WF18: Create Maintenance Cost Estimate (MCE)

Pre-requisites

• RAM Module: Reliability, Availability and Maintainability (RAM) Module enables access to Maintenance Cost Estimates (MCE).
• FBD Model: contains model items that populate MCE.
• Mission Profile: establishes timeframe for MCE.

Detailed Descriptions (numbered steps)

1. Access Maintenance Cost Estimates under 'Analyses' in the main menu bar.
2. Determine whether to create a MCE or open an existing one, to review/revise.
3. To create an MCE, select the button with green plus icon. Define name, description (optional), and select a Mission Profile.
4. To open the MCE, select the button with opened folder icon. MCE can also be copied or deleted with appropriate buttons.
5. Select a model item from list under 'System Breakdown'.
6. Select Maintenance Category from drop-down menu, choosing either Breakdown, Scheduled or Condition-based Maintenance.
7. Select Maintenance Type from drop-down menu, with options dependent upon Maintenance Category.
8. Open 'Costs' tab and enter Cost parameters enabled for the selected Maintenance category and Type.
9. Open 'Maintenance' tab and enter Maintenance parameters enabled accordingly.
10. Continue until maintenance cost estimates for all model items have been defined.
11. Return to the 'Overview / Management' tab to review the MCE.
12. If MCE is not acceptable, revise it or create a new one.
13. Created MCE is acceptable and a report may be generated.

Fields referenced in the diagram

• Create Maintenance Cost Estimate: Analysis Name, Description, Mission Profile, Applied Environment
• Select Maintenance Category: Breakdown Maintenance, Scheduled Maintenance, On-condition Maintenance
• Enter Costs Parameters / Enter Maintenance Parameters: see Step 7/8 details below

Decision points

• Create MCE? — Yes → Create Maintenance Cost Estimate; No → Open Maintenance Cost Estimate.
• All Costs Defined? — No → loop back to Select Model Item; Yes → Review Maintenance Cost Estimate.
• MCE Acceptable? — No → loop back to Create MCE? decision; Yes → Maintenance Cost Estimate Created.

Outputs

• Maintenance Cost Estimates Report: a report for a selected MCE, containing cost summaries and maintenance type/costs/suppliers/countries breakdown, generated through the MADE Report Wizard.

Screenshot walkthrough (captions/labels extracted)

Step 1: Access Maintenance Cost Estimates

• 'Analyses' menu: Fault Tree, Response Paths, Connection Matrix, Common Mode Analysis, Critical Item Analysis, Criticality & Reliability Editor, Technical Budget Analysis, Failure Rate Prediction, Markov Analysis, RBD Analysis, Reliability Allocation Editor, Back-Fit RCM, Classic RCM, Maintenance Cost Estimates (highlighted).

Step 2: Create Maintenance Cost Estimate

• "Maintenance Cost Estimates" tab "Training MCE (Vehicle System)": "Maintenance Cost Estimates" tree (Vehicle System > Training MCE) with add/copy/open/delete icons. "Details": Name "Training MCE", Description "Maintenance Cost estimation for the Power Generation system." "Mission Profile Definition": Mission Profile "Model Based Duration of Operation", Duration "1.30278 h (hours)", Mission Cycles "N/A", Σ Total "N/A". "Summary": Total Time Span (Hours) "1.303 hr (1.303 hours)", Total Sustainment Cost (USD) "$2,017.50", Cost per System Operating Hour (USD) "$1,548.61". "Maintenance by Type" pie chart (Breakdown Maintenance / Scheduled Maintenance / Condition Based Maintenance, roughly even thirds). "Operating Environments": Environment "Ground - Urban", Applied Environment "No Applied Environment", ELF "1.00", ID, Category, Description fields; "Relative Impact of Factors on System" radar chart (Acceleration, Electromagnetic Radiation, Gaseous Contamination, Humidity, Liquid Contamination, Nuclear Radiation, Pressure, Shock, Solid Contamination, Temperature, Vibration) scaled 1-10, plotted for "Ground - Urban".

Step 5: Select Maintenance Category

• "System Breakdown" tree: Vehicle System (Total cost $0.00, Cost per hour $0.00) > Coupling, Driveline, Power Generation, Vehicle (selected). "Proposed Maintenance Approach": Name "Vehicle", Mission Profile "Model Based Duration of Operation", Maintenance Category dropdown expanded: None (selected), Breakdown Maintenance, Scheduled Maintenance, Condition Based Maintenance. Tabs: Overview (selected)/Cost/Maintenance. "Item Summary": Total Time Span "91.194 hr (3.8 days)", Duration of Operation "91.194 hr (3.8 days)", Maintenance Supplier, Maintenance Country "NO COUNTRY", MTTF (hrs) "1,000,000 hr (114.077 years)". "Cost Breakdown": Acquisition Cost $0.00 [1], Maintenance Cost $0.00 [2], Detection Cost $0.00 [3]; "No Maintenance Type selected."

Step 6: Select Maintenance Type

• Three examples of Maintenance Type dropdown per category:
  • Maintenance Category "Breakdown Maintenance" → Maintenance Type options: Breakdown - Repair, Breakdown - Replace.
  • Maintenance Category "Scheduled Maintenance" → Maintenance Type options: Scheduled - Repair, Scheduled - Replace, Scheduled - Service.
  • Maintenance Category "Condition Based Maintenance" → Maintenance Type options: Condition-based - Repair - Continuous monitoring, Condition-based - Replace - Continuous monitoring, Condition-based - Service - Continuous monitoring, Condition-based - Repair - Periodic inspection, Condition-based - Replace - Periodic inspection, Condition-based - Service - Periodic inspection.
  • Each example shows: Name "Vehicle", Mission Profile "Model Based Duration of Operation", Item Summary (Total Time Span/Duration of Operation "91.194 hr (3.8 days)", Maintenance Supplier, Maintenance Country "NO COUNTRY", MTTF (hrs) "1,000,000 hr (114.077 years)").

Step 7: Enter Costs Parameters

• "Cost" tab (highlighted) fields: "Cost Details": Acquisition Cost (USD) $0.00, Cost of Failure (USD) $0.00, Downtime Cost (USD/hr) $0.00, Personnel Cost (USD/person/hr) $0.00, Equipment Renewal Factor (grey/disabled). "Maintenance Cost Details": Tools & Equipment Cost (USD) $0.00, Consumables Cost (USD) $0.00, Spares Cost Factor 0.000/$0.00. "Detection Cost Details": Tools & Equipment Cost (USD) $0.00, Consumables Cost (USD) $0.00. Each field has an info (i) tooltip icon.

Step 8: Enter Maintenance Parameters

• "Maintenance" tab (highlighted): "Maintenance Information and Factors": Maintenance Supplier, Maintenance Country "NO COUNTRY", Estimated MTTF (blank, hours), ELF "1.00", Revised MTTF "1000000.000 hours". "Maintenance Details": Requires Shutdown? Yes/No, Maintenance Interval 0.000 hours, Maintenance Time (MTTR) 0.000 hours, Maintenance Frequency "N/A", Number of Personnel "1". "Detection Details": Requires Shutdown? Yes/No/Not Applicable (selected), Detection Interval 0.000 hours, Detection Time 0.000 hours, Detection Frequency "N/A", Number of Personnel "1".

Step 10: Review Maintenance Cost Estimate

• "Maintenance Cost Estimates" tab "*Training MCE (Vehicle System)" (unsaved): same layout as Step 2 but with "Mission Profile Definition" Duration "91.19436 h (hours)"; "Summary": Total Time Span (Hours) "91.194 hr (3.8 days)", Total Sustainment Cost (USD) "$0.00", Cost per System Operating Hour (USD) "N/A"; "Operating Environments": Environment "Ground - Urban", Applied Environment "Benign Environment", ELF "1.07", Category "User Library", Description "Most benign environment. All environmental parameters are at nominal levels. This can be considered to be a room temperature environment at 1 atmosphere of pressure with 50% humidity normal levels of contamination and negligible vibration and shock." Radar chart compares "Ground - Urban" vs "Benign Environment".

Step 13: Maintenance Cost Estimate Created

• "Maintenance Cost Estimates Report" (page 2 of 9) — "MAINTENANCE COST ESTIMATE SUMMARY" for "TRAINING MCE": Item ID "VS1", Item Name "Vehicle System", Mission Profile "Model Based Duration of Operation", Total Time Span "2.286 hr (2.286 hours)", Baseline Environment "Ground - Urban", Applied Environment "Benign Environment". Total Sustainment Cost $2,052.40, Cost per System Operating Hour $897.77. "Cost Breakdown" table: 1 Equipment $2,000.00, 2 Consumables $1.03, 3 Spares $9.60, 4 Personnel $2.27, 5 System Downtime $35.65, 6 Cost of Failure $3.85 (with pie chart). "Maintenance by Type" table: 1 Breakdown Maintenance, 2 Scheduled Maintenance, 3 Condition Based Maintenance (each count 1, with pie chart). Radar charts for "Baseline Environment" and "Applied Environment" showing Relative Impact of Factors on System (Acceleration, Electromagnetic Radiation, Gaseous Contamination, Humidity, Liquid Contamination, Nuclear Radiation, Pressure, Shock, Solid Contamination, Temperature, Vibration).