Solved Assignment July Dec 2016

MS-57 (Sample Copy)

Course Code

MS - 57

Course Title

Total Quality Management

Assignment Code

MS-57/TMA/SEM - II/2016

Assignment Coverage

All Blocks

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1. What is reliability centred maintenance? What are the important steps involved in implementing it in any
plant?
Reliability-Centred Maintenance (RCM) is the process of determining the most effective maintenance approach. The RCM
philosophy employs Preventive Maintenance (PM), -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------function of the facility, with the required
reliability and availability at the lowest cost. RCM requires that maintenance decisions be based on maintenance requirements
supported by sound technical and economic justification.
The primary RCM principles are:
1. RCM is Function Oriented It seeks to -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------functional reliability, but increases life cycle cost in
terms of procurement and operating costs.
2. RCM is System Focused It is ---------------------------------------------------------------------------- component function.
3. RCM is Reliability Centered It treats failure statistics ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------occur in each given operating age bracket).
4. RCM Acknowledges Design Limitations Its objective is to maintain -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------that a difference often
exists between the perceived design life and the intrinsic or actual design life, and addresses this through the Age Exploration
(AE) process.
5. RCM is driven by Safety and Economics Safety must be ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- becomes the criterion.

6. RCM ------------------------------------------------------ Condition Therefore, failure ------------------------------------------------------------------------------------------------------------------- of acceptable quality (operation continues).
7. RCM --------------------------------------------- Screen Maintenance Tasks This ------------------------------------------------------------------------------------------------------------------------------------------------------. See Figure 1.
8. RCM Tasks ---------------------- The tasks must address the ------------------------------------------------------ characteristics.
9. RCM ---------------- Be Effective The ----------------------------------------------------------------------- and be cost effective.
10. RCM is a Living System It gathers -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------Proactive Maintenance element of the RCM program.
There are several different ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- that are recommended, summarized in the following 7 steps.
Step 1: Selection of equipment for RCM analysis
The first step is to ----------------------------------------------------------------------------------------------------- selected should be critical,
in terms of its effect on operations, its previous costs of repair and previous costs of preventative maintenance.
Step 2: Define the ------------------------------------------------------- that contain the selected equipment
The equipment belongs to a system that performs a crucial function. The system can be large or small, but the function of the
system, and its inputs and outputs, should be known. For example, the -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------at the other end. In this
case, the electric motor supplying the mechanical energy would be considered as part of a different system.
Step 3: Define ------------------------------------------------- can fail (failure modes)
In step 3 the objective is to list all of the ways that the function of the system can fail. For example, the ------------------------------------------------------------------------------------------------------------------------------- transport the goods quickly enough.
Step 4: Identify the ----------------------------------------------- modes
With the help of operators, experienced -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------conveyor could include a lack of lubrication on the
rollers, a failure of a bearing, or a loosened belt.
Step 5: Assess the effects of failure
In this step the effects of each ---------------------------------------------------------------------------------------------------------------------------------------------------------------------- and other equipment. Criticality of each of these failure modes can also be considered.
There are various recommended techniques that are used to give this step a systematic approach. These include:
1. Failure, ---------------------------------------------------- (FMEA)
2. Failure, --------------------------------------------- criticality analysis
3. Hazard -------------------------------------------- studies (HAZOPS)
4. Fault ------------------------------------------- (FTA)
5. Risk-------------------------------------- (RBI)
The most important failure modes will be determined -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------for further analysis. Importantly, the failure
modes that are retained include only those that have a real probability of occurring under realistic operating conditions.

Step 6: Select a ---------------------------------------- each failure mode

At this step, the most ----------------------------------------------------------------------------------------------------------- maintenance tactic
that is selected must be technically and economically feasible.
Condition-based maintenance is ------------------------------------------------------------------------ the onset of the failure mode.
Time or usage-based preventative maintenance is selected when ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- risk of failure using this method.
For failure modes that do --------------------------------------------------------------------------------------------------------- options, then a
redesign of the system to eliminate or modify the failure mode should be considered.
Failure

modes

that

were

not

---------------------------------------------------------------------------------------------------------------

candidates for a run-to-failure maintenance schedule.

Step 7: Implement -------------------------------------------------------------- tactic selected
Importantly, the RCM methodology will only ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------reviewed and renewed as additional information is found.

2. What is the importance of maintenance budgeting? Give the advantage of Zero Based Budget.

Maintenance budgetingA budget is a detailed plan of operations for some ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------and other expenses. It is prepared to bring efficiency and economy in the
maintenance activities.
Since the importance of the maintenance costs lies in their influence on production costs, the budgets must therefore portray them
in production terms, and must result from ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- the information, prepares the budget statement and issues the periodic returns and
statistics relating to actual performance against forecasted performance.
Maintenance costing and budgeting is a planning and ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- discussion

between

the maintenance management, the production

management and the financial control.

ImportanceThe central importance of budgeting to the formulation of maintenance strategy, is stressed and it is explained, by reference to real
case examples, that the maintenance budget should be -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------units and, finally, it is explained that, all too often, maintenance budgeting is

rarely as rational as described, senior management seeing maintenance only as a cost and ignoring the linkage between
maintenance expenditure and production output.
The need for a maintenance budget arises from the -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------needs, e.g. operating pattern and availability) and in turn generates the
maintenance workload.

Most large process plants use some form of strategic -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------replacement of capital equipment (which I find surprising).
Budgeting has two primary functions: planning and control. -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------control of a budget benefit a company in many ways, including:
ENHANCING MANAGERIAL PERSPECTIVE- In -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------company's ability to respond to them, forces managers to synthesize the
external economic environment with their internal goals and objectives.

FLAGGING POTENTIAL PROBLEMS- Because the -----------------------------------------------------------------------------------------------------------------------------------------------------------------------, managers can revise their immediate plans to change a product mix,
revamp an advertising campaign, or borrow money to cover cash shortfalls.
COORDINATING ACTIVITIES- Preparation ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- demonstrates to managers the inter-connectedness of their activities.

EVALUATING PERFORMANCE- Budgets ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------ a consistent pattern of inefficiency.

REFINING THE HISTORICAL VIEW- The importance ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------. The need for a flexible and relevant historical perspective warrants
its vigilant revision and expansion as conditions and experience warrant.
Since the importance of the maintenance costs lies in their influence on production costs, the budgets must therefore portray them
in production terms, and must result from discussions -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------information, prepares the budget statement and issues the periodic returns and
statistics relating to actual performance against forecasted performance.

Zero Based BudgetZero Base Budgeting is the latest technique of budgeting. ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------to develop standard costs. Where it is difficult to compare the resources
allocation with the output, ZBB is more appropriate in controlling.

ADVANTAGES OF ZERO BASE BUDGETINGZBB is a revolutionary concept. The benefits are as under:
1. ---------------------------- of Funds: Funds are scarce. Priority ---------------------------------------------- on cost-benefit analysis.

2. Systematic Evaluation: Manager has ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------for the ongoing projects is made, if there is justification to continue, further.
In other words, there is no difference between the new projects and ongoing projects from the view-point of allocation of funds.
3. Links Budgets with Goals of Enterprise: Those -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------of the enterprise would be developed.

4. Zero Base Approach: Zero is taken as the base, ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------is on analysis and decision-making

5. Optimum use of Resources: As cost--------------------------------------------------------------------------------------------------------------------------------------------------------------------------, resources are used to the optimum advantage of the organization.
6. No Incremental Approach: Normally, budgets -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------with Zero-Base Budgeting. Manager has to justify their activities and the funds
requested.
7. Most Appropriate for Non-Manufacturing Areas: Zero--------------------------------------------------------------------------------------------------------------------------------------------------- is not, directly, related with the final output of the organization.
Within the business world, ZBB can be applied to research and development, data processing, quality control, marketing
and transportation, legal staff and personnel office.

Example: A separate training department may -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------types of training to staff, outside the firm, may be more ideally suitable, while
reducing the costs to the enterprise.

3. A remote control unit has 25 components in series. Each component has a reliability of 0.999. What is the
reliability of the remote control unit? If it is desired to have a reliability of 0.996 for 3000 hours of operation,
what should be the failure rate of each component? Assume that the time to failure for each component is
exponentially distributed.

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

4. Define hazard rate the discuss the three periods or regions of the life cycle of a unit or device as illustrated by
the bath-tub curve.

The hazard rate is defined for -----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------change and the units that have already failed play no further role since only the survivors count.
The failure rate (or hazard rate) is denoted by h(t) and is calculated from
h(t)=f(t)1F(t----------------------------------------------------------------------------------------------------------------------------) failure rate.
The failure rate is sometimes called a "conditional failure -------------------------------------------------------------------------------------------------------------------------------- population survivors) converts the expression into a conditional rate, given survival past time t.
Since h(t) is also equal to the negative -------------------------------------------------------------------- the useful identity:

be the Cumulative Hazard Function, -------------------------------------------------------------------- follow from these formulas are:

It is also sometimes useful to define an average --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- that can be used as a specification or target for the
population failure rate over that interval. If T1 is 0, it is dropped from the expression. Thus, for example, AFR------------------------------------------------------------------------------------------------------- over the first 40,000 hours of operation.
The formulas -------------------------------------------- are:

Three periods or regions of --------------------------------------------------------------------- bath-tub curveAfter years of research examining the failure data of many types of components and devices, several modes of failure have come
to light. This is illustrated by -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- against time, which denotes the life cycle of the component or device.
From the figure, it is seen that the life cycle of a unit or device can be sub-divided into three distinct periods or regions. These
three regions of the life cycle are as follows:
1.

Early failure, or initial failure, or running in failure, or infant mortality region : When a batch of new items just
produced or -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------during the initial failure period, this period is also known as the debugging or burn-in period.

2.

Incidental or random failure region: After the initial failures, ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------stress or part strengths meeting up to them as
deterministic functions of time.

3.

Wear-out failure region: As time passes, the units --------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------and generally are in the form of physico-chemical or metallurgical degradation.
This region is called the wear-out failure region and in this period the hazard rate increases.

In the early failure region, both h(t) and f(t) decrease ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------the figure, we call discern
the shapes of the failure distributions in the three regions of the life cycle of a unit or device.
These shapes have led to early authors on reliability to propose the use ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------is that of
constant hazard in the random variable region.
Before we close our discussion on ------------------------------------------------------------------------------------------------ in the three
regions of the bath-tub curve. The factors contributing to the early failures are as follows:
i)

design ----------------------------------------------------,

ii)

----------------------------------------------------- defects,

iii)

-------------------------------------- defects,

iv)

commissioning ---------------------------------, and

v)

Operating defects.

Moreover the design and manufacturing defects -----------------------------------------------------------------------------------------------------------------------------------------------------------------------. The main contributors of wear-out failures are as follows:
i)

overload,

ii)

looseness, -----------------------------------------------

iii) Metallurgical ------------------------------------------.

ConclusionWith respect to both human and electromechanical failures, the shape of the hazard function over the lifetime appears to take on a
shape somewhat like a bathtub. We are of the opinion that the bathtub curves for electrical and mechanical devices are different
and further more each has been changed since attention to quality became a strategic issue in America.
Prior to the quality movement, a ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------hazard rate begins to increase. We feel that
todays plots of h(t) vs. t are not like the traditional bathtub shapes.
A few arguments for the demise of the bathtub curve will now be pre- sented. The initial portion, called the burn-in period for
electronic devices and the period of early failures ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------, nurturing of suppliers, supplier
evaluation and certification and with attention to eliminating and removing the root causes of defects in manufacturing, quality
has vastly improved. There is very little poor quality to improve upon and hence few reasons to expect a downward slope to the
curve.

Many manufacturers of consumer products, with substantial electronic circuitry, e.g., appliances, are now foregoing the burn-in
period. That is , no burn-in. The reason for burn-in (high temperatures, and sometimes vibration) is to allow substandard
components (e.g., bad capacitor and faulty processes, ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------components or processes.
This is somewhat analogous to the cessation of polio immunizations in the United States, with the belief that it is more likely that
the polio shot will cause the disease than prevent it since it is now so rare in the U.S. population.
Since the exponential distribution, as will be shown in a ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------of the hazard function
relate to its facility and stability when there is censoring of some of the data and when there are several modes of failure present in
the failure process.

5. How can be questionnaire for Maintenance Audit prepared? What is the main difference of audition result
areas compared to auditing management processes?
It has been observed that one third of all ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------maintenance can result in unnecessary
maintenance activity and downtime and in excessive spares usage, whilst being ineffective in preventing breakdown.
Performing a periodic maintenance audit is essential in maintaining a profitable business. A maintenance audit answers the
following questions: How effective is your current planned maintenance program? What areas are working? What areas could be
improved?
The objective of this performance maintenance audit program is to demonstrate a process of identifying specific business
functions associated with a companys core business services and or products and identify a series of questions related to service
deliverables to establish a performance benchmark ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------and improve your processes
a process optimization' process. The following audit process can be adapted for any business type, simply identify the functional
areas and then establish the performance questions.
The auditors prepare a detailed questionnaire on the various issues of concern in maintenance management and circulate in
advance to the company management personnel. ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------questionnaire are compiled and
conclusions are arrived at as to the selected areas and management personnel to be concentrated upon during the next steps.
The organizational performance of maintenance ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------, service response time, meantime to repair, and breakdown
analysis reporting.

The review process is designed to evaluate the effectiveness of an existing maintenance management program. By assessing each
of the key elements, one can obtain an overview of program effectiveness. This overview provides:
A program ------------------------------------------------- rating
Identification -------------------------------------- improvement
A ----------------------------------------------------------- productivity gains
The overall review process, together with a ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------is a concern of senior management or where staff is unavailable to
complete part or all of the audit process.
As a general rule, the better the maintenance ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------management program.
These components are further subdivided into key elements. The five basic components. Alternative groupings and factors can be
developed for special applications. For example, a ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------own unique conditions. However, variations on the forms,
processes, and procedures should only be undertaken after becoming familiar with the audit process, after several iterations.
The maintenance management audit process described in this article is designed to identify the tasks of a facilities organization
seeking to improve effectiveness and efficiency. ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------merit the most intensive
investigation. Either way, the audit process defines checklists of facilities maintenance management performance and provides
measures of effectiveness, setting up a baseline for future comparisons.
Implementing condition based maintenance involves measurement or monitoring of appropriate physical variables or signatures of
the machine using instrumentation and interpreting the signatures to indicate if maintenance of the machine is called for or not..

Listing and Identification of Plant Machines

Listing and numbering of all --------------------------------------------------------------------------------------------------------------------------------------------- locate all machines within the plant, identify them in the maintenance program and retrieve data.

Selection of Critical Machines

Critical machines are those whose failure may ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------history records are not available
the knowledge and experience of maintenance and operation personnel will be of great help in identifying the critical machines.
The performance of a plant unit is a useful measure of its condition, for prognosis and need for maintenance
action. The variety of units and their ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- the innovation of condition monitoring engineers.

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------At the end of your audit you should have a good idea of potential problem areas, where you can improve and where you are doing
well. ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------ or semi-annual are also useful, a yearly audit can help
smooth out performance fluctuations caused by seasonal changes. Examples of seasonal changes are equipment running at
maximum

load

to

-------------------------------------------------------------------------------------------------------------------------

maintenance spikes that can make it hard to compare performance against a prior quarter.

6. Write short notes on the following:

a) Maintenance windows
A maintenance window is a ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------of defining standard maintenance windows is to allow
clients of the service to prepare for possible disruption or changes.
We encourage all services and systems to negotiate a maintenance window with their clients via an Service Level Agreement
(SLA). For --------------------------------------------------------------------------- the ITS Service Managers.
If a service does not have a ---------------------------------------------------------- equivalent) the following guidelines apply:

Planned outages should be --------------------------------------------------------------------------------------------------- outside of

this window should have explicit sign-off from the system steward or designated client representative.

Planned outages and ---------------------------------------------------------------------------------------------------------------------------- grading week of the academic quarters, or during other significant campus events or key dates

Production means -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- academic tasks and objectives.

Windows for the whole plant ------------------------------------------------------------------------------- for the product.

Windows for -------------------------------------------------------------------------------------- by production scheduling.

Windows arising for the ------------------------------------------------------------------------------------------------------------------------------------- changes, catalyst changes, equipment cleaning etc.). These tend to have poor predictability.

Windows for major sections of plant, or for units, that can be created by the use of standby or redundant plant, or inter
stage storage.

Windows arising for the -------------------------------------------------------------------------------------- safety work.

Maintenance Windows are defined by collection, and when configured, can be set with an effective start date, start and end
times, and a set recurrence pattern. ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------content outside of the maintenance window.

b) Cost Absorption and Cost Apportionment

Cost Allocation: Cost Allocation means the ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------, accumulating the costs that relate to
the object of costing and choosing the method to identify those costs. Usually, the allocation of costs would be done based on
machine-hours, direct-labor hours etc.
Example: Say a -----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------labor hours. The direct labor hours for Products A, B and C are
2000, 1000 and 3000 respectively.
Solution: Total labor hours = 6000
Cost allocation:
Overheads allocated for Product A = ----------------------------------------------- =$10,000
Overheads ---------------------------------------------------- B = 30000*1000/6000 = $5,000
Overheads allocated for Product C = 30000*3000/-----------------------------------Allocation of overheads is the process of ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------of that particular department. For
example, the whole amount of repair and maintenance expenses for a machine is charged or allocated to that department where
the machine has been installed.
Cost Apportionment: Cost allocation is also referred to as Cost apportionment. Cost apportionment means the allotment of
proportions of items of cost of cost centers or cost units.

Distribution of an overhead cost to ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------. Similarly, the amount of remuneration of the

general manager should be distributed to the production, administration and marketing departments as the general manager is
associated with all these departments.
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

c) Design and Maintainability

In engineering, maintainability is the ease with which a product can be maintained in order to: isolate defects or their cause,
correct defects or their cause, repair or replace faulty or -------------------------------------------------------------------------------------------------

----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------of interest in maintainability analysis is time-to-repair rather

than time-to-failure.
For example, if it is said that a particular ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------the overall performance (availability, uptime, downtime, etc.) that will
help you to make decisions about the design and/or operation of a repairable system.
Maintainability is the parameter concerned with how the ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------requirement. This would take the form of sparing
strategies, maintainer training, maintenance manuals, and identification of required support equipment.
In some cases, maintainability involves a system of continuous improvement - learning from the past in order to improve the
ability to maintain systems, or improve reliability of systems based on maintenance experience.

d) Maintenance Audit
A Maintenance Systems Audit (our organization calls it a Maintenance Business Review to emphasize business aspects of the
maintenance function) can best be described as ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------involve individuals and their
performance, though it does assess training and personnel development needs.
Maintenance audit is applied to a service company. ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------means of decision rules the
previous values are interconnected using different first and second level variables to establish the state of the maintenance
activities by sections
The development of a maintenance audit in a service ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------expert system to create a
maintenance audit. The maintenance audit developed can be applied in the context of a continuous improvement environment.
The audit addresses seven Maintenance ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- maintenance aspects. The audit structure is as follows:
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

Management:
Management -------------------- Leadership
Maintenance Policy
Maintenance Improvement Program
----------------------------------------------Quality Assurance
Maintenance Review Program
Health, --------------------- Management
Spare -------------------------------:
Spare Parts Procurements
------------------------ Management
Personnel:
Organizational Structure
Workforce -------------------------- Participation
Personnel Development Program

Contractors --------------------------------------- & Scheduling:

Daily Planning
Outage Planning
Maintenance ------------------------------------:
Operational -------------------------Maintenance --------------------- Development
Asset Lifecycle Management
Plant & ---------------------- Monitoring
Standard Procedures and Job Instructions
Plant and ----------------------- Analysis
Maintenance Management System
Document Control System
Repair Services

The development of a maintenance audit in a service ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------system to create a maintenance audit. The maintenance audit
developed can be applied in the context of a continuous improvement environment.

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