3	Relative outcome of the two overhaul cycles
Table 5.4	Comparative results of both overhaul cycles (Variant 1)
Table 5.5	Comparative results of both overhaul cycles (Variant 2)
Table 5.6	Results-failure mode wise for first overhaul cycle
Table 5.7	Results-failure mode wise for t 2OH
Table 5.8	Failure mode wise percent improvement
Table 5.9	Comparative results of both overhaul cycles for the aero engine
Table 6.1	Extensions to standard FMEA
Table 6.2	Failure cause-mode effect relationship
Table 6.3	Severity rating
Table 6.4	Occurrence rating
Table 6.5	Failure mode wise initial RPN
Table 6.6	Failure mode wise values of final Q
Table 6.7	Final RPNs
Table 6.8	FM1
Table 6.9	FM2
Table 6.10	FM3
Table 6.11	Comparative results
Table 7.1	Brief literature review on WSCE using MCDM
Table 7.2	Weights for API
Table 7.3	Actual and scaled API values of each weapon category
Table 7.4	APV estimation of combat force “ALPHA”
Table 7.5	APV enhancement
Table 7.6	API ijvalues
Table 7.7	C ij(million USD), a i, d i, and m i
Table 7.8	A ijvalues
Table 7.9	Optimal x ijvalues
Table 8.1	Brief literature review on TH analysis
Table 8.2	Required TH of the three components
Table 8.3	Process requirements of LPCR blades repair
Table 8.4	Process requirements of CCOC repair
Table 8.5	Process requirements of LPTR blades repair
Table 8.6	Component 1—LPCR blades
Table 8.7	Component 2—CCOC
Table 8.8	Component 3—LPTR blades

List of Figures

Figure 1.1	Types of repair
Figure 1.2	Various techniques for reliability analysis
Figure 2.1	A MCF example
Figure 2.2	An improving system
Figure 2.3	A stable system
Figure 2.4	A deteriorating system
Figure 2.5	History and distribution of failures observed at age t
Figure 2.6	MCF plot of Example 2.2
Figure 2.7	Graphical plots of Example 2.3
Figure 2.8	MCF with confidence bounds of Example 2.2 data
Figure 2.9	MCF plot of Example 2.4
Figure 2.10	A ROV. (Image taken from: https://www.pinterest.com/pin/552676185495210644/?nic=1)
Figure 2.11	MCF by combining all failure modes
Figure 2.12	Event plot for each system
Figure 2.13	MCF plot of each system
Figure 2.14	Grouping of systems based on performance behavior
Figure 2.15	Event plot of all three groups
Figure 2.16	MCF plot of all three groups
Figure 3.1	Bathtub-shaped intensity function
Figure 3.2	Conditional probability of occurrence of failures
Figure 3.3	Photograph of an aero engine
Figure 3.4	Intensity function plot for Example 3.1
Figure 3.5	Intensity function plot for Example 3.2
Figure 3.6	Intensity function plot for Example 3.3
Figure 3.7	Availability plot for Example 3.3
Figure 5.1	Reliability-based HFRC threshold
Figure 5.2	Availability-based threshold for HFRC
Figure 5.3	Flying task vs. availability
Figure 6.1	q vs. F(v i\| v i–1) for FM1
Figure 6.2	q vs. F(v i\| v i–1) for FM2
Figure 6.3	q vs. F(v i\| v i–1) for FM3
Figure 7.1	Overview of the approach
Figure 7.2	Evaluation of alternatives through ANP
Figure 7.3	Evaluation of APE through AHP
Figure 8.1	Overview of Chapter 8
Figure 8.2	Propagation of variability between workstations in series
Figure 8.3	Work flow/work stations for engine overhaul line
Figure 8.4	Work flow/work stations for LPCR blades
Figure 8.5	Work flow/work stations for CCOC
Figure 8.6	Work flow/work stations for LPTR blades repair