A Classic Text —

Maintenance, Replacement and Reliability:
Theory and Application

by Dr. A.K.S. Jardine and
Dr. Albert H.C. Tsang

To Order

While reliability-centered maintenance answers the questions about what type of maintenance actions need to be taken, it does not address the issue of when to perform the recommended maintenance action that will provide the best results. Decisions need to be made about asset replacement in the best interests of an organization and about how to meet the resource requirements of the maintenance operation in a cost-effective manner. Maintenance, Replacement and Reliability: Theory and Application demonstrates how data-driven procedures and tools can be used to address improtant optimization issues in an organization's pursuit of excellece in asset management.

Authors Jardine and Tsang begin by presenting a framework that organizes the key areas of maintenance and replacement decisions, setting the scene for a range of problems covered in the book. This is followed by discussions that highlight the principles associated with optimization, model construction, and analysis. The problem areas studied include preventive replacement intervals, inspection frequencies, condtion-based maintenance actions, capital equipment replacement, and maintenance resource requirements. The book contains models firmly rooted in reality and based on the results of real world research. The appendices provide the relevant statistics, Weibull analysis tools, and the time value of money concepts that support the formulation of maintenance models.

The book meets the increasing demand for knowledge tools that practicing maintenance and reliablity professionals can use to optimize their maintenance/reliablity decisions.

Table of Contents

Chapter 1:

1.1 From Maintenance Management to Physical Asset Management
1.2 The Challenges of Physical Asset Management
1.3 Improving Physical Asset Management
1.4 Reliability through the Operator: Total Productive Maintenance
1.5 Reliability by Design: Reliability-Centered Maintenance
1.6 Optimizing Maintenance and Replacement Decisions
1.7 The Quantitative Approach

Chapter 2:
Component Replacement Decisions

2.1 Introduction
2.2 Optimal Replacement Times for Equipment Whose Operating Cost Increases with Use
2.3 Stochastic Preventive Replacement: Some Introductory Comments
2.4 Optimal Preventive Replacement Interval of Items Subject to Breakdown (Also Known as the Group or Block Policy
2.5 Optimal Preventive Replacement Age of an Item Subject to Breakdown
2.6 Optimal Preventive Replacement Age of an Item Subject to Breakdown, Taking Account of the Times Required to Effect Failure and Preventive Replacements
2.7 Optimal Preventive Replacement Interval or Age of an Item Subject to Breakdown: Minimization of Downtime
2.8 Group Replacement: Optimal Interval between Group Replacements of Items That Are Subject to Failure: The Lamp Replacement Problem
2.9 Further Replacement Models
2.10 Spare Parts Provisioning: Preventive Replacement Spares
2.11 Spare Parts Provisioning: Insurance Spares
2.12 Solving the Constant-Interval and Age-Based Models Graphically:
2.13 Solving the Constant-Interval and Age-Based Models Using the
OREST Software

Chapter 3:
Inspection Decisions

3.1 Introduction
3.2 Optimal Inspection Frequency: Maximization of Profit
3.3 Optimal Inspection Frequency: Minimization of Downtime
3.4 Optimal Inspection Interval to Maximize the Availability of Equipment Used in Emergency Conditions, Such as a Protective Device
3.5 Optimizing Condition-Based Maintenance (CBM) Decisions References Problems

Chapter 4:
Capital Equipment Replacement Decisions

4.1 Introduction
4.2 Optimal Replacement Interval for Capital Equipment: Minimization of Total Cost
4.3 Optimal Replacement Interval for Capital Equipment: Maximization of Discounted Benefits
4.4 Optimal Replacement Interval for Capital Equipment Whose Planned Utilization Pattern Is Variable: Minimization of Total Cost
4.5 Optimal Replacement Policy for Capital Equipment Taking into Account Technological Improvement: Finite Planning Horizon
4.6 Optimal Replacement Policy for Capital Equipment Taking into Account Technological Improvement: Infinite Planning Horizon
4.7 Software for Economic Life Optimization

Chapter 5:
Maintenance Resource

5.1 Introduction
5.2 Queuing Theory Preliminaries
5.3 Optimal Number of Workshop Machines to Meet a Fluctuating Workload
5.4 Optimal Mix of Two Classes of Similar Equipment (such as Medium/Large Lathes) to Meet a Fluctuating Workload
5.5 Rightsizing a Fleet of Equipment: An Application
5.6 Optimal Size of a Maintenance Workforce to Meet a Fluctuating Workload, Taking Account of Subcontracting Opportunities
5.7 The Lease or Buy Decision
5.7.1 Statement of Problem References

Appendix 1:
Statistics Primer

A1.1 Introduction
A1.2 Relative Frequency Histogram
A1.3 Probability Density Function
A1.4 Cumulative Distribution Function
A1.5 Reliability Function
A1.6 Hazard Rate
Further Reading

Appendix 2:
Weibull Analysis

A2.1 Weibull Distribution
A2.2 Weibull Paper
A2.3 Weibull Plot
A2.4 Confidence Interval of Weibull Plot
A2.5 Bq Life
A2.6 Kolmogorov–Smirnov Goodness-of-Fit Test
A2.7 Analyzing Failure Data with Suspensions
A2.8 Analyzing Grouped Failure Data with Multiple Suspensions
A2.9 Analyzing Competing Failure Data
A2.10 Hazard Plot
A2.11 Other Approaches to Weibull Analysis
A2.12 Analyzing Trends of Failure Data

Appendix 3:
Time Value of Money: Discounted Cash Flow Analysis

A3.1 Introduction
A3.2 Present Value Formulae
A3.3 Determination of Appropriate Interest Rate
A3.4 Inflation
A3.5 The Equivalent Annual Cost
A3.6 Example: Selecting an Alternative — A One-Shot Decision
A3.7 Further Comments

Appendix 4:
List of Applications of Maintenance Decision O
ptimization Models

Appendix 5:
Ordinates of the Standard Normal Distribution

Appendix 6:
Areas in the Tail of the Standard Normal Distribution

Appendix 7:
Values of Gamma Function

Appendix 8:
Median Ranks Table

Appendix 9:
Five Percent Ranks Table

Appendix 10:
Ninety-Five Percent Ranks Table

Appendix 11:
Critical Values for the Kolmogorov–Smirnov Statistic

Appendix 12:
Answers to Problems