Maintenance, Replacement, and Reliability: Theory and Applications, Second Edition

360 Pages·2013·4.283 MB·English

by  Jardine, Andrew K. S., Tsang, Albert H. C

Manufacturing and Industrial Engineering
SEcoNd
Maintenance, Replacement, and Reliability
EditioN
Theory and Applications
T M
S E c oN d E d i t i oN h
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A completely revised and updated edition of a bestseller, Maintenance, Replacement, and o i
n
Reliability: Theory and Applications, Second Edition supplies the tools needed for making r
y t
data-driven physical asset management decisions. The well-received first edition quickly e

became a mainstay for professors, students, and professionals, with its clear presentation a n
of concepts immediately applicable to real-life situations. However, research is ongoing and n a
relentless—in only a few short years, much has changed. d n

A c
See What’s New in the Second Edition: p e
p ,
New Topics
l R
• The role of maintenance in sustainability issues i
c
e
• PAS 55, a framework for optimizing management assets a
p
• Data management issues, including cases where data are unavailable or sparse t
i l
• How candidates for component replacement can be prioritized using the Jack-knife o a
diagram n c
s e
m
New Appendices
• Maximum Likelihood Estimated (MLE) e
• Markov chains and knowledge elicitation procedures based on a Bayesian approach n
to parameter estimation t
,
• E-learning materials now supplement two previous appendices (Statistics Primer and
a
Weibull Analysis)
n
• Updated the appendix List of Applications of Maintenance Decision Optimization
d
Models
R
Firmly based on the results of real-world research in physical asset management, the book e
focuses on data-driven tools for asset management decisions. It provides a solid theoretical l
i
foundation for various tools (mathematical models) that, in turn, can be used to optimize a a
variety of key maintenance/replacement/reliability decisions. It presents cases that illustrate b
i
the application of these tools in a variety of settings, such as food processing, petrochemi- l
i
cal, steel and pharmaceutical industries, as well as the military, mining, and transportation t
y
(land and air) sectors.
Based on the authors’ experience, the second edition maintains the format that made the
previous edition so popular. It covers theories and methodologies grounded in the real
world. Simply stated, no other book available addresses the range of methodologies asso-
ciated with, or focusing on, tools to ensure that asset management decisions are optimized
over the product’s life cycle. And then presents them in an easily digestable and immedi- Jardine
ately applicable way.
tsang
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Maintenance,
Replacement,
and Reliability
Theory and Applications
S e c o n d e d i t i o n

Maintenance,
Replacement,
and Reliability
Theory and Applications
S e c o n d e d i t i o n
Andrew K.S. Jardine
Albert H.c. tsang
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2013 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
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Version Date: 20130515
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Dedication
To my wife Renee, daughter Charis, and son Alvin.
Albert H.C. Tsang
To BANAK (minus an A), their spouses and bairns
(Callum, Cameron, Lachlan, Meghan, and Andrew).
Andrew K.S. Jardine

Contents
Preface for the First Edition .....................................................................................xv
Preface for the Second Edition ..............................................................................xvii
Acknowledgments for the First Edition ..................................................................xix
Acknowledgments for the Second Edition ..............................................................xxi
Authors .................................................................................................................xxiii
Abstract ..................................................................................................................xxv
Chapter 1 Introduction ..........................................................................................1
1.1 From Maintenance Management to Physical Asset
Management ..............................................................................1
1.2 Challenges of PAM ....................................................................2
1.2.1 Emerging Trends of Operation Strategies ....................2
1.2.2 Toughening Societal Expectations ...............................2
1.2.3 Technological Changes .................................................2
1.2.4 Increased Emphasis on Sustainability ..........................3
1.3 Improving PAM .........................................................................4
1.3.1 Maintenance Excellence ...............................................4
1.3.1.1 Strategic ........................................................5
1.3.1.2 Tactical ..........................................................5
1.3.1.3 Continuous Improvements ............................6
1.3.2 Quantum Leaps ............................................................6
1.4 PAS 55—A Framework for Optimized Management of
Physical Assets ..........................................................................6
1.5 Reliability through the Operator: TPM .....................................7
1.6 Reliability by Design: RCM ......................................................9
1.7 Optimizing Maintenance and Replacement Decisions ...........13
1.8 The Quantitative Approach .....................................................16
1.8.1 Setting Objectives .......................................................17
1.8.2 Models ........................................................................18
1.8.3 Obtaining Solutions from Models ..............................21
1.8.4 Maintenance Control and Mathematical Models .......22
1.9 Data Requirements for Modeling ............................................24
References ..........................................................................................24
Chapter 2 Component Replacement Decisions ...................................................27
2.1 Introduction .............................................................................27
2.2 Optimal Replacement Times for Equipment Whose
Operating Cost Increases with Use .........................................30
2.2.1 Statement of the Problem ...........................................30
vii
viii Contents
2.2.2 Construction of the Model..........................................31
2.2.3 Numerical Example ....................................................33
2.2.4 Further Comments .....................................................34
2.2.5 Applications ................................................................36
2.2.5.1 Replacing the Air Filter in an Automobile ...36
2.2.5.2 Overhauling a Boiler Plant .........................37
2.3 Stochastic Preventive Replacement: Some Introductory
Comments ................................................................................38
2.4 Optimal Preventive Replacement Interval of Items
Subject to Breakdown (Also Known as the Group or
Block Policy) ............................................................................39
2.4.1 Statement of the Problem ...........................................39
2.4.2 Construction of the Model..........................................40
2.4.3 Determination of H(t) .................................................41
2.4.3.1 Renewal Theory Approach .........................41
2.4.3.2 Discrete Approach ......................................43
2.4.4 Numerical Example ....................................................46
2.4.5 Further Comments .....................................................47
2.4.6 An Application: Optimal Replacement Interval
for a Left-Hand Steering Clutch .................................48
2.5 Optimal Preventive Replacement Age of an Item Subject
to Breakdown ...........................................................................48
2.5.1 Statement of the Problem ...........................................48
2.5.2 Construction of the Model..........................................49
2.5.3 Numerical Example ....................................................52
2.5.4 Further Comments .....................................................53
2.5.5 An Application: Optimal Bearing
Replacement Age .......................................................54
2.6 Optimal Preventive Replacement Age of an Item Subject
to Breakdown, Taking Account of the Times Required to
Carry Out Failure and Preventive Replacements ....................55
2.6.1 Statement of the Problem ...........................................55
2.6.2 Construction of the Model..........................................55
2.6.3 Numerical Example ....................................................56
2.7 Optimal Preventive Replacement Interval or Age of an
Item Subject to Breakdown: Minimization of Downtime .......57
2.7.1 Statement of the Problem ...........................................57
2.7.2 Construction of the Models ........................................58
2.7.2.1 Model 1: Determination of Optimal
Preventive Replacement Interval ................58
2.7.2.2 Model 2: Determination of Optimal
Preventive Replacement Age ......................59
2.7.3 Numerical Examples ..................................................59
2.7.3.1 Model 1: Replacement Interval ...................59
2.7.3.2 Model 2: Replacement Age .........................60
2.7.4 Further Comments .....................................................61