Session 5.1: Maintenance Cost Estimates

Session 5 takes place in the RAM module and focuses on Maintenance: Maintenance Cost Estimate, Maintenance Actions, Reliability Centred Maintenance (Classic), and Reliability Centred Maintenance (Back-Fit).

Note: Users can define custom maintenance terminologies suitable for their application in Application Preferences > Modeling > Maintenance Type Terminologies. These terminologies are displayed in all the maintenance features mentioned above.

Session 5.1 Outline

• 5.1.1: MCE Management
• 5.1.2: MCE Summary & Details
• 5.1.3: Charting & MCE Report

Discussion 5.1: Maintenance Cost Estimates

• MCE generates and compares costs of maintenance procedures over the operational timespan of an item
• Typically used in early stages of the design lifecycle to estimate and predict the total maintenance costs
• Can be used to detail the maintenance and support aspect of lifecycle costs

Discussion 5.1.1: MCE Management

• This page is used to create, store and edit MCE analyses
• The page also provides an overview for a specific analysis

Exercise 5.1.1: Create a New MCE Analysis

1. Select the new-analysis icon to create a new MCE analysis
2. Enter the MCE Name: Training MCE
3. Enter the MCE Description: Maintenance Cost estimation for the Power Generation system.

Edit Applied Environment

1. Select the icon to choose an applied environment
2. Under User Library select Benign Environment
3. Select to close dialog and select applied environment
4. Verify that Environmental Loading Factor (ELF) is: 0.59

Note: The ELF is calculated based on the selected environment.

Discussion 5.1.2: MCE Page

• After a new MCE analysis has been created, maintenance and item costs must be estimated (MCE is a bottom-up approach)
• Accessed by selecting the new analysis and clicking Open
• This page defines the estimated cost of sustainment for the system based on the component maintenance actions
• If item maintenance estimates are unknown, costs can be estimated at the subsystem level (less detailed/rough estimates; lower-level component estimates can be updated later)

Exercise 5.1.2: Add Breakdown Repair for Fuel Tank Component

1. Select Training MCE then select Open
2. Expand the system tree and select Fuel Tank
3. Under Proposed Maintenance Approach section:
   • Select Maintenance Category: Breakdown Maintenance
   • Select Maintenance Type: Breakdown Repair
4. Select the Cost tab and enter:
   • Acquisition cost: $500
   • Cost of Failure: $10,000
   • Downtime cost: $1,000
   • Personnel cost: $100 (per person per hour)
   • Equipment Renewal Factor: 2.00
   • Tools & Equipment Cost: $500
   • Consumables Cost: $100
5. Select the Maintenance tab and enter:
   • Maintenance Supplier: ACME Inc.
   • Maintenance Country: Australia
   • Estimated MTTF: 10,000 Hours
   • Maintenance Time: 1 Hour
   • No. of Personnel: 1
6. Verify Total Cost: $1672.11
7. Verify Cost per Hour: $18.36

Exercise 5.1.3: Add Scheduled Service for Control Unit Component

To add expected maintenance for an item:

1. Select Control Unit from the System Breakdown tree
2. Under Proposed Maintenance Approach section:
   • Set Maintenance Category to Scheduled Maintenance
   • Set Maintenance Type to Scheduled Service
3. Select the Cost tab and enter:
   • Acquisition cost: $2000
   • Downtime cost: $1,000
   • Personnel cost: $100 (person per hour)
   • Equipment Renewal Factor: 1.00
   • Tools & Equipment Cost: $100
   • Consumables Cost: $100
   • Spares Cost Factor: 1
4. Select the Maintenance tab and enter:
   • Maintenance Supplier: ACME Inc.
   • Maintenance Country: Australia
   • Estimated MTTF: 10,000 Hours
   • Maintenance Interval: 800 Hours
   • MTTR: 2 Hours
   • No. of Personnel: 1
5. Verify Total Cost: $1,022.62
6. Verify Cost per Hour: $11.23

Exercise 5.1.4: Add Condition Based Replace for Coupling Component

1. Select Coupling 1 from the system tree
2. Under Proposed Maintenance Approach section:
   • Select Maintenance Category: Condition Based Maintenance
   • Select Maintenance Type: Condition Based Replace — Continuous Monitoring
3. Select the Cost tab and enter:
   • Acquisition cost: $250
   • Downtime cost: $10,000
   • Personnel cost: $100 (person per hour)
   • Equipment Renewal Factor: 1.00
   • Maintenance Tools & Equipment Cost: $100
   • Maintenance Consumables Cost: $100
   • Maintenance Spares cost factor: 0
   • Detection Tools & Equipment Cost: $50
   • Detection Consumables Cost: $0
4. Select the Maintenance tab and enter:
   • Maintenance Supplier: ACME Inc.
   • Maintenance Country: Australia
   • Estimated MTTF: 1,000 Hours
   • Requires shutdown (Maintenance): Yes
   • Maintenance Interval: 750 Hours
   • MTTR: 0.5 Hours
   • No. of Personnel: 2
   • Requires shutdown (Detection): No
   • Detection Interval: 250 hours
   • Detection Time: 5 minutes
   • No. of Personnel (Detection): 1
5. Verify Total Cost: $1,357.20
6. Verify Cost per Hour: $14.90

Discussion 5.1.5: Charting & MCE Report

Once all relevant analysis information has been provided, the user can view the breakdown of the MCE analysis in the Overview/Management page.

Exercise 5.1.5: Generate a MCE Report

1. Select Reports > Report Wizard
2. Select Maintenance Cost Estimates Report
3. Select Next
4. Select Training MCE and select Next
5. Set formatting or select Generate to generate the report

Session 5.1 Summary

MCE Analysis for Fuel Tank, Control Unit & Coupling components:

• Determine Total MCE per item/cost per operating hour
• Generate MCE Report