FEDERATION EUROPEENNE DE LA MANUTENTION

Section IX
FEM·
SERIES LIFTING EQUIPMENT 9-.222
Standards of the acceptance and
availability of installations with storage/retrieval 06.1989 (E)
machines and other machinery

Table of contents

Page

1 Symbols and meaning 2

2 Scope 3

3 Availability : : ;.. 3
3.1 , Fault 3
3.2 Malfunction 3
3.3 Reliability 3
3.4 Times 3
3.4.1 Unattended time {~) : 3
3.4.2 ,Standby time (tBer) 3
3.4.3 Operating time (tBtr) 4
3.4.4 'Time in service (te = tBer+tBlr) 4
3.4.5 Downtime (tA = tA1+tA2+tA3+tA4) 4
3.4.6 Maintenance time {tl ) 5
3.4.7 Influence of the Sub-periods 5
3.5 Availability , 5
3.6 Methods of achieving a high reliability 6

4 Acceptance te'sting 8
4.1 Preliminary inspections 8
4.2 Intermediate inspections 8
4.3 Partial hand-overs : 8
4.4 Official inspection 8
4.5 Acceptance of the installation 8
4.6 Proof of agreed characteristics ·.9
4.6.1 Function test 9
4.6.2 Performance test ; 10
4.6.3 Availability test ; 10
4.7 Outstanding work after acceptance 12

5 Operational·phase : 12
5.1 Running-in operation : 12
5.2 Measurement phase 12
5.3 Checking point 12

6 Contract procedure scheme 13

7 Examples for determining availability 14

7.1 High bay warehouse (HBW) 14
7.2 Computer-controlled warehouse system 15
7.3 Installation with Storage/Retrieval machines, Assembly and test stands : 16

Continued page 2 to 22

Federation Europeenne de la Manutention

Copyright by FEM Section IX Available in Engllsh(E), German (D), French (F) For references see end of Document
· Page 2
FEM 9.222 (06.1989)

1 Symbols and Meaning

Symbol Dimen- Meaning

sion

A - Availability

k; - Weighting factor

MTBF min Mean time between failures

MTTR min Mean time to repair

nf - Number of operations carried out incorrectly.

nr - NLimber of correct or trouble-free operations

tA min Downtime

tAl min Downtime of a single element i ofa system

t A1 min Period between the occurrence of a fault and start of the search for the fault

t A2 min Period needed to find the cause of the fault

t A3 min Period to prepare and organize correction of the fault

t
A4
- min Period needed to clear the fault for operational readiness or until resumption of
operations
t ABer min Downtime during the standby time

tABIr min Downtime during the operating time

t Ber min Standby time

t BIr min Total operating time

t E min Total time in service

t1 min Maintenance time

tR min Unattended time

r:p % Reliability

TI % Availability

TlBIr
% Availability during the total operating time -
TIE
% Availability considering only the time in service

T/TOI % Total availability

TIn % Availability of an element

 Page 3
FEM 9.222 (06.1989)

2 Scope

The following standard gives recommendations for the determination of the availability and for the
commissioning, hand-over and testing of installations with storage/retrieval machines, material-handling
facilities and other machinery and their controls.

3 Availability
3.1 Fault
A fault is the inadmissible deviation of a characteristic from a prescribed value.

3.2 Malfunction
A malfunction is the inadmissible impairment of a function:

In determining the reliability and availability, only those malfunctions are considered which actually impair the
operation.

3.3 Reliability
The reliability <p of a discontinuously loaded element of a system is equal to the probability of that element
carrying out its function under given boundary conditions correctly and without malfunctions. It is a measure
of the functional safety of an installation.

The reliability is determined experimentally by the quotients

nr
ffJ = (1 )

where

nr =Number of correct or trouble-free operations

nf =Number of operations carried out incorrectly

As systems consist of several elements, which are normally independent of each other, the appropriate model for
determining the reliability and the availability must be formulated. When Considering this the following applies:

If, for a system to function, it is necessary that every eiement functions, itfollows that the elements are arranged in
series, ie if an element fails the functioning of the system is disrupted.

If, for a system to function, it is adequate that only one of the elements functions, it follows that the elements are
arranged in parallel, Le. if an element fails the functioning of the system can be maintained due to redundancy (e.g.
by-pass).

The function under observation must be tested with an adequate statistical frequency.

The deviations to be rated as faults or malfunctions are to be defined for the particular application.

In general the term .Reliability" makes no statement about the characteristics of a system in the case of a malfunction,
but does give information about the susceptibility of a system to disruption.

3.4 Times

3.4.1 Unattended time (t R)

Unattended time is when the installation is switched-off and is neither being maintained nor repaired.

3.4.2 Standby time (t Ber>

Standby time is when the installation is switched on but is not, however, performing its functions.
 Page 4
FEM 9.222 (06.1989)

0 100%
tR tE t,
I· ~I· ~I· ~I

I I I I
I I. tBer
~I~
tBIr
~I I
I I I I
• •
Tt
I I
T
I
• •
tABer.&. tABIr 1
T
I I
•I tA
•I
It t I
eA••A3.
t tA2 A4 •
Figure 1: Possible time-proportions of an installation In the course of a day

3.4.3 Operating tilile (t Btr)

Operating time is when the installation is used under operating conditions.

3.4.4 Time in service (t E =t Ber + t Btr)

Time in service time is the sum of the standby time and the operating time.

3.4.5 Downtime (tA = t A1 + t A2 + tA3 + t A4)

The period of time between the occurrence of a fault and the restoration of operational readiness. The down
time is established with reference to FEM 9.221 "Performance Data of SIR Machines, Reliability, Availability".
. Downtime contains the following sub-periods:

t A1 = Period between the occurrence of the fault and start of the search for the fault by the responsible
personnel
t A2 = Period needed to find the cause of the fault
t A3 = Period to prepare and organize correction of the fault, making ready etc.
tM = Period needed to clear the fault for operational readiness or until resumption of operations (the actual
repair time). the operational readiness of the installation can be restored before the final completion
of the repair. It should be noted here that the downtime can lie in both the standby time and in the
operating time. Therefore the following applies:

t ABer = Breakdown time during the standby time

t A Btr = Breakdown time during operating time
 PageS
FEM 9.222 (06.1989)

3.4.6 Maintenance time ( t I )

Time period during which the installation is maintained.

3.4.7 Influence of the Sub-periods

Different sub-periods can be used for calculating the availability.

~s a rule downtime during the operating time has the effect of reducing the availability, particularly when the
installation has no redundancy, stores, buffers etc. Downtime during the standby time does not have the
effect of reducing the availability. .

If intolerable downtime tA1 - tA4 arises due to lack of readiness or qualification of the personnel, it can be
deducted proportionately.

3.5 Availability
In theory availability is described as the probability of finding a system at a given time in an operable
condition.

In practice the availability is the measure of the useful operating! service time of an installation and thus also
dependant on how quickly a fault, on average, can be cleared. The availability is calculated as

I Btr -IABtr
17Btr = 1 (2)
Btr

on condition that breakdowns during the standby time do not effectively impair the operation or
t E -tA
~= ~
tE

on condition that portions of downtime during the standby time should also count as reducing the availability
where

17 BIr = Availability during the total operating time

. 17 E = Availability considering only the service time
t BIr = Total operating time
tE = Total service time
t A BIr = Portion of the.downtime which falls within the operating time
tA = Total downtime

As the systems consist of several system elements, the appropriate availability model must be formulated:

- If, for a system to function, it is necessary that every element functions, it follows that the elements are
arranged in series:

170es = 171 . 172 •173 ' 17n (4)

- . If, for a system to function, it is adequate that one of the elements functions, it follows that the elements
are arranged in parallel:

170es 7" 1-[(1- 171 ). (1- 172)' (1- 17n)] (5)

 Page 6
. FEM 9.222 (06.1989)

In reality these formulas are strongly idealised partly because:

- The elements can have not only the conditions. "functional" or· "failed" but also "diminished
performance", .
- Normally the elements are not independent of each other but are linked together ego by a control system,
- Downtimes of different elements can coincide.

It is recommended that the following adaptation of the formula (3) is used in practice:

(6)

where:

tE = Total service time

t Ai = Total downtime of the system element i
kj = Weighting factor of the system element i which represents the influence of the disruption of this
element on the total function. For a series arrangement of the elements k j = 1. For a parallel
arrangement of the elements this becomes 1 ~ k j > O. For n identical parts of the system this
becomes k j = 1/n

3.6 Methods of achieving a high reliability

From the relationship:

(7)

it can be deduced that to achieve a high availability there are principally two approaches:

- keep the breakdown time tA low.

- keep the value of t E high in comparison to t AI Le. to achieve a low downtime rate which corresponds to a
high reliability.

These facts are represented in Fig. 3 with a list of methods.

 Page?
FEM 9.222 (06.1989)

Requirement I High availability I

Approaches Short I /\ High reliability
to Breakdown V \ Low susceptibility
solutions time to disruption
I - automatic . I-High grade
fault recognition . materials
I- Computer-aided I- Testing of the
fault location components
,--Simple
fault diagnosis - Proven design

Methods '-- Service-friendly High class manufacture

construction f-- reliable installation
I- keeping spare-
. parts in stock f--Precise inspection
Qualified
'-- maintenance Correct usage
I-

personal as authorized
'-- Repairs are Carefully trained
started quickly f--and proficient
personnel
'-- Repair instructions Preventive
and documentation '--maintenance

Fig. 3. Approaches to achieving a high level of availability

NOTE The formiJlae for the availability TJ contain portions of time which can be measured experimentally during a
certain observation period. The formulae can thus be used as measurement instructions. In some cases the availability
is not regarded as a measurement instruction but as a property of the system.

Figure 2 shows clearly that the mean value of t E - t A and of t A correspond to the usual terms in the English speaking
world of MTBF and MTTR

The availability as a system property is defined there as A (availability)

A= MTBF
MTBF+MTTR

where MTBF =Mean Time Between Failures

MTTR =Mean Time To Repair

'El IE2 lE:!

d ~
I
t.l\ I I
lA 21
ItE
I

Mean lE
J
~l,\
I
I
Mean lA
I I
I I I Flg.2 Relationship between
MTBF MTTR the availability definitions
 Page 8
FEM 9.222 (06.1989)

4 Acceptance Testing

The customer and the contractor haVe to reach an agreement before the contract is signed on which
regulations are to complied with (customer's as well as statutary regulations and recommendations) and
which inspections are to be carried out.

The inspections and the hand-overs can be carried out in several intermediate steps described below. Some
of these can be omitted or combined.

4.1 Preliminary inspections

When required the following contract conditions regarding inspections can be agreed before delivery .
commences:
- Inspection of the approval drawings of the individual parts of the system
-' Inspection of sub-assemblies or components which will not be accessible later
- Arrangement of the controls
- Factory inspections

4.2 Intermediate inspections

Among other things the following intermediate inspections can be agreed for checking the progress of the
project:
- Completion of phases
- Completeness of deliveries
- Deliveries free from damage
- Completed installation, commissioning
- Computer link to the system
- Interfaces (for example: building tolerances, software and hardware interfaces etc.)
- Comparison between delivery and specification

In the case of export contracts intermediate inspections will be arranged.

4.3 Partial hand-overs

Partial hand-overs can take place for provisional use or to support the work of third parties. In doing so the
risks involved in this use pass to the user. In this case the question of the warranty is to be agreed.

4.4 Official inspections

The customer arranges for the official inspections after the contractor has indicated to him his readiness for
them. The contractor is to assist in this inspection and afterwards is responsible for the rectification of
outstanding work over which he has control.

4.5 Acceptance of the installation

The installation is ready for acceptance as soon as it is in a condition to fulfill the functions agreed in the
contract. In this connection it is not required to demonstrate the full performance capability.

The acceptance of the installation takes place in the presence of the customer and the contractor.

Insofar as it has not previously been shown the acceptance of the total installation covers:
- Completeness of the delivery
- Adherence to the promised characteristics
- Agreed situation at the interfaces
 Page 9
FEM 9.222 (06.1989)

- Compliance with statutory regulations

- Hand-over of the documentation

A report is to be drawn up concerning the acceptance.

Outstanding work which has no essential influence on the overall function are not grounds for refusal of
acceptance.

The warranty commences with the acceptance.

Exclusions and reservations must be in writing. Outstanding work current at the time of acceptance is to be .
set down in writing. Outstanding work which becomes evident or occurs later come under the warranty
obligations of the contractor.

If the customer is unwilling to take over the installation a description of the situation is to be recorded by
. mutual agreement. Further acceptance conditions shall be negotiated.

After the acceptance has taken place the responsibility for the use and risk passes to the customer. In
particular the customer is responsible for seeing that the maintenance and service work is carried out in
accordance with the contractors guidelines. The customer is responsible for the holding of spare parts.

Adherence to the safety regulations and obtaining licences to operate is a matter for the customer. The
contractor has only a limited influence on the inspection by the authorities, therefore a delayed inspectiOn by
these authorities shall not delay the hand-over.

If the customer uses the installation before the acceptance the transfer of risk to the customer takes place at
the latest from the moment it is used, the warranty period beginning at the same time.

4.6 Proof of agreed characteristics

Depending onthe type of installation and the operating philosophy, functional -, performance - or availability-
tests can be agreed before, during or after the acceptance.

At the request of the contractor the customer will make available in the necessary quantities for all phases of
the test and hand-over:
- Qualified inspection, works and operating staff
- .Transport units
- Means of transport ( Reach trucks, trailors etc.)

4.6.1 Function test

In this test the functions of the installation are demonstrated. In doing so criteria such as performance and
availability are not taken into consideration.

Errors and faults over which the contractor has no control are to be recorded, such as :
- Voltage interruption
- Voltage fluctuations
- Inadmissible ambient temperature
- Unsuitable loading aids
'- Unstable loads
- Operating errors
- Escape of liquids, granulates, loose paper, protruding foil or parts of the load
 Page 10
·FEM 9.222 (06.1989)

- High air pollution (dust)

- Inadequate air conditioning for computer installations
- Interference with the installation by the customer

Faults or malfunctions which do not impair the operational readiness of the installation are not taken into
consideration. Different functional areas in larger installations are often separated from each other by buffers.
Faults in sub areas do not, therefore, necessarily have an effect throughout the entire installation.

4.6.2 Performance test

A performance test presupposes that a clearly measurable performance specification is defined in the
contract.

.The performance of the installation is composed of the performances of the individual elements. The
performance can be demonstrated separately for the individual elements of material handling and storage
equipment and for the entire installation.

For the demonstration of the performance of the individual elements of material handling equipment the
existing recommendations can be used e.g. FEM 9.851 "Performance data of SIR Machines - Cycle Times".
These recommendations can also be applied in whole or in part to narrow aisle stacker trucks.

The performance of the entire installation is only then demonstrated if the responsibility for it rests with the
contractor. The test procedure is to be clearly established between the customer and the contractor.

In doing so the problems which arise when several lines of conveyors are operated at the same time are to
be taken into consideration such as, for example, the build-up of accumulations, response times of the
higher-order computer. The customer has to fulfill the boundary conditions necessary for the performance
test in good time, above all providing the necessary unit loads as well as personnel and machinery for
placing the unit loads onto the conveyor system.

4.6.3 Availability test

The availability of the installation should be specified, at the latest, before signing the contract with the
customer. The availability model forthe installation must be defined. It includes:

- Structure or linkage of the individual elements of the system

- Weighting distribution of the individual elements of the system
- Distribution of the goods in the storage aisles
- Buffering in the individual areas
- Redundancy
- Test procedure

The duration of the fault rectification is dependant on human factors, which are to be considered.

If, in certain cases, an analysis is required of the faults which occur, then the analysis time is not added to
the downtime.

In the case of complex installations the time of the availability testing must be agreed between the customer
and the contractor.
 Page 11
FEM 9.222 (06.1989) ... ,

Availability (%)
Upper envelope curve
'1n
100 roOC:::::==---~---+-----+---------+----""'-'--1------l
9S -------
90 r - - - - - t - - - - -.........t - -.........---l-----4------+----:..··~ld~eal value
as
·80
- - -.-~
--------
----

Lower envelope curve

15 20 25 JS 45 00
Number of faults

Figure 4: Accuracy of the determination of an availability

A high availability is not generally achieved until after a sufficiently long period of running:-in operations. If,
after the first test, an installation does not fulfill the agreed values, the contractor is to be allowed, after a
period of time in which to effect improvements, further testing opportunities. During the acceptance test the
availability is considered reduced only if the faults in the functioning of the installation really impair the
operation; for example an automatic repeat of a positioning operation after a fault, without manual
intervention, is not to be taken into consideration.

The accuracy with which the availability of an element of a system can be demonstrated increases with the
duration of the observation.

Figure 4 serves as an example for the quantitative envelope curves which are to be expected for an·
availability of 90 .% of an individual element. The values determined in the practical test can lie in the area
between the envelope curves.

One can see that approximation to the underlying availability of 90% for the element does not come into
effect until there are a large number of faults.

Because of the significance of this behaviour the observation time should be laid down when the contract is
agreed.
 Page 12
FEM 9.222 (06.1989)

4.7 Outstanding work after acceptance

The contractor has to rectify the outstanding work within the shortest possible time. The contractor and the
customer have to reach an agreement about the chronological sequence of the completion of outstanding
work. The contractor has to show the customer that the outstanding work has been completed.

5 Operational phase

5.1 Running-in operations

After the hand-over of the installation to the customer the practical phase of ramping-up begins. The duration
is set appropriate to the complexity of the installation. The objective of these operations is to stabilize the
system technology, to give the staff the opportunity to operate the installation safely and to recognize and
rectify external disruptive influences at the interfaces. .

In this phase it must be possible for t~e operator to use the installation as agreed, sacrifices in performance
and reduced availability may, though, occur.

5.2 Measurement phase

After completion of the running-in operations and after rectification of the faults which have arisen during
them, it is useful to make the analysis of the availability

5.3 Checking point

The contractor must confirm to the customer, in good time before the end of the warranty period, that listed
outstanding work has been completed and that all outstanding contract conditions have been complied with.
 Page 13
FEM 9.222 (06.1989)

6 Contract procedure scheme

The contract process chart (Figure 5) describes with an example the essential steps in the processing and
handling of a contract up to the end of the warranty period.

Placing of the contract

Processing in the works

Installation and commissioning

Functional check

System check

Acceptance testing
(Extent of supply, conformity of supply, I - - - -........---",.--_-............-r---r----,~'_"'l
functions )

c
0
;l
lU
U

ifif
~
:::J ...
ell

-
lU
u. E
0
en
:::J
u
ell

-
5
.c
i
~
c
~
-E
ell

~
en
C
0
;l
.!!!

....-
; ell
.c 19en
iii 0 .E
:::J ell
C
U ~
~
0
;l ...
,C
0
f!
ell
.e
0 c.
0 ~
ell :c
"~ "jjj
u:::J C
0
"C C.
e
D. 0::
en
ell

Figure 5: Contract procedure scheme

 Page 14
FEM 9.222 (06.1989)

7·Examples for determining availability

7.1 High bay warehouse (HBW)

Installation considered
The installation includes 3 SIR machines and stationary material handling equipment in the front zone of the
warehouse. It is not possible to run the warehouse without the stationary materials handling equipment being
operative.

Definitions
The breakdown time of one of the 3 SIR machines is multiplied by the weighting factor k; = 1/3. The
breakdown of the stationary material-handling equipment counts as a total breakdown of the system; ki = 1

The availability is calculated according to formula (6)

tE = Time in service (affected with faults) here two days, e.g. two-shift working, tE = 32 h.
t Ai = The breakdown time for the part i of the installation
k; = Weighting factor of the element i of the installation; it characterizes the share of that part in the total
functioning of the installation.

Record of measurements for Time in service tE = 32 h

Part of the Weighting Measured Due to Due to ki • tAl
installation factor downtime customer faults
i kj h. h h h

1: S/RM 1 1/3 1 0.4 0.6 0.2

2: S/RM2 1/3 0.6 - 0.6 0.2

3: S/RM 3 1/3 0.3 - 0.3 0.1

4: Front zone 1 0.5 0.2 0.3 0.3

4
2:tA; 'k; =0.8
;=1

Calculation

17E = 32h-0.8h =0.975=97.5%

32h

To compare the availability of the partial system ,,3 SIR machines· (i :':: 1....3)

17E = 32h - O.5h = 0.984 = 98.4%

32h
 Page 15
FEM 9.222 (06.1989)

7.2 Computer controlled warehouse system

The installation consists of the following sub-systems:

1 Warehouse management system (WMS)

- 6 Automatic SIR machines (S/RM) .
- 1 Transport installation for storage (TIS)
- 1 Transport installation for retrieval (TIR)
- 1 Automatic Guided Vehicle system with 6 vehicles which connects to the transport installation for retrieval
(AGV).

Conditions SIR machine

For putting goods into the warehouse the principle of cross-section storage applies, that is, the number of
articles is considerably less than the number of compartments. With this arrangement each article can be
available in several aisles. The WMS decides on the allocation of article to the aisle.

Under these conditions every breakdown of a sub-system goes into the calculation of the availability only as
the percentage with which the part has a share in the overall function. In the case of 6 SIR machines for
example each SIR machine with 1/6.

Conditions TIS I TIR

If storage and retrieval operations are carried out in the same ratio and at the same time (normal operation in
a high bay warehouse) then if the input conveyor fails the function is only reduced by 50%. If the last element
of a transport chain breaks down (for example if the last aisle of a high bay warehouse can no longer be
operated) then the breakdown goes with 1/6 of 50% into the availability of the entire installation.

Conditions AGV
If all 6 vehicles are required to produce the necessary throughput the breakdown of one AGV goes into the
calculation as 1/6. If the required throughput is achieved due to available reserves despite the breakdown of
a vehicle, then the breakdown time is omitted from the evaluation.

Conditions WMS
If the WMS breaks down then in general only emergency functions are possible. e g. single fast withdrawals
using the subordinate control system. The breakdown of the WMS goes into the availability calculation at
100%

Example:
Operating time: 8 hours = 480 minute
Computer breakdown: 3 min
Fault S/RM 1: 12 min.
Fault S/RM 3: 8 min.
Fault S/RM 6: 2 x 5 min. = 10 min.
Data concentrator S/RM breakdown:· 8 min.

Transport installation

3 Faults:
1. The input conveyor could not serve the aisles 5 and 6 during a period of 30 min.
2. The entire input system did not function for a period of 12 min. (Problems with the pallet checking device).
3. The control of the output conveyor was disrupted for 10 min. i.e. no withdrawals were possible.

Conveyor controls breakdown: 6 min.

 Page 16
FEM 9.222 (06.1989)

AGVsystem

Breakdown of one vehicle 30 min.

Evaluation:

Downtime Influence kj • fAi

Fault
fAi Description of Factor min
min breakdown k
Computer breakdown 3 Installation at a standstill 1.0 3.0
S/RM 1 12 1 aisle from 6 1/6 2.0
S/RM 3 8 1 aisle from 6 1/6 1.3
S/RM6 10 1 aisle from 6 1/6 1.7

Concentrator S/RM 8 all aisles 1.0 8.0

TIS 12 Entire input system 0.5 6.0
TIS aisles 5 & 6 30 Input system 2 aisles 1/2 x 2/6 5.0
TIR control device 10 entire retrieval system 1/2 5.0

Conveyor control 6 All conveyors 1.0 6.0

1 AGV 30 Redundant 0.0 -
(or 1 of 6 ) 1/6 5.0
Sum 129 Sum 38.0
(43.0)

With the formula (6) the availability of the installation can be calculated

480-38 =92.1%
480

or 91.0 % respectively if the AGV cannot be reckoned as redundant.

This example shows the calculation procedure. In order to acbiev~ an adequate statistical accuracy of the
availability the observation time must be increased. Compare section 4.6.3. .

7.3 Installation with SIR machines, Assembly and test stands

Problems with the calculation of the availability and the effects of buffers and interconnections are explained
using the example with the two variants A and B.

.System configuration
An SIR machine serves two assembly lines, two test stands for the parts are arranged on each of the
assembly lines.

Two further assembly lines follow before the removal of the parts takes place in common for both lines.

When laying out the system the performance of all parts of the installation was designed for the maximum
without regard to the losses due to availability. This resulted in parallel tracks. There was no
overdimensioning. The parallel tracks do not therefore represent any redundancy. The splitting only has the
function of dividing the throughput and does not increase redundancy.
 Page 17
FEM 9.222 (06.1989)

The availability of the individual elements is:

TJ Str tAi kj
% hrs

SIR machine TJStr SRM 97 3 1.0 Whether the availability of the individual
Assembly line I TJ Str Ass. I 95 5 Y2 elements was estimated or measured
Test stand TJ Str Test 90 10 % against comparable elements is irrelevant
Assembly line 11 TJ Str Ass. 11 95 5 Y2 to this example:

Assembly line Assembly line

Storage/
retrieval Assembly line Assembly line
machine

Figure 6: Variant A

Variant A, Calculation to formula (5)

As the installation has parallel paths for reasons of splitting the throughput (and not for reasons of increasing
the redundancy) the formula for the series arrangement applies

Tlrot =1]1 '1]2 '1]3 ··1]n

1]Tot =1] Btr SRM '1] Btr Ass! • 1] Btr Test • 1] Btr Ass!!

'l Btr Tot =0.97 . 0.95 . 0.90 . 0.95 = 78.8%

Variant A, Calculation to formula (7)

n
tE - Lkki .
tAl
1]E _---.:':.=·=1=--_ _
tE

tE = Observed time in service (affected with faults) ( here 100 h).

t Ai = The breakdown time for the part of the installation ( in h)

n
Lkl . tAl = 1· 3 + 2(1/2. 5)+ 4(1/ 4.10)+ 2(1/2.5) =3 + 5 + 10 + 5 =23
;=1

_ 100 - 23 _ 770/
'lE - - 1'0
100
 Page 18
FEM 9.222 (06.1989)

Variant A, Simulation
The simulated value for the total availability (with a user-specific simulation model) amounts to
" BIT.Tot. =82.9 %
This value is slightly higher than the values from formulae (5) and (7). The cause is that in the formulae no
consideration is given to the fact that the breakdown times of individual elements can coincide and that the
time which is affected with faults is shorter with reference to the installation.

Buffer Buffer Buffer Buffer

Assembly line Assembly line

Assembly line Assembly line

Test stand

Figure 7: Variant B

Variant B
Provides three buffers with cross-distribution facilities. The buffers were dimensioned such that the capacity
comes to twice that of the parts which are conveyed through the installation in 4.5 min. (80 % of all the
downtimes are in this selected case smaller)

Variant B simulation
An empirical determination of the availability from existing installations which consist of intermeshed networks
with buffers is very difficult as the effects of faults on other areas, and thus also on the filling levels of the
buffers, must be observed at the same time.

There is no known analytical procedure for determining the availability of planned installations which consist .
of intermeshed networks with buffers.

A determination of the availability of such installations is possible by means of simulation if realistic estimated
values on the availability of the individual elements are to hand.

The simulated value for the total availability (with a user-specific simulation model) amounts to

TJBtr.Tot. = 89.6%

The maximum possible value of 90 % (this is the minimum value of the individual elements, in this case the
value of the test stands) is barely reached. A value over 90 % would also not be possible even with further
buffers.

In the calculation of complex installations a precise check should be made on which formula it is possible to
work with.

In the case of intermeshed installations with buffers it is recommended that a simulation be carried out in the
planning phase, before the final commitment to the layout. In doing so the effects of intermeshings, buffers
and redundancies can be determined and compared with the appropriate costs.
References

Prepared by the Committee "Storage/retrieval-machines and stacker cranes" of Section IX

of the Federation Europeenne de la Manutention (FEM)

Sekretariat der FEM Sektlon IX

Secretariat: c/o VOMA
Fachverband Fordertechnik
Postfach 71 08 64
0-60498 Frankfurt .

Available from the above secretariat or from the following national committees of FEM:

Belgium Luxembourg
Comite National Beige de la FEM Comite National Luxembourgeois de la FEM
Fabdmetal Federation des Industriels Luxembourgeois
Rue des Drapiers 21 Groupement des Constructeurs et Fondeurs du
B-1050 Bruxelles Grande-Duche de Luxembourg
Tel: +32-2-706 7982 Boite Postale 1304
Fax: +32-2-706 7988 Rue A1cide de Gasperi 7
[email protected] L-1013 Luxembourg
wwwJabrimetal.be Tel:+35-2-435366-1
Fax:+35-2-43 2328
[email protected]
wwwJedil.lu

Finland Netherlands
Finnish National Committee of FEM Nederland Nationaal Comite bij de FEM
. Federation of Finnish Metal, Eng. and Electro- Vereniging FME
technical Industries (FIMET) Postbus 190, Boerhaavelaan 40
Etel~ranta 10 NL-2700 AD Zoetermeer
FIN-00130 Helsinki Tel: +31-79-353 11 00
Tel: +358-9-192 31 Fax: +31-79-3531365
Fax: +358-9-624 462 [email protected]
www.met.fi wwwJme.nl

France Norway
Comite National Franyais de la FEM Norwegian FEM Groups
Syndicat des industries de materiels Norsk Verkstedsindustris
de manutention (SIMMA) Standardiseringssentral NVS
39/41 rue Louis Blanc - F-92406 Courbevoie Box 7072 / Oscars Gate 20
cedex 72 - F-92038 Paris la Defense Majorstua
Tel: +33-1-4717 6321 N-0306 Oslo
Fax: +33-:1-4717 6260 Tel: +47-22-590-000
Mtps@wanadooJr Fax: +47-22-590-001
www.mtps.org www.tbl.no
 Germany Portugal
Deutsches Nationalkomitee der FEM Comissao Nacional Portuguesa da FEM
·VDMA ANEMM
Fachverband Fordertechnik Estrada do Pac;o do Lumiar
Postfach 71 08 64 Polo Technologico de Lisboa
D-60498 Lote 13, P-1600 Lisboa
Lyoner Str. 18 Tel: +351-21-71521 27
D-60528 Frankfurt Fax: +351-21-7150403
Te:+49-69-6603 1508 [email protected]
Fax: +49-69-6603 1496 www.anemm.pt
[email protected]
www.vdma.org

Great Britain Spain

British National Committee of FEM Comite Nacional Espaliol de la FEM
British Materials Handling Federation Asociaci6n Ncional de Manutenci6n (AEM)
The McLaren Building, 6th Floor ETSEIB Pabellon F
~5 Dale End Diagonal,647
Birmingham B4 7LN West Midlands E-08028 Barcelona
Tel: +44-121-200 21 00 Tel: +34-93-401 60 60
Fax: +44-121-200 1306 Fax: +34-93-401 6058
[email protected]
www.bli1hf.org.uk

Italy Sweden
Comitato Nazionale Italiano della FEM Swedish National Committee of FEM
Federazione delle Associazioni Nazionali Swedish Association of Suppliers of
dell'lndustria Mechanical Handling Equipment MHG
Meccanica Varia ed Affine (ANIMA) Sorgatan 5, P.O. Box 5510
Via L. Battistotti Sassi S-11485 Stockholm
Tel: +39-02-7397 356 Tel: +46-8-782 08 00
Fax: +39-02-7397 7845 Fax: +46-8-321-6977
1-20133 Milano www.vibab.se
[email protected]
www:anima.it.com

Switzerland
Schweizerisches Nationalkomitee der FEM
Verein Schweizerischer Maschinen-Industrieller (VSM)
Kirchenweg 4/Postfach 179
CH-8032 ZOrich
Tel: +41-1-38441 11.
Fax: +41-1-3844242
[email protected]
www.swissrnem.ch