Question 1

Which of the following is TRUE regarding total productive maintenance (TPM)?

Accepted Answer

A)  TPM is concerned with machine operation, not machine design. 
B)  Field service and depot service perform virtually all maintenance and repair activities. 
C)  Operators run their machines, but maintenance departments maintain them. 
D)  TPM reduces variability through autonomous maintenance and excellent maintenance practices. 
E)  TPM views maintenance and repair as tactical issues, not strategic ones. 
A)  TPM is concerned with machine operation, not machine design. 
B)  Field service and depot service perform virtually all maintenance and repair activities. 
C)  Operators run their machines, but maintenance departments maintain them. 
D)  TPM reduces variability through autonomous maintenance and excellent maintenance practices. 
E)  TPM views maintenance and repair as tactical issues, not strategic ones.

Question 2

The ________ takes into account such costs as deteriorated customer relations and lost sales.

Accepted Answer

full cost

Question 3

Ten high-intensity bulbs are tested for 100 hours each. One failed at 10 hours; all others completed the test. Calculate FR(%), FR(N) and MTBF.

Accepted Answer

FR(%) = 1/10 or 10%; operating

Question 4

Autonomous maintenance occurs when:

Accepted Answer

A)  employees are empowered to observe, check, adjust, clean, and notify. 
B)  a remote computer system signals the need for breakdown maintenance. 
C)  a remote computer system signals the need for preventive maintenance. 
D)  employees perform their own breakdown maintenance. 
E)  none of these 
A)  employees are empowered to observe, check, adjust, clean, and notify. 
B)  a remote computer system signals the need for breakdown maintenance. 
C)  a remote computer system signals the need for preventive maintenance. 
D)  employees perform their own breakdown maintenance. 
E)  none of these

Question 5

________ is a plan that involves routine inspections, servicing, and keeping facilities in good repair to prevent failure.

Accepted Answer

Preventive

Question 6

DuLarge Marine manufactures diesel engines for shrimp trawlers and other small commercial boats. One of their CNC machines has caused several problems. Over the past 30 weeks, the machine has broken down as indicated below.   What is the expected number of breakdowns per week?

Accepted Answer

A)  1.7 
B)  2 
C)  6 
D)  10 
E)  30 
A)  1.7 
B)  2 
C)  6 
D)  10 
E)  30

Question 7

TPM (total productive maintenance) is an application of TQM (total quality management) principles to the area of maintenance.

Accepted Answer

A) True 
 B)False

Question 8

Given the following data, find the expected breakdown cost. The cost per breakdown is $100.

Accepted Answer

@#IMG-DLM& Expected number of breakdowns

Question 9

As a firm's maintenance commitment increases:

Accepted Answer

A)  the breakdown maintenance costs increase, and the preventive maintenance costs decrease. 
B)  both the breakdown maintenance costs and the preventive maintenance costs decrease. 
C)  the breakdown maintenance costs decrease, and the preventive maintenance costs increase. 
D)  both the breakdown maintenance costs and the preventive maintenance costs increase. 
E)  None of these is true. 
A)  the breakdown maintenance costs increase, and the preventive maintenance costs decrease. 
B)  both the breakdown maintenance costs and the preventive maintenance costs decrease. 
C)  the breakdown maintenance costs decrease, and the preventive maintenance costs increase. 
D)  both the breakdown maintenance costs and the preventive maintenance costs increase. 
E)  None of these is true.

Question 10

Ten high-technology batteries are tested for 200 hours each. Two failed at 20 hours; all others completed the test. FR(%) is ________ and MTBF is ________.

Accepted Answer

A)  20%; 1/820 
B)  80%; 1/820 
C)  80%; 820 hours 
D)  20%; 820 hours 
E)  20%; 2000 hours 
A)  20%; 1/820 
B)  80%; 1/820 
C)  80%; 820 hours 
D)  20%; 820 hours 
E)  20%; 2000 hours

Question 11

Suppose that the introduction of a preventive maintenance program is deemed cost effective. Which of the following is most likely TRUE if the cost to actually perform preventive maintenance is very expensive?

Accepted Answer

A)  high standard deviation in MTBF 
B)  low standard deviation in MTBF 
C)  low cost to repair 
D)  Repairs carry little nonmonetary consequences. 
E)  The system never fails. 
A)  high standard deviation in MTBF 
B)  low standard deviation in MTBF 
C)  low cost to repair 
D)  Repairs carry little nonmonetary consequences. 
E)  The system never fails.

Question 12

A two-component process has a 90.25% success rate in series and a 99.75% success rate in parallel. If each component has the same reliability, what is the reliability of an individual component?

Accepted Answer

A)  50% 
B)  90% 
C)  95% 
D)  99% 
E)  97% 
A)  50% 
B)  90% 
C)  95% 
D)  99% 
E)  97%

Question 13

The MTBF distributions of products, machines, or processes that have "settled in," or gone beyond the infant mortality phase, often follow the exponential distribution.

Accepted Answer

A) True 
 B)False

Question 14

Infant mortality refers to the high failure rate often encountered in the early stages of the lifetime of a product.

Accepted Answer

A) True 
 B)False

Question 15

The inverse of the mean time between failures is the ________.

Accepted Answer

number of failures d

Question 16

DuLarge Marine manufactures diesel engines for shrimp trawlers and other small commercial boats. One of their CNC machines has caused several problems. Over the past 30 weeks, the machine has broken down as indicated below. Each time the machine breaks down, the firm loses an average of $2,000 in time and repair expenses. If preventive maintenance were implemented, it is estimated that an average of only one breakdown per week would occur. The cost of preventive maintenance is $1,000 per week.   What is the weekly total maintenance cost of the best program?

Accepted Answer

A)  $1,000 
B)  $3,000 
C)  $4,000 
D)  $5,000 
E)  $8,000 
A)  $1,000 
B)  $3,000 
C)  $4,000 
D)  $5,000 
E)  $8,000

Question 17

A simple electrical motor has three components: windings, armature, and housing. These three components have reliabilities of .993, .95, and .999. There is no possibility of redundant parts. The motor must have an overall reliability of at least 0.980, according to the product line manager who will use the motor as an input. What would you do to redesign the motor to meet this specification? Discuss, including a recalculation to meet the standard.

Accepted Answer

Since no backup is possible, individual

Question 18

Ten high-intensity bulbs are tested for 100 hours each. One failed at 40 hours; another failed at 70 hours; all others completed the test. Calculate FR(%), FR(N), and MTBF.

Accepted Answer

FR(%) = 2/10 or 20%;

Question 19

The objective of maintenance and reliability is to:

Accepted Answer

A)  ensure that breakdowns do not affect the quality of the products. 
B)  ensure that no breakdowns will ever occur. 
C)  ensure that preventive maintenance costs are kept as low as possible. 
D)  maintain the capability of the system. 
E)  ensure that maintenance employees are fully utilized. 
A)  ensure that breakdowns do not affect the quality of the products. 
B)  ensure that no breakdowns will ever occur. 
C)  ensure that preventive maintenance costs are kept as low as possible. 
D)  maintain the capability of the system. 
E)  ensure that maintenance employees are fully utilized.

Question 20

The diagram below identifies the elements of service as provided by a soft drink vending machine. Each element has an estimate of its own reliability, independent of the others. What is the reliability of the "system"?

Accepted Answer

Reliability = (.85)(

Exam 16: Maintenance and Reliability

Which of the following is TRUE regarding total productive maintenance (TPM)?

The ________ takes into account such costs as deteriorated customer relations and lost sales.

Ten high-intensity bulbs are tested for 100 hours each. One failed at 10 hours; all others completed the test. Calculate FR(%), FR(N) and MTBF.

Autonomous maintenance occurs when:

________ is a plan that involves routine inspections, servicing, and keeping facilities in good repair to prevent failure.

DuLarge Marine manufactures diesel engines for shrimp trawlers and other small commercial boats. One of their CNC machines has caused several problems. Over the past 30 weeks, the machine has broken down as indicated below. What is the expected number of breakdowns per week?

TPM (total productive maintenance) is an application of TQM (total quality management) principles to the area of maintenance.

Given the following data, find the expected breakdown cost. The cost per breakdown is $100.

As a firm's maintenance commitment increases:

Ten high-technology batteries are tested for 200 hours each. Two failed at 20 hours; all others completed the test. FR(%) is ________ and MTBF is ________.

Suppose that the introduction of a preventive maintenance program is deemed cost effective. Which of the following is most likely TRUE if the cost to actually perform preventive maintenance is very expensive?

A two-component process has a 90.25% success rate in series and a 99.75% success rate in parallel. If each component has the same reliability, what is the reliability of an individual component?

The MTBF distributions of products, machines, or processes that have "settled in," or gone beyond the infant mortality phase, often follow the exponential distribution.

Infant mortality refers to the high failure rate often encountered in the early stages of the lifetime of a product.

The inverse of the mean time between failures is the ________.

Ten high-intensity bulbs are tested for 100 hours each. One failed at 40 hours; another failed at 70 hours; all others completed the test. Calculate FR(%), FR(N), and MTBF.

The objective of maintenance and reliability is to:

The diagram below identifies the elements of service as provided by a soft drink vending machine. Each element has an estimate of its own reliability, independent of the others. What is the reliability of the "system"?

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Ten high-technology batteries are tested for 200 hours each. Two failed at 20 hours; all others completed the test. FR(%) is and MTBF is .