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Purpose - The purpose of this paper is to demonstrate a tactical approach to cope with the issues related to low availability of repairable machines or systems because of their poor reliability and maintainability. It not only explores the significance of availability, but also embarks upon a step-by-step procedure to earmark a relevant replenishment plan to check the mean time between failure (MTBF) and the mean time to repair (MTTR) efficiently. Design/methodology/approach - The literature review identifies the extent to which availability depends on reliability and maintainability, and highlights the diversified challenges appearing among repairable systems. Different improvement initiatives have been suggested to avoid downtime, after analyzing the failure and repair time data graphically. Relevant plots and growth curves captured the historical deviations and trends along with the time, which further helps to create more robust action plans to enrich the respective reliability and maintainability of machines. During the case study, the proposed methodology has been tested on four SPMs and successfully validated the claims after achieving around a 98 percent availability at the end. Findings - Graphical analysis is the key to developing suitable action plans to enhance the corresponding reliability and maintainability of a machine or system. By increasing the MTBF, the reliability level can be improved and similarly quick maintenance activities can help to restore the prospect of maintainability. Both of these actions ultimately reduce the downtime or increase the associated availability exponentially. Research limitations/implications - The work revolves around the availability of SPMs. Moreover, SPMs have been divided only into series sub-systems. The testability and supportability aspects have not been considered thoroughly during the fabrication of the approach. Originality/value - The work focusses on the availability of systems and proposed frameworks that helps to reduce downtime or its associated expenditure, which is generally being ignored. As a case study-based work especially on SPMs in the auto sector this paper is quite rare and will motivate affiliated engineers and practitioners to achieve future breakthroughs.

Given the pressing need to strengthen operational reliability in electrical distribution networks, this study proposes an optimization methodology based on the Teaching–Learning-Based Optimization (TLBO) algorithm for the strategic location of redundant lines. The model is validated on the “MV Distribution Network—Base Model” test system, considering the combination of the MTBF (Mean Time Between Failures) and MTTR (Mean Time To Repair) indicators as the objective function. After 500 independent runs, it is determined that the configuration with three redundant lines identified as LN_1011, LN_1058, and LN_0871 offers the most stable solution. Specifically, this topology increases the MTBF from 403.64 h to 409.42 h and reduces the MTTR from 2.351 h to 2.306 h. In addition, significant improvements are observed in the voltage profile and angle, along with a more balanced redistribution of active and reactive power, more efficient use of existing lines, and an overall reduction in energy losses.

PurposeTotal productive maintenance consists of strategies and procedures that aim to guarantee the entire functioning of machines in a production process so that production is not interrupted and no loss of quality in the final product occurs. Planned maintenance is one of the eight pillars of total productive maintenance, a set of tools considered essential to ensure equipment reliability and availability, reduce unplanned stoppage and increase productivity. This study aims to analyze the influence of statistical reliability on the performance of such a pillar.Design/methodology/approachIn this study, we utilized a multi-method approach to rigorously examine the impact of statistical reliability on the planned maintenance pillar within total productive maintenance. Our methodology combined a detailed statistical analysis of maintenance data with advanced reliability modeling, specifically employing Weibull distribution to analyze failure patterns. Additionally, we integrated qualitative insights gathered through semi-structured interviews with the maintenance team, enhancing the depth of our analysis. The case study, conducted in a fertilizer granulation plant, focused on a critical failure in the granulator pillow block bearing, providing a comprehensive perspective on the practical application of statistical reliability within total productive maintenance; and not presupposing statistical reliability is the solution over more effective methods for the case.FindingsOur findings reveal that the integration of statistical reliability within the planned maintenance pillar significantly enhances predictive maintenance capabilities, leading to more accurate forecasts of equipment failure modes. The Weibull analysis of the granulator pillow block bearing indicated a mean time between failures of 191.3 days, providing support for optimizing maintenance schedules. Moreover, the qualitative insights from the maintenance team highlighted the operational benefits of our approach, such as improved resource allocation and the need for specialized training. These results demonstrate the practical impact of statistical reliability in preventing unplanned downtimes and informing strategic decisions in maintenance planning, thereby emphasizing the importance of your work in the field.Originality/valueIn terms of the originality and practicality of this study, we emphasize the significant findings that underscore the positive influence of using statistical reliability in conjunction with the planned maintenance pillar. This approach can be instrumental in designing and enhancing component preventive maintenance plans. Furthermore, it can effectively manage equipment failure modes and monitor their useful life, providing valuable insights for professionals in total productive maintenance.

For many years, the programmable positioners have been widely applied in structures of modern electro-pneumatic final control elements. The positioner consists of an electro-pneumatic transducer, embedded controller, and measuring instrumentation. Electro-pneumatic transducers that are used in positioners are characterized by a relatively short mean time-to-failure. The practical and economical method of a reasonable prolongation of this time is proposed in this paper. It is principally based on assessment and minimizing the effort of the embedded controller. For this purpose, some measures were introduced: The control value variability, mean-time, and the cumulative controller’s effort. The diminishing of controller effort has significant practical repercussions because it reduces the intensity of mechanical wear of the final control element components. On the other hand, the reduction of the cumulative effort is important in the context of process economy due to limitation of the consumption of energy of compressed air supplying the final control element. Therefore, the minimization of control effort indicators has an impact on the increase of the functional safety and economics of the controlled process. The simulations were performed in the Matlab-Simulink environment with the use of the liquid level control system in which a phenomenological model of a final control element was deployed. As a result of the performed simulations, the recommendations regarding the selection of the structure of positioner controller were elaborated.

Among the most valuable types of renewable energy available today is wind energy. The reliability of WF systems must be regularly evaluated at every stage of their “life,” from design to operation, if a wind farm energy system is to be effective and function damage-free. Three key goals are presented in the article. The theory of fundamental quantities in reliability and maintenance analysis should be derived and explained first. Second, as a consequence of maintainability, theoretical correlations between reliability and mean time between failures (MTBF) are provided. The three-state theory of the WF procedure for operation presented in the research serves as the foundation for the analytical analysis of WF reliability. The time between failures is investigated as a function of maintainability, and the dependability of the WF under examination is assessed as a function of service life. The WF owner can make the best decisions to renew the WF and increase its reliability, energy, financial efficiency, etc. by being aware of the existing reliability of the WF system in use.

This paper investigates the optimization of maintenance strategies to improve the reliability of equipment at the Kapshagay Hydropower Plant (HPP), located in Kazakhstan. Operational data for the period 2020–2025 were analyzed to evaluate the effectiveness of existing maintenance systems. The analysis showed that the failure frequency of the main equipment averaged 3.8–4.2 events per year, while annual unplanned downtime reached 80–100 h, resulting in electricity generation losses of 2.5–3.2%. In addition, total maintenance costs were approximately 150 million KZT per year, with about 40% related to unplanned repairs. A reliability-centered maintenance model was developed using mathematical modeling and simulation tools such as Python 3.11 and SMath Solver 0.99.7920. The study integrates reliability theory, exponential failure modeling, and statistical performance analysis based on operational data from the Kapshagay HPP. Simulation-based validation was performed to compare baseline and optimized maintenance strategies under real operating conditions. After implementing the proposed model, equipment failure probability decreased by 15%, failure rate decreased by 28%, the mean time between failures increased from 120 days to 165 days, and repair duration decreased from 6 days to 4 days. Additionally, failure probability decreased from 0.10 to 0.07, while annual downtime decreased from 6.2 days to 4.1 days. Electricity generation losses decreased by approximately 18–22 GWh per year, while the annual economic benefit was estimated at 320–480 million KZTn. The results demonstrate that reliability-centered maintenance can increase equipment reliability by 20–30%, reduce maintenance costs by 10–12%, and improve electricity generation efficiency by 1.8–2.4%. The obtained results have practical significance for improving the technical and economic performance of hydropower plants.

The reliability of software has a tremendous influence on the reliability of systems. Software dependability models are frequently utilized to statistically analyze the reliability of software. Numerous reliability models are based on the nonhomogeneous Poisson method (NHPP). In this respect, in the current study, a novel NHPP model established on the basis of the new power function distribution is suggested. The mathematical formulas for its reliability measurements were found and are visually illustrated. The parameters of the suggested model are assessed utilizing the weighted nonlinear least-squares, maximum-likelihood, and nonlinear least-squares estimation techniques. The model is subsequently verified using a variety of reliability datasets. Four separate criteria were used to assess and compare the estimating techniques. Additionally, the effectiveness of the novel model is assessed and evaluated with two foundation models both objectively and subjectively. The implementation results reveal that our novel model performed well in the failure data that we examined.

Purpose This paper aims to simulate vital corrective actions (CAs) affecting system availability through a system dynamics approach based on the results obtained by analyzing the causal relationships among failure modes and effects analysis elements. Design/methodology/approach A stock and flow diagram has been developed to simulate system behaviors during a timeframe. Some improvement scenarios regarding the most necessary CAs according to their strategic priority and the possibility of eliminating root causes of critical failure modes in a roller-transmission system have been simulated and analyzed to choose the most effective one(s) for the system availability. The proposed approach has been examined in a steel-manufacturing company. Findings Results indicated the most effective CAs to remove or diminish critical failure causes that led to the less reliability of the system. It illustrated the impacts of the selected CAs on eliminating or decreasing root causes of the critical failure modes, lessening the system’s failure rate and increasing the system availability more effectively. Research limitations/implications Results allow managers and decision-makers to consider different maintenance scenarios without wasting time and more cost, choosing the most appropriate option according to system conditions. Originality/value This study innovation would be the dynamic analysis of interactions among failure modes, effects and causes over time to predict the system behavior and improve availability by choosing the most effective CAs through improvement scenario simulation via VENSIM software.

In a weapon system, the accurate forecasting of the spare parts demand can help avoid the excess inventory, leading to the efficient use of budget. It can also help develop the combat readiness of the weapon system by improving weapon system utilization. Moreover, as performance-based logistics (PBL) projects have recently emerged, the accurate demand forecasting of spare parts has become an important issue for the PBL contractors as well. However, for the demand forecasting of spare parts, the time series methods, typically used in the military sector, have low prediction accuracies and the PBL contractors are mostly based on the judgment of practitioners. Meanwhile, most of the previous studies in the military sector have not considered the managerial characteristics of spare parts (e.g., reparability and the irregularity of maintenance). No previous work has considered any such features, which can indicate the reliability of spare parts (e.g., mean time between failures (MTBF)), although they can affect the spare parts demand. Therefore, to develop a more accurate forecasting of the spare parts demand of military aircraft, we designed and examined a systematic approach that uses data mining techniques. To fill up the research gaps of related works, our approach also considered the managerial characteristics of spare parts and included the new features that represent the reliability of spare parts. Consequently, given the case of South Korea and the full feature set, we found random forest gave better results than the other data mining techniques and the conventional time series methods. Using the best technique Random Forest, we identified the contribution of each managerial feature set to improving the prediction accuracy, and we found the reliability and operation environment are valuable feature sets in a significant way, so they should be collected, managed more carefully, and included for better prediction of spare parts demand of military aircraft.

In the production, the efficient employment of machines is realized as a source of industry competition and strategic planning. In the manufacturing industries, data silos are harvested, which is needful to be monitored and deployed as an operational tool, which will associate with a right decision-making for minimizing maintenance cost. However, it is complex to prioritize and decide between several results. This article utilizes a synthetic data from a factory, mines the data to filter for an insight and performs machine learning (ML) tool in artificial intelligence (AI) to strategize a decision support and schedule a plan for maintenance. Data includes machinery, category, machinery, usage statistics, acquisition, owner’s unit, location, classification, and downtime. An open-source ML software tool is used to replace the short of maintenance planning and schedule. Upon data mining three promising training algorithms for the insightful data are employed as a result their accuracy figures are obtained. Then the accuracy as weighted factors to forecast the priority in maintenance schedule is proposed. The analysis helps monitor the anticipation of new machines in order to minimize mean time between failures (MTBF), promote the continuous manufacturing and achieve production’s safety.