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AS IEC 60300.3.

102004
IEC 60300-3-10:2001

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AS IEC 60300.3.10

Australian Standard
Dependability management
Part 3.10: Application guide
Maintainability

This Australian Standard was prepared by Committee QR-005, Dependability. It


was approved on behalf of the Council of Standards Australia on
12 February 2004 and published on 1 April 2004.

The following are represented on Committee QR-005:


AirServices Australia
Australian Chamber of Commerce and Industry
Australian Electrical and Electronic Manufacturers Association
Australian Industry Group
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Australian Organisation for Quality


Department of Transport and Regional Services (Commonwealth)
Department of Defence (Australia)
Electricity Supply Association of Australia
Institution of Engineers Australia
Quality Society of Australasia
University of New South Wales

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2001.

This Standard was issued in draft form for comment as DR 03533.

AS IEC 60300.3.102004

This is a free 9 page sample. Access the full version at http://infostore.saiglobal.com.

Australian Standard
Dependability management
Part 3.10: Application guide
Maintainability

First published as AS IEC 60300.3.102004.

COPYRIGHT
Standards Australia International
All rights are reserved. No part of this work may be reproduced or copied in any form or by any
means, electronic or mechanical, including photocopying, without the written permission of the
publisher.
Published by Standards Australia International Ltd
GPO Box 5420, Sydney, NSW 2001, Australia
ISBN 0 7337 5798 7

ii

PREFACE
This Standard was prepared by the Standards Australia Committee QR-005, Dependability. This
Standard is identical with, and has been reproduced from, IEC 60300-3-10:2001, Dependability
management, Part 3-10: Application guide Maintainability.
Dependability is a collective term for performance characteristics (reliability, availability,
maintainability) of simple or complex products and systems. The AS IEC 60300 series of
dependability management Standards provide general guidelines for establishing a dependability
management system to meet most organizational or project needs, supported by a tool kit of nonprescriptive standards on a range of dependability application guidelines and methods.

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As this Standard is reproduced from an International Standard, the following applies:


(a) Its number appears on the cover and title page while the International Standard number appears
only on the cover.
(b) In the source text this International Standard should read this Australian Standard.
(c) A full point substitutes for a comma when referring to a decimal marker.
References to International Standards should be replaced by references to Australian or
Australian/New Zealand Standards, as follows:
Reference to International Standard

Australian or Australian/New Zealand Standard

IEC

AS IEC

60300

Dependability management

60300

Dependability management

60300-1

Part 1: Dependability programme


management

60300.1

Part 1: Dependability programme


management

60300-2

Part 2: Dependability programme


elements and tasks

60300.2

Part 2: Dependability programme


elements and tasks (in preparation)

60300.3.3

Part 3.3: Application guideLife


cycle costing

60300-3-3 Part 3: Application guide


Section 3: Life cycle costing

AS/NZS
60300-3-9 Part 3: Application guide
Section 9: Risk analysis of
technological equipment

3931

Risk analysis of technological


systemsApplication guide

AS IEC
60300-3-11 Dependability management
Part 3-11: Application guide
Reliability centred maintenance

60300.3.11 Dependability management


Part 3.11: Application guide
Reliability centred maintenance

Only International Standard referenced documents identical to Australian Standards have been listed.

iii

CONTENTS

INTRODUCTION................................................................................................................... v
Clause

Scope ............................................................................................................................. 1

Normative references ..................................................................................................... 1

Definitions and acronyms ............................................................................................... 2

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3.1
3.2
4

Maintainability overview.................................................................................................. 4
4.1
4.2

General .................................................................................................................
Product life cycle ...................................................................................................
4.2.1 Concept and definition phase ....................................................................
4.2.2 Design and development phase .................................................................
4.2.3 Manufacturing phase .................................................................................
4.2.4 Installation phase ......................................................................................
4.2.5 Operation and maintenance phase ............................................................
4.2.6 Disposal phase ..........................................................................................

4
4
5
5
5
6
6
6

Maintainability programme.............................................................................................. 6
5.1
5.2

Definitions ............................................................................................................. 2
Acronyms .............................................................................................................. 4

General .................................................................................................................
Criteria for the development of maintainability programmes...................................
5.2.1 User application.........................................................................................
5.2.2 Product related factors ..............................................................................

6
8
8
8

Maintainability programme elements and tasks ............................................................... 9


6.1

6.2

6.3

6.4

Planning and constraints ....................................................................................... 9


6.1.1 Maintenance policy .................................................................................... 9
6.1.2 Maintenance concept.................................................................................10
6.1.3 Specification of maintainability requirements .............................................11
Maintainability studies ...........................................................................................12
6.2.1 Maintainability allocation ...........................................................................12
6.2.2 Maintainability analysis ..............................................................................13
6.2.3 Requirements interpretation.......................................................................13
Project management .............................................................................................13
6.3.1 Maintainability management ......................................................................14
6.3.2 Maintainability programme plans ...............................................................14
6.3.3 Project decision management ....................................................................14
6.3.4 Configuration management ........................................................................15
Design for maintainability ......................................................................................15
6.4.1 Maintainability design ................................................................................15
6.4.2 Reliability and maintainability trade off ......................................................16
6.4.3 Design for maintenance support ................................................................16
6.4.4 Testability..................................................................................................16
6.4.5 Human factors ...........................................................................................17

iv

Clause

Page

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6.5

Externally provided products .................................................................................18


6.5.1 Subcontracted products .............................................................................18
6.5.2 Customer-provided products ......................................................................18
6.6 Analysis and prediction methods ...........................................................................19
6.6.1 Maintainability aspects of FMEA and FMECA ............................................19
6.6.2 Fault tree analysis .....................................................................................19
6.6.3 Reliability centred maintenance (RCM) ......................................................19
6.6.4 Maintainability predictions .........................................................................20
6.6.5 Trade-off analysis ......................................................................................21
6.6.6 Risk analysis .............................................................................................21
6.6.7 Design review ............................................................................................21
6.7 Verification, validation and test..............................................................................22
6.7.1 Maintainability verification .........................................................................22
6.7.2 Validation and test planning.......................................................................22
6.8 Life cycle cost .......................................................................................................23
6.9 Maintenance support planning ...............................................................................24
6.9.1 Maintenance support planning ...................................................................24
6.9.2 Installation.................................................................................................24
6.9.3 Support services........................................................................................25
6.10 Improvements and modifications ...........................................................................26
6.10.1 Improvement programmes .........................................................................26
6.10.2 Modification control ...................................................................................26
6.11 Collection and analysis of maintenance data .........................................................27
6.11.1 Data collection...........................................................................................27
6.11.2 Data analysis.............................................................................................28

Figure 1 Design process and the maintainability related design tasks ................................ 7
Figure 2 Active and inactive downtime spent by maintainers ..............................................10
Figure 3 Planning of maintenance and maintenance support..............................................25

INTRODUCTION
0.1 Purpose
The IEC 60300 1) series of standards and guides explain the procedures for implementing a
Dependability Programme during the design and development of a product in order to achieve
specified levels of dependability.
IEC 60300-1 is the top-level standard which provides guidance on dependability programme
management.

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IEC 60300-2 is the next level down which defines the tasks that need to be carried out and
gives guidance on how they should be undertaken.
IEC 60300-3 encompasses a series of application guides which develop the tasks in
IEC 60300-2 into specific areas. These then lead to further documents which describe the
"tools" to be used when applying a guide.
IEC 60300-1 and IEC 60300-2 are written to provide a guide on dependability, and are
predominantly centred on the reliability aspects. It was considered that a guide was required
to link IEC 60300-2 to the existing standards on maintainability, that is the IEC 60706 series
of guides on maintainability of equipment and other standards covering specific procedures
used in maintainability programmes. The original IEC 60706 series is being updated to ensure
that there is no undue duplication with this guide, and IEC 60706 is intended to provide the
tools for the procedures specified here. The relevant parts of IEC 60706 are referenced where
they will provide further guidance.
0.2

Concept of maintainability

Maintainability refers to the ease with which maintenance work can be done. It involves
the process of ensuring that products can be easily and safely maintained and that the
maintenance support requirement is minimized.
When a product has a reasonably long life, the cost of operation and support during that life
can greatly exceed the initial capital cost. The value to the customer of optimizing
maintainability should be evident. Some effort and expense applied to achieving a product
which can be easily and cheaply maintained will make very significant savings in the life cycle
costs.
The maintenance costs of a product are also dependent on the quantity in use. For a large
fleet of equipment, such as trucks, even a small improvement in maintainability can render
significant cost savings in the long term.
When a product is to be sold on the open market, the concept of easy maintenance at
low cost is an important consideration in the selection by the customer of equipment with low
operating costs.

________
1)

IEC 60300 (all parts), Dependability management.

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vi

NOTES

1
AUSTRALIAN STANDARD

Dependability management
Part 3.10:
Application guideMaintainability

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Scope

This International Standard, which forms part of the series of standards in the IEC 60300-3
series, is the application guide for maintainability. It can be used to implement a
maintainability programme covering the initiation, development and in-service phases of a
product, which form part of the tasks described in IEC 60300-2.
It provides guidance on how the maintenance aspects of the tasks should be considered in
order to achieve optimum maintainability. It should be noted that the full programme described
in this standard would only be applied to a major complex product with the potential for longterm usage.
For less complex maintainable products, a simpler programme should be adopted by tailoring
the programme to suit the degree of complexity and the requirements of the customer. The
standard uses other IEC standards and guides, notably IEC 60706, as reference documents
or tools to provide more detail as to how a task should be undertaken.
Contracts between customer and supplier will vary widely according to conditions and
circumstances in different industries. This standard is written on the premise that a product is
to be developed by a contractor from a basic concept for the particular requirements of a user
when the product is considered to be a development item (DI). However, in many instances,
where a product already exists and needs little or no development effort; it is a Nondevelopment item (NDI) and the full maintainability programme as described in this standard
will not be required. However, the principles laid down in the standard can be applied as
required, by tailoring the maintainability programme to suit the needs of the project.

Normative references

The following normative documents contain provisions which, through reference in this text,
constitute provisions of this part of IEC 60300. For dated references, subsequent
amendments to, or revisions of, any of these publications do not apply. However, parties to
agreements based on this this part of IEC 60300 are encouraged to investigate the possibility
of applying the most recent editions of the normative documents indicated below. For undated
references, the latest edition of the normative document referred to applies. Members of ISO
and IEC maintain registers of currently valid International Standards.
IEC 60050(191), International Electrotechnical Vocabulary (IEV) Chapter 191: Dependability
and quality of service
IEC 60300-1, Dependability management Part 1: Dependability programme management
IEC 60300-2:1995, Dependability management Part 2: Dependability programme elements
and tasks
IEC 60300-3 (all sections), Dependability management Part 3: Application guide

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Standards Australia

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AS IEC 60300.3.10-2004, Dependability


management Application guide - Maintainability

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