Question 1

What is the primary concept of total productive maintenance (TPM)? Identify the four elements that productive maintenance includes.

Accepted Answer

TPM's primary concept is reducing variability through autonomous maintenance and excellent maintenance practices.Four other ingredients of TPM are:
1.Designing machines that are reliable,easy to operate,and easy to maintain
2.Emphasizing total cost of ownership when purchasing machines,so that service and maintenance are included in the cost
3.Developing preventive maintenance plans that utilize the best practices of operators,maintenance departments,and depot service
4.Training for autonomous maintenance so operators maintain their own machines and partner with maintenance personnel

Question 2

A simple electrical motor has three components: windings,armature,and housing.These three components have reliabilities of .97,.992,and .999.There is no possibility of redundant parts.The motor must have an overall reliability of at least 0.980,according to the product line manager who will use the motor as an input.What would you do to redesign the motor to meet this specification? Discuss,including a recalculation to meet the standard.

Accepted Answer

Since no backup is possible,individual components must be redesigned.The windings represent the weak link,and represent the obvious choice (windings have to be improved at least some or overall reliability will not be able to exceed 0.980).If only the windings are improved,their new reliability must be at least 0.980 / [(0.992)(0.999)] = 0.988893.(The last decimal was rounded up to ensure at least .980 for the system. )

Question 3

Ten high-intensity bulbs are tested for 100 hours each.One failed at 40 hours;another failed at 70 hours;all others completed the test.Calculate FR(%),FR(N),and MTBF.

Accepted Answer

FR(%)= 2/10 or 20%;FR(N)= 2/910 or .0022;MTBF = 455 hours

Question 4

What is the reliability of the three components connected in series shown below?

Accepted Answer

A) 0.799425 
B) 0.85000 
C) 0.91333 
D) 0.95000 
E) 2.79 
A) 0.799425 
B) 0.85000 
C) 0.91333 
D) 0.95000 
E) 2.79

Question 5

Great Southern Consultants Group's computer system has been down several times over the past few months,as shown below.
   Each time the system is down,the firm loses an average of $400 in time and service expenses.They are considering signing a contract for preventive maintenance.With preventive maintenance,the system would be down on average only 0.5 per month.The monthly cost of preventive maintenance would be $200 a month.Which is cheaper,breakdown or preventive maintenance?

Accepted Answer

@#IMG-DLM& Expected # of breakdowns per month = (0

Question 6

As far as maintenance costs are concerned:

Accepted Answer

A) for low levels of maintenance commitment,breakdown maintenance costs exceed preventive maintenance costs. 
B) for low levels of maintenance commitment,preventive maintenance costs exceed breakdown maintenance costs. 
C) for high levels of maintenance commitment,breakdown maintenance costs exceed preventive maintenance costs. 
D) preventive maintenance is always more economical than breakdown maintenance. 
E) breakdown maintenance is always more economical than preventive maintenance when the "full cost of breakdowns" is taken into consideration. 
A) for low levels of maintenance commitment,breakdown maintenance costs exceed preventive maintenance costs. 
B) for low levels of maintenance commitment,preventive maintenance costs exceed breakdown maintenance costs. 
C) for high levels of maintenance commitment,breakdown maintenance costs exceed preventive maintenance costs. 
D) preventive maintenance is always more economical than breakdown maintenance. 
E) breakdown maintenance is always more economical than preventive maintenance when the "full cost of breakdowns" is taken into consideration.

Question 7

Suppose that a process is comprised of five components,each having a 75% success rate.By how much would reliability change if the process switched from having the components in series to having the components in parallel?

Accepted Answer

A) no change 
B) 100% increase 
C) 76.2% increase 
D) 76.2 % decrease 
E) 50% increase 
A) no change 
B) 100% increase 
C) 76.2% increase 
D) 76.2 % decrease 
E) 50% increase

Question 8

Ten high-technology batteries are tested for 200 hours each.One failed at 50 hours;all others completed the test.FR(%)is ________ and FR(N)is ________.

Accepted Answer

A) 10%;1/1850 
B) 10%;1/2000 
C) 25%;1850 hours 
D) 90%;1/2000 
E) 10%;1/1950 
A) 10%;1/1850 
B) 10%;1/2000 
C) 25%;1850 hours 
D) 90%;1/2000 
E) 10%;1/1950

Question 9

Autonomous maintenance occurs when:

Accepted Answer

A) employees are empowered to observe,check,adjust,clean,and notify. 
B) a remote computer system signals the need for breakdown maintenance. 
C) a remote computer system signals the need for preventative maintenance. 
D) employees perform their own breakdown maintenance. 
E) none of the above 
A) employees are empowered to observe,check,adjust,clean,and notify. 
B) a remote computer system signals the need for breakdown maintenance. 
C) a remote computer system signals the need for preventative maintenance. 
D) employees perform their own breakdown maintenance. 
E) none of the above

Question 10

Preventive maintenance implies that we can determine when a system needs service or will need repair.

Accepted Answer

A) True 
 B)False

Question 11

The MTBF distributions of products,machines,or processes that have "settled in," or gone beyond the infant mortality phase,often follow the normal distribution.

Accepted Answer

A) True 
 B)False

Question 12

The normal distribution is an appropriate model of:

Accepted Answer

A) the high initial failure rates of product,machine,or processes. 
B) system reliability where components are connected in series. 
C) system reliability where components are connected in parallel. 
D) the MTBF distribution of products,machines,or processes that have "settled in." 
E) the full cost view of maintenance. 
A) the high initial failure rates of product,machine,or processes. 
B) system reliability where components are connected in series. 
C) system reliability where components are connected in parallel. 
D) the MTBF distribution of products,machines,or processes that have "settled in." 
E) the full cost view of maintenance.

Question 13

How is MTBF related to FR(N)?

Accepted Answer

A) MTBF is measured in hours,while FR(N)is measured in years. 
B) MTBF is normally distributed,with FR(%)as its mean and FR(N)as its standard deviation. 
C) MTBF is the reciprocal of FR(N). 
D) Both MTBF and FR(N)increase when breakdown maintenance is replaced by preventive maintenance. 
E) MTBF and FR(N)are unrelated concepts. 
A) MTBF is measured in hours,while FR(N)is measured in years. 
B) MTBF is normally distributed,with FR(%)as its mean and FR(N)as its standard deviation. 
C) MTBF is the reciprocal of FR(N). 
D) Both MTBF and FR(N)increase when breakdown maintenance is replaced by preventive maintenance. 
E) MTBF and FR(N)are unrelated concepts.

Question 14

A simple electrical motor has three components: windings,armature,and housing.These three components have reliabilities of .9998,.9992,and .9999.There is no possibility of redundant parts.What is the reliability of the motor? Round your answer to four decimal places.

Accepted Answer

(0.9998)(0

Question 15

A two-component process has an 81% success rate in series and a 99% success rate in parallel.If each component has the same reliability,what is the reliability of an individual component?

Accepted Answer

A) 50% 
B) 90% 
C) 99% 
D) 18% 
E) 81% 
A) 50% 
B) 90% 
C) 99% 
D) 18% 
E) 81%

Question 16

A manager is comparing the total maintenance (preventive plus breakdown)cost curves for two scenarios.The graphs have maintenance commitment on the x-axis and costs on the y-axis.Scenario A includes the direct breakdown maintenance costs,while Scenario B includes the "full" (direct and indirect)breakdown maintenance costs.Which of the following should the manager notice when going from Scenario A to Scenario B?

Accepted Answer

A) Total cost is decreased. 
B) Optimal point is moved to the left. 
C) Optimal point is moved to the right. 
D) Preventative maintenance cost slope is increased. 
E) None of the above 
A) Total cost is decreased. 
B) Optimal point is moved to the left. 
C) Optimal point is moved to the right. 
D) Preventative maintenance cost slope is increased. 
E) None of the above

Question 17

A component must have reliability of .9925.Two technologies are available for this component: one produces a component with .999 reliability at a cost of $2000.Another produces a component with .73 reliability at a cost of $450.Which is cheaper: one high quality component or a parallel set of inferior components? (Hint: for the inferior components,you first need to determine the number of them that would be needed to ensure overall reliability of .9925. )

Accepted Answer

First,determine how many of the 0.73 rel

Question 18

Ten high-technology batteries are tested for 200 hours each.One failed at 20 hours;all others completed the test.FR(%)is ________ and MTBF is ________.

Accepted Answer

A) 10%;1/1820 
B) 90%;1/1820 
C) 10%;1820 hours 
D) 10%;1980 hours 
E) 10%;2000 hours 
A) 10%;1/1820 
B) 90%;1/1820 
C) 10%;1820 hours 
D) 10%;1980 hours 
E) 10%;2000 hours

Question 19

Which of the following is a reliability tactic?

Accepted Answer

A) improving individual components 
B) increasing repair speed 
C) providing redundancy 
D) A and C 
E) A,B,and C 
A) improving individual components 
B) increasing repair speed 
C) providing redundancy 
D) A and C 
E) A,B,and C

Question 20

A product is composed of a series connection of four components with the following reliabilities.What is the reliability of the system?

Accepted Answer

The reliability of t

Exam 17: Maintenance and Reliability

What is the primary concept of total productive maintenance (TPM)? Identify the four elements that productive maintenance includes.

Ten high-intensity bulbs are tested for 100 hours each.One failed at 40 hours;another failed at 70 hours;all others completed the test.Calculate FR(%),FR(N),and MTBF.

What is the reliability of the three components connected in series shown below?

As far as maintenance costs are concerned:

Suppose that a process is comprised of five components,each having a 75% success rate.By how much would reliability change if the process switched from having the components in series to having the components in parallel?

Ten high-technology batteries are tested for 200 hours each.One failed at 50 hours;all others completed the test.FR(%)is ________ and FR(N)is ________.

Autonomous maintenance occurs when:

Preventive maintenance implies that we can determine when a system needs service or will need repair.

The MTBF distributions of products,machines,or processes that have "settled in," or gone beyond the infant mortality phase,often follow the normal distribution.

The normal distribution is an appropriate model of:

How is MTBF related to FR(N)?

A simple electrical motor has three components: windings,armature,and housing.These three components have reliabilities of .9998,.9992,and .9999.There is no possibility of redundant parts.What is the reliability of the motor? Round your answer to four decimal places.

A two-component process has an 81% success rate in series and a 99% success rate in parallel.If each component has the same reliability,what is the reliability of an individual component?

Ten high-technology batteries are tested for 200 hours each.One failed at 20 hours;all others completed the test.FR(%)is ________ and MTBF is ________.

Which of the following is a reliability tactic?

A product is composed of a series connection of four components with the following reliabilities.What is the reliability of the system?

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Ten high-technology batteries are tested for 200 hours each.One failed at 50 hours;all others completed the test.FR(%)is and FR(N)is .

Ten high-technology batteries are tested for 200 hours each.One failed at 20 hours;all others completed the test.FR(%)is and MTBF is .