Life Cycle Reliability Engineering

DR. GUANGBIN YANG is a Reliability Technical Expert at Ford Motor Company. He is Chair of the Automotive Systems Committee of the IEEE Reliability Society and was the recipient of the Society's Engineer of the Year Award for 2002. A recognized leader in areas of reliability and quality, he has published numerous articles in technical journals.

"This book is quite different from traditional books written on reliability engineering so far and is authored by a person who has a rich industrial experience of working with Ford Motor Company. The book is quite informative and provides a good insight of methodologies and techniques used in reliability engineering. This will go a long way in creating competitive products that perform well in the market and also provide customer satisfaction." (International Journal of Performability Engineering; 1/09) "It is a very practical book which provides a comprehensive discussion on reliability engineering concepts and techniques throughout a product life cycle. The author has done a great job in explaining the up-to-date reliability techniques in a very practical manner and using simple and straightforward language. This book will prove very useful for reliability engineers, testing engineers, quality engineers and design engineers." (Reliability Review, December 2008)"This book gives both starting and experienced engineers a very nice overview of the different methods and tools that can be used for reliability engineering. It is very nice that the book gives a lot of (often simplified) examples; it will therefore not be difficult to apply the theory in industrial practice." (Quality and Reliability Engineering International, 2008)" This is a useful and an important book. It should be on the shelf of all reliability engineers and other engineers who have responsibility for product reliability. It will also be of interest to many of those doing research in the area. Overall, the book is well-written and easy to read." (Journal of Quality Technology, April 2008)"The author has done a great job in explaining the practical and state-of-the-art techniques to access and enhance reliability throughout the product life cycle. This book deliberates on a wide range of topics in reliability engineering. Practical examples and exercises, mostly from the automotive industry, are used to illustrate the ideas and methodologies. Readers of this book are expected to have some knowledge of basic statistical inference, statistical modeling, and probability theory. This book will be of practical use for a variety of engineers, including reliability engineers, quality engineers, test engineers, systems engineers, or design engineers, who are working in different stages of the product life cycle. It will also serve well as a textbook or a reference book to students in a course on reliability, quality, or industrial engineering." (Technometrics, February 2008)

• 1 Reliability Engineering and Product Life Cycle 11.1 Reliability Engineering 11.2 Product Life Cycle 21.3 Integration of Reliability Engineering into the Product Life Cycle 51.4 Reliability in the Concurrent Product Realization Process 6Problems 72 Reliability Definition Metrics and Product Life Distributions 92.1 Introduction 92.2 Reliability Definition 102.3 Reliability Metrics 122.4 Exponential Distribution 172.5 Weibull Distribution 192.6 Mixed Weibull Distribution 222.7 Smallest Extreme Value Distribution 242.8 Normal Distribution 262.9 Lognormal Distribution 28Problems 313 Reliability Planning and Specification 333.1 Introduction 333.2 Customer Expectations and Satisfaction 343.3 Reliability Requirements 413.4 Reliability Program Development 483.5 Reliability Design and Design for Six Sigma 61Problems 644 System Reliability Evaluation and Allocation 654.1 Introduction 654.2 Reliability Block Diagram 664.3 Series Systems 684.4 Parallel Systems 714.5 Mixed Configurations 734.6 k-out-of-n Systems 774.7 Redundant Systems 794.8 Reliability Evaluation of Complex Systems 844.9 Confidence Intervals for System Reliability 914.10 Measures of Component Importance 994.11 Reliability Allocation 106Problems 1185 Reliability Improvement Through Robust Design 1225.1 Introduction 1225.2 Reliability and Robustness 1235.3 Reliability Degradation and Quality Loss 1255.4 Robust Design Process 1295.5 Boundary Definition and Interaction Analysis 1325.6 P-Diagram 1335.7 Noise Effects Management 1345.8 Design of Experiments 1365.9 Experimental Life Data Analysis 1485.10 Experimental Degradation Data Analysis 1525.11 Design Optimization 1565.12 Robust Reliability Design of Diagnostic Systems 1725.13 Case Study 1795.14 Advanced Topics in Robust Design 181Problems 1906 Potential Failure Mode Avoidance 1946.1 Introduction 1946.2 Failure Mode and Effects Analysis 1956.3 Advanced Topics in FMEA 2086.4 Fault Tree Analysis 2126.5 Advanced Topics in FTA 2256.6 Computer-Aided Design Controls 230Problems 2357 Accelerated Life Tests 2377.1 Introduction 2377.2 Development of Test Plans 2387.3 Common Stresses and Their Effects 2467.4 Life–Stress Relationships 2527.5 Graphical Reliability Estimation at Individual Test Conditions 2667.6 Analytical Reliability Estimation at Individual Test Conditions 2747.7 Reliability Estimation at Use Condition 2927.8 Compromise Test Plans 3027.9 Highly Accelerated Life Tests 326Problems 3278 Degradation Testing and Analysis 3328.1 Introduction 3328.2 Determination of the Critical Performance Characteristic 3338.3 Reliability Estimation from Pseudo life 3348.4 Degradation Analysis with Random-Effect Models 3378.5 Degradation Analysis for Destructive Inspections 3458.6 Stress-Accelerated Degradation Tests 3518.7 Accelerated Degradation Tests with Tightened Thresholds 3588.8 Accelerated Degradation Test Planning 364Problems 3739 Reliability Verification Testing 3799.1 Introduction 3799.2 Planning Reliability Verification Tests 3809.3 Bogey Testing 3839.4 Sample Size Reduction by Tail Testing 3899.5 Sequential Life Testing 3949.6 Reliability Verification Using Prior Information 4069.7 Reliability Verification Through Degradation Testing 408Problems 41010 Stress Screening 41210.1 Introduction 41210.2 Screening Techniques 41310.3 Design of Screen Plans 41510.4 Principle of Degradation Screening 41710.5 Part-Level Degradation Screening 41910.6 Module-Level Screening 42510.7 Module Reliability Modeling 43110.8 Cost Modeling 43310.9 Optimal Screen Plans 435Problems 43811 Warranty Analysis 44211.1 Introduction 44211.2 Warranty Policies 44311.3 Warranty Data Mining 44711.4 Reliability Estimation from Warranty Claim Times 45111.5 Two-Dimensional Reliability Estimation 45411.6 Warranty Repair Modeling 47011.7 Warranty Cost Estimation 47311.8 Field Failure Monitoring 47711.9 Warranty Cost Reduction 480Problems 482Appendix: Orthogonal Arrays Linear Graphs and Interaction Tables 486References 495Index 511