G522A - System Reliability and Maintainability Analysis and Optimization
Learn System Reliability / Maintainability and Related Analyses
G522A explores advanced concepts and applications for system reliability/maintainability analysis and optimization utilizing a reliability block diagram (RBD) or fault tree analysis (FTA) approach.
The course presents concepts and software tools that you could use to help your organization:
- Identify critical components (or failure modes) and determine the most effective ways to improve system performance through design improvements and/or maintenance planning.
- Use simulation to obtain estimated performance metrics that can facilitate decision-making in a variety of areas, such as scheduling planned maintenance, planning for spares, identifying bottlenecks in production throughput and estimating life cycle costs.
Principles and Theory
Introduction and Overview
- Defining a system.
- Viewing a system as a collection of components and/or component failure modes.
RBD Configurations and Fault Tree Gates and Events
- Using reliability block diagrams (RBDs) to represent the reliability model of system.
- Series configurations.
- Simple parallel configurations.
- k-out-of-n configurations.
- Complex configurations.
- Bayes' theorem method.
- Complex configurations for failure modes, networks and mechanical systems.
Introduction to Time Dependency
- Introduction to time dependency.
- Inclusion of "used" components in modeling.
- System reliability metrics:
- Obtaining a system pdf.
- Derivation of functions of interest: system failure rate function, system MTTF, etc.
Advanced Reliability Block Diagram (RBD) Constructs and their Analytic Quantification
- Modeling block dependency:
- Combining life distributions with life-stress (load) relationships to describe dependency effects.
- Basic load sharing configurations.
- k-out-of-n load sharing configurations.
- Modeling standby redundancy:
- Energized and quiescent failure distributions.
- "Hot," "Warm" and "Cold" standby definitions.
- Switching (perfect or imperfect switching, with delays, retries and switch quiescent failure probabilities).
- k-out-of-n-plus-M standby configurations.
- Additional reliability block diagram (RBD) constructs:
- Block Encapsulation (subdiagram blocks).
- Block Multiplicity.
- Block Mirroring.
- Identifying importance of components, subsystems (and or modes) and their overall impact on system reliability.
Optimum Reliability Allocation
- Cost/Feasibility functions.
- Determining component reliabilities to achieve system goal.
Introduction to Discrete Event Simulation
Introduction to Repairable Systems Analysis: Fundamentals of Maintainability and Availability
- Repair and downtime distributions and metrics.
- Introduction to renewal theory.
- Introduction to maintainability.
- Imperfect repairs (restoration factors).
- Availability definitions:
- Instantaneous (Point) Availability
- Mean Availability
- Steady State Availability
- Inherent Availability
- Achieved Availability
- Operational Availability
Introduction to Preventive Maintenance (PM) Principles
- When does "Preventive Maintenance" make sense?
- The fallacy of "Constant Failure Rate" and "Preventive Replacement."
- Quantifying preventive vs. corrective replacement strategies.
- Determining optimum PM intervals.
- Modeling effects of PM actions.
Advanced Simulation Options: Using Policies, Pools and Resources
- Adding Crews to the analysis.
- Probabilistic elements.
- Crew costs.
- Crew utilization metrics and bottlenecks.
- Adding Spare Part Pools (Depots) to the analysis.
- Probabilistic elements.
- Spare part inventory management, costs.
- Spare utilization metrics and bottlenecks.
- Standard, on-condition and upon emergency spare part provisioning with associated costs and probabilistic delays.
- Utilizing "Corrective," "Preventive" and "Inspection" actions
with associated policies.
- Corrective actions, "Immediate" or "Upon Inspection" (hidden/discovery).
- Inspections based on system time, component age and/or other system events (e.g., similar component failure elsewhere in the system).
- PM actions based on system time, component age and/or other system events (e.g., similar component failure elsewhere in the system).
Visualizing and Improving System Availability
- Looking at common metrics (MTBF, MTBDE, MTBE, AX, etc.) and charts.
- Additional (new) metrics for identifying opportunities in repairable
- RS-FCI (ReliaSoft's Failure Criticality Index).
- RS-DECI (ReliaSoft's Downing Event Criticality Index).
- FRED reports.
- Throughput metrics and terminology.
- System throughput.
- Component throughput.
- System and component utilization metrics.
- Bottlenecks identification.
- Backlog processing.
Including Costs in the Analysis, Introduction to Life Cycle Cost Analysis
- Determination of the probabilistic costs associated with system operation.
- Sample financial analysis.
Introduction to Reliability Phase Diagrams
Hands-On Software Practice
- Introduction to and familiarization with BlockSim.
- Creating models in BlockSim that apply all of the above principles.
- Using realistic cases (described in an objective statement), determine how to set up and analyze each case in a team environment.