Optimizing Total Cost: Finding MTBF for Maximum Savings in 5 Years

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SUMMARY

The discussion focuses on optimizing the Total Cost of a system over a five-year period by determining the Mean Time Between Failures (MTBF), denoted as θ. The Total Cost is calculated as the sum of Acquisition cost, Spares cost, and Downtime cost, with the Acquisition cost defined by the formula CA(θ) = 685.2917e0.003779θ. The average costs for spare items and downtime are $1,000 and $5,000 respectively. To minimize the Total Cost, participants suggest taking the derivative of the cost function with respect to the failure rate (R) and setting it to zero.

PREREQUISITES
  • Understanding of Total Cost calculations in operational systems
  • Familiarity with Mean Time Between Failures (MTBF) and its implications
  • Basic knowledge of calculus, specifically derivatives
  • Experience with exponential functions and their applications in cost modeling
NEXT STEPS
  • Learn how to derive cost functions to find minimum values
  • Study the implications of MTBF on operational efficiency and cost
  • Explore the relationship between failure rates and total operational costs
  • Investigate advanced optimization techniques for cost minimization in engineering systems
USEFUL FOR

Engineers, operations managers, and financial analysts involved in system optimization, cost analysis, and maintenance planning will benefit from this discussion.

ptlnguyen
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Homework Statement


A system is to be operated 5000 hours per year, where
Total Cost (for 5 years) = Acquisition cost + Spares cost + Downtime cost
System acquisition cost is related to MTBF, θ, as follows:

CA(θ) = 685.2917e0.003779θ
The average cost of a spare item is $1,000 and the average cost of downtime associated with failure is $5,000.

Homework Equations


Find MTBF or θ required for a system that will result in approximate minimum total cost over a five-year period if the

The Attempt at a Solution


This is my attempt but not sure
Find θ = MTBF
1/MTBF = R/T where R= rate of failure and T= total time = 5000hrs
=> MTBF =T/R = 5000/R
Total Cost = Acquisition cost + Spares cost + Downtime cost
= 685.2917e^0.003779(5000/R) + 5000R + 1000R
= 685e^20/R + 6000R
I need to find R such that it will minimize Total Cost and I am stuck. Please check if my approach is correct. Thanks.
 
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ptlnguyen said:

Homework Statement


A system is to be operated 5000 hours per year, where
Total Cost (for 5 years) = Acquisition cost + Spares cost + Downtime cost
System acquisition cost is related to MTBF, θ, as follows:

CA(θ) = 685.2917e0.003779θ
The average cost of a spare item is $1,000 and the average cost of downtime associated with failure is $5,000.

Homework Equations


Find MTBF or θ required for a system that will result in approximate minimum total cost over a five-year period if the

The Attempt at a Solution


This is my attempt but not sure
Find θ = MTBF
1/MTBF = R/T where R= rate of failure and T= total time = 5000hrs
=> MTBF =T/R = 5000/R
Total Cost = Acquisition cost + Spares cost + Downtime cost
= 685.2917e^0.003779(5000/R) + 5000R + 1000R
= 685e^20/R + 6000R
I need to find R such that it will minimize Total Cost and I am stuck. Please check if my approach is correct. Thanks.

Welcome to PF, ptlnguyen! :smile:

Overall your formula seem fine, but I'm missing references to the 5 year the system is supposed to operate.
So I think you should have a couple of factors 5 in there somewhere...

To minimize total cost, you're supposed to take the derivative with respect to R.
Set it equal to zero, and solve R.
Do you know how to take a derivative?
 

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