CMRP Practice Questions And Answers With Complete Tests, Exams of Advanced Education

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CMRP Practice Questions And Answers

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Replacement Asset Value (RAV) Correct Answer: defined as the cost that would be incurred, in today's dollars, to replace the facility and equipment in its current configuration. Overall Equipment Effectiveness (OEE) definition Correct Answer: metric for measuring how well a process is operating by evaluating the three major process components: availability, performance efficiency (rate/speed) and quality. The process can be a single piece of equipment, a manufacturing cell, a production line or a plant Overall Equipment Effectiveness (OEE) equation Correct Answer: Availability × Performance Efficiency × Quality Availability Correct Answer: defined as the percentage of time that the process is actually operating (uptime) compared to when it is scheduled to operate Performance efficiency (rate/speed) Correct Answer: defined as the percentage of Actual Run Rate/Cycle Time to the Best Run Rate/Cycle Time Quality Correct Answer: defined as the percentage of "First Pass, First Time" Saleable Production to the Actual Production Actual Production Correct Answer: total quantity of production produced in the given time period, regardless of its quality Lagging Indicator Correct Answer: An indicator that measures performance after the business or process result starts to follow a particular pattern or trend Leading Indicator Correct Answer: An indicator that measures performance before the business or process result starts to follow a particular pattern or trend Three (3) sets of measurable components that make up the maintenance and reliability process Correct Answer: 1. Management processes and behaviors (mission and vision, people skills)

2. Operational execution (operations, design and maintenance)
3. Manufacturing performance (availability, quality, cost and benefits) mean metrics Correct Answer: metrics that describe the Reliability, Availability and Maintainability (RAM) characteristics of a component, asset or even facility Inherent Availability Correct Answer: measure of the variables inherent in the design that affect availability. In the calculation of downtime, it usually includes only active

repair time. It does not include preventive maintenance time and administrative or logistic delays, but does include corrective maintenance downtime Inherent Availability Formula Correct Answer: Ai = MTBF / (MTBF + MTTR) Where MTBF = Mean Time Between Failures And MTTR = Mean Time to Repair (corrective maintenance only) Achieved Availability Correct Answer: probability that an item, when used under design conditions in an ideal support environment, will perform satisfactorily. It includes both active repair time and preventive maintenance time, but excludes administrative and logistic delay times Achieved Availability Formula Correct Answer: Aa = MTBM / (MTBM + MDTM) Where MTBM = Mean Time Between Maintenance And MDTM = Mean Downtime for Maintenance Operational Availability Correct Answer: probability that an item, when used under design conditions in an operational environment, will perform satisfactorily. It includes active repair time, preventive maintenance time and administrative and logistic delays and represents the availability that is actually experienced Operational Availability Formula Correct Answer: Ao = MTBM / (MTBM + MDT) Where MTBM = Mean Time Between Maintenance And MDT = Mean Down Time Equipment Availability Correct Answer: defined by The Association for Manufacturing Technology as the percentage of potential production time during which equipment is operable. The term is applied to a single piece of manufacturing equipment (or several machines acting as a unit) Equipment Availability Formula Correct Answer: = [Production Time / Potential Production Time] x 100 Point Availability Correct Answer: probability that a device, system or component will be operational at any random point in time Point Availability Formula Correct Answer: At = R(t) + ∫ t R(t - u)m(u)du Where R(t) = Probability of operating during time (t) m(u) = The renewal density function And u = The last repair time (0 < u < t) Average Availability Correct Answer: average availability over a specific time period when an asset is available for use. It is also called mean availability Limiting Availability Correct Answer: the limit of the point availability function as time approaches infinity. It is also called steady-state availability

Limiting Availability Formula Correct Answer: A∞ = lim At t → ∞ Maintenance training ROI Correct Answer: the ratio of the benefit to the cost of training maintenance employees Ratio of Replacement Asset Value (RAV) to Craft-Wage Headcount Correct Answer: Replacement Asset Value (RAV) of the assets being maintained at the plant divided by the craft-wage employee headcount Ratio of Replacement Asset Value (RAV) to Craft-Wage Headcount Formula Correct Answer: Ratio of Replacement Asset Value ($) to Craft-Wage Head Count = RAV ($) ÷ Craft-Wage Headcount Maintenance Unit Cost Correct Answer: The metric is the measure of the total maintenance cost required for an asset or facility to generate a unit of production. Maintenance Unit Cost Formula Correct Answer: = Total Maintenance Cost ÷ Standard Units Produced Standard Units Produced Correct Answer: A typical quantity produced as output. The output has acceptable quality and consistent means to quantify. Examples would include gallons, liters, pounds, kilograms or other standard units of measures. Total Maintenance Cost Correct Answer: Total expenditures for maintenance labor (including maintenance performed by operators, e.g., total productive maintenance (TPM), materials, contractors, services and resources. Include all maintenance expenses for outages, shutdowns or turnarounds, as well as normal operating times. Include capital expenditures directly related to end-of-life machinery replacement Stocked MRO Inventory Value As a Percent of Replacement Value (RAV) Correct Answer: The metric is the value of maintenance, repair and operating materials (MRO) and spare parts stocked on site to support maintenance, divided by the Replacement Asset Value (RAV) of the assets being maintained at the plant, expressed as a percentage. Stocked MRO Inventory Value As a Percent of Replacement Value (RAV) Formula Correct Answer: Stocked MRO Inventory Value per RAV (%) = [Stocked MRO Value ($) × 100] ÷ Replacement Asset Value ($) Replacement Asset Value (RAV) Correct Answer: This is the dollar value that would be required to replace the production capability of the present assets in the plant. Include production/process equipment, as well as utilities, facilities and related assets. Do not use the insured value or depreciated value of the assets. Include replacement value of buildings and grounds if these assets are maintained by the maintenance expenditures

Total Maintenance Cost As a Percent of Replacement Asset Value (RAV) Correct Answer: The metric is the amount of money spent annually maintaining assets, divided by the Replacement Asset Value (RAV) of the assets being maintained, expressed as a percentage. Total Maintenance Cost As a Percent of Replacement Asset Value (RAV) Formula Correct Answer: Total Maintenance Cost per RAV (%) = [Total Maintenance Cost ($) × 100] ÷ Replacement Asset Value ($) Overall Equipment Effectiveness (OEE) Correct Answer: The metric is a measure of equipment or asset performance based on actual availability, performance efficiency, and quality of product or output when the asset is scheduled to operate Idle Time Correct Answer: The amount of time an asset is idle or waiting to run. It is the sum of the times when there is no demand, feedstock or raw material and other administrative idle time (e.g. not scheduled for production). Uptime Correct Answer: The amount of time an asset is actively producing a product or providing a service. It is the actual running time. Downtime Event Correct Answer: An event when the asset is down and not capable of performing its intended function. Scheduled Downtime Correct Answer: Time to do required work on an asset that is on the finalized weekly maintenance schedule. Unscheduled Downtime Correct Answer: Time an asset is down for repairs or modifications that are not on the weekly maintenance schedule. Performance Efficiency Correct Answer: The degree to which the equipment operates at historical best speeds, rates, and/or cycle times. Quality Rate Correct Answer: The degree to which product characteristics meet the product or output specifications. Actual Production Rate Correct Answer: The rate at which an asset actually produces product during a designated time period. Best Production Rate Correct Answer: The rate at which an asset is designed to produce product during a designated time period or the demonstrated best sustained rate, whichever is higher. Total Units Produced Correct Answer: The number of units produced during a designated time period.

Defective Units Produced Correct Answer: The number of unacceptable units produced during a time period (i.e. losses, rework, scrap, etc.). Total Effective Equipment Performance (TEEP) Correct Answer: This metric is a measure of equipment or asset performance based on actual utilization time, availability, performance efficiency and quality of product or output over all the hours in the period. TEEP is expressed as a percentage. Total Effective Equipment Performance (TEEP) Formula Correct Answer: Utilization Time % × Availability % × Performance Efficiency % × Quality Rate % UTILIZATION TIME Correct Answer: Time when the asset is scheduled to run divided by total available time expressed as a percentage. AVAILABILITY Correct Answer: Availability is the percentage of the time that the asset is actually operating (uptime) compared to when it is scheduled to operate. This is also called operational availability. TOTAL AVAILABLE TIME Correct Answer: 365 days x 24 hours = 8760 hours per year. Availability Formula Correct Answer: % = {Uptime (hrs) ÷ [Total Available Time (hrs) - Idle Time (hrs)]} x 100 Uptime Formula Correct Answer: = Total Available Time - (Idle Time + Downtime) Down time Formula Correct Answer: = Scheduled Downtime + Unscheduled Downtime Systems Covered by Criticality Analysis Correct Answer: This metric is the ratio of the number of systems in a facility for which a criticality analysis has been performed divided by the total number of systems in the facility, expressed as a percentage. Systems Covered by Criticality Analysis formula Correct Answer: Systems Covered by Criticality Analysis (%) = [Number of Critical Systems (for which a criticality analysis has been performed) ÷ Total Number of Systems] × 100 SYSTEMS Correct Answer: A set of interrelated or interacting elements. In the context of dependability, a system will have the following: a defined purpose expressed in terms of required functions, stated conditions of operation and defined boundaries. CRITICAL ANALYSIS Correct Answer: A quantitative analysis of events and faults and the ranking of these in order, based on a weighted combination of the seriousness of their consequences and frequency of occurrence. CRITICAL SYSTEMS Correct Answer: The systems that are vital to continued operations, will significantly impact production or have inherent risks to personnel safety or the environment should they fail.

Mean Time Between Failures (MTBF) Correct Answer: the average length of operating time between failures for an asset or component used primarily for non-repairable assets and components Mean Time Between Failures (MTBF) Formula Correct Answer: = Operating time (hours) ÷ Number of Failures Mean Time To Repair or Replace (MTTR) Correct Answer: the average time needed to restore an asset to its full operational capabilities after a failure, a measure of asset maintainability, usually expressed as the probability that a machine can be restored to its specified operable condition within a specified interval of time, regardless of whether an asset is repaired or replaced Mean Time To Repair or Replace (MTTR) Formula Correct Answer: MTTR = Total repair or replacement time (hours) ÷ Number of repair/replacement events Repair/Replacement Event Correct Answer: The act of restoring the function of an asset after failure or imminent failure by repairing or replacing the asset. Failure When Failure Correct Answer: When an asset is unable to perform its required function. This excludes proactive work. Mean Time Between Maintenance (MTBM) Correct Answer: The metric is the average length of operating time between one maintenance action and another maintenance action for an asset or component. This metric is applied only for maintenance actions which require or result in function interruption. Mean Time Between Maintenance (MTBM) Formula Correct Answer: Mean Time Between Maintenance (MTBM) = Operating Time (hours) / Number of Maintenance Actions Maintenance Action Correct Answer: One or more tasks necessary to retain an item in or restore it to a specified operating condition. A maintenance action includes corrective, as well as preventative and predictive maintenance tasks that interrupt the asset function. Mean Downtime (MDT) Correct Answer: The metric is the average downtime required to restore an asset or component to its full operational capabilities. MDT includes the time from failure to restoration of an asset or component. Mean Downtime (MDT) Formula Correct Answer: = Total Downtime (hours) ÷ Number of Downtime Events

Mean Time to Failure (MTTF) Correct Answer: the average length of operating time to failure of a non-repairable asset or component, i.e., light bulbs, rocket engines Mean Time to Failure (MTTF) Formula Correct Answer: = Operating time to failure (hours) / # Assets/components run to failure Rework Correct Answer: corrective work done on previously maintained equipment that has prematurely failed due to maintenance, operations or material problems Rework Formula Correct Answer: (%) = [Corrective Work Identified as Rework (hours) ÷ Total Maintenance Labor Hours] × 100 Corrective Work Correct Answer: Work done to restore the function of an asset after failure or when failure is imminent. Maintenance Training Cost Correct Answer: This metric is the cost for the formal training that internal maintenance employees receive annually. It is expressed as cost per employee. Maintenance Training Cost (per employee) Formula Correct Answer: = Total Maintenance Training Cost ÷ Number of Internal Maintenance Employees TOTAL MAINTENANCE TRAINING COST Correct Answer: the sum of all costs for formal training that is directed at improving job skills for maintenance employees TOTAL INTERNAL MAINTENANCE EMPLOYEE LABOR COSTS Correct Answer: all internal maintenance labor costs, including benefits and both straight time and overtime, for all direct and indirect maintenance employees INTERNAL MAINTENANCE EMPLOYEES Correct Answer: All personnel, salaried and hourly, direct and indirect, who are responsible for executing work assignments pertaining to the maintenance of physical assets and components Maintenance Training Hours Correct Answer: The metric is the number of hours of formal training that maintenance personnel receive annually. It is expressed as hours per employee Maintenance Training Hours Formula Correct Answer: = Training Hours ÷ Number of Maintenance Employees Maintenance Training Return on Investment (ROI) Correct Answer: This metric is the ratio of the benefit to the cost of training internal maintenance employees. Maintenance Training ROI Formula Correct Answer: (%) = [Business Benefits ($) ÷ Training Cost ($)] × 100

Corrective Maintenance Cost Correct Answer: the percentage of total maintenance cost that is used to restore equipment to a functional state after a failure or when failure is imminent Corrective Maintenance Cost Formula Correct Answer: (%) = (Corrective Maintenance Cost ×100) ÷ Total Maintenance Cost Corrective Maintenance Hours Correct Answer: the percentage of total maintenance labor hours used to restore equipment to a functional state after a failure or when failure is imminent Corrective Maintenance Hours Formula Correct Answer: (%) = (Corrective Maintenance Hours × 100) ÷ Total Maintenance Labor Hours Preventive Maintenance Cost Correct Answer: the maintenance cost that is used to perform fixed interval maintenance tasks, regardless of the equipment condition at the time Preventive Maintenance Cost Formula Correct Answer: (%) = [Preventive Maintenance Cost ($) ÷ Total Maintenance Cost ($)] × 100 Preventive Maintenance Hours Correct Answer: This metric is the percentage of maintenance labor hours used to perform fixed interval maintenance tasks, regardless of the equipment condition at the time Preventive Maintenance Hours Formula Correct Answer: (%) = (Preventive Maintenance Hours ÷ Total Maintenance Labor Hours) × 100 Condition Based Maintenance Cost Correct Answer: This metric is the maintenance cost that is used to measure, trend and compare equipment conditions against known standards to detect, analyze and correct problems before they cause functional failures Condition Based Maintenance Cost Formula Correct Answer: % = [Condition Based Maintenance Cost ($) ÷ Total Maintenance Cost ($)] × 100 Best Practices are practices that are defined and applied by an organization to improve their operation. These practices may or may not be proven, but results are found to be acceptable. (T/F) Correct Answer: True Maintainability is measured by PM schedule compliance. (T/F) Correct Answer: False All maintenance personnel's time should be covered by work orders. (T/F) Correct Answer: True Operations and Maintenance must work as a team to achieve improved OEE. (T/F) Correct Answer: True

Best practices would indicate that 90% or more of all maintenance work is planned. (T/F) Correct Answer: True 100% of PM and PdM tasks should be developed using FMEA/PCM methodology. (T/F) Correct Answer: True Utilization of assets in a world-class facility should be about 85%. (T/F) Correct Answer: True 100% of maintenance personnel's (craft) time should be scheduled. (T/F) Correct Answer: True Time-Based PMs should be less than 20% of all PMs.(T/F) Correct Answer: True The 10% rule of PM is applied on critical assets. (T/F) Correct Answer: True Most emergency work orders should be written by production/operations. (T/F) Correct Answer: True It should be common practice for operators to perform PMs. (T/F) Correct Answer: True The P-F interval can be applied to visual inspections. (T/F) Correct Answer: True The best method of measuring the reliability of an asset is by counting downtime events. (T/F) Correct Answer: True The primary purpose of scheduling is to coordinate maintenance jobs for greatest utilization of maintenance resources. (T/F) Correct Answer: True What percentage of your assets should be ranked critical based on the risk to business? Correct Answer: Less than 20% Vibration monitoring can detect uniform impeller wear. (T/F) Correct Answer: False Understanding the known and likely causes of failures can help design a maintenance strategy for an asset to prevent or predict failure. (T/F) Correct Answer: True Reliability can be improved easily after a maintenance plan has been put into operation. (T/F) Correct Answer: False What percentage of maintenance work should be proactive? Correct Answer: 85% or more MTBF is measured by operating time divided by the number of failures of an asset. (T/F) Correct Answer: True

Maintenance cost will decrease as reliability increases. (T/F) Correct Answer: True The "F" on the P-F interval indicates that equipment is still functioning. (T/F) Correct Answer: False A rule of thumb is that, on average, an experienced planner can plan work for how many craft people? Correct Answer: 15 Which of the following is not a primary objective for implementing a planning process? Correct Answer: Mesh the production schedule and the maintenance schedule. The best method of measuring the reliability of an asset is by? Correct Answer: MTBF With the exception of emergency work orders, planning and scheduling will benefit all maintenance work. (T/F) Correct Answer: True Leading KPIs predict results. (T/F) Correct Answer: True The 6th S in 6S (also called 5S plus) stands for safety. (T/F) Correct Answer: True RCM stands for: Correct Answer: Reliability Centered Maintenance The objective of RCM is to preserve functions. (T/F) Correct Answer: True An MRO storeroom shouldn't be stocking parts for emergencies. (T/F) Correct Answer: False The inventory turnover ratio for MRO store should be: Correct Answer: Less than 2 PM compliance is a ________ KPI. Correct Answer: Lagging and Leading Quality is one key component of OEE. (T/F) Correct Answer: True Reliability and Maintainability can only be designed in. (T/F) Correct Answer: True Creating a reliability culture from a reactive mode can be accomplished in a short period of time if enough resources are made available. (T/F) Correct Answer: False Karl Fischer's Coulometric Titration Method is an effective technique to determine the metallic content (in PPM) in an oil sample. (T/F) Correct Answer: False An IR thermography window is an effective method to satisfy NFPA 70E arc flash requirements. (T/F) Correct Answer: True FMEA is applicable only to assets currently in use. (T/F) Correct Answer: False

RCM Methodology can't be used effectively on new systems being designed. (t/F) Correct Answer: False Properly training the M&R workforce can increase asset and plant availability. (T/F) Correct Answer: True TPM is a type of maintenance performed by the operators. (T/F) Correct Answer: True Lagging KPIs are the results of a process. (T/F) Correct Answer: True EOQ improves the inventory turn ratio. (T/F) Correct Answer: False New incoming oil from the supplier is always clean and ready to be used. (T/F) Correct Answer: False Which phase of the asset life cycle has the highest cost? Correct Answer: O&M Most of the maintenance costs become fixed at what phase? Correct Answer: During design RCM provides best results when used during what phase? Correct Answer: During design and development How soon can we restore an asset is measured by: Correct Answer: MTTR Availability is a function of: Correct Answer: Uptime and downtime The failure rate of a component/asset can be calculated by knowing: Correct Answer: MTBF The biggest benefit of failure modes and effects analysis occurs during: Correct Answer: Design Phase PM schedule compliance should be equal or greater than 95%. (T/F) Correct Answer: True