Practical Reliability Engineering

Patrick D.T. O’Connor received his engineering training at the Royal Air Force (RAF) Technical College and served for 16 years in the RAF Engineer Branch. Following a broad career that included posts as a visiting lecturer at the Universities of Lancaster, Leeds, and Cranfield (UK), he is now retired. Andre V. Kleyner, PhD has over 30 years of engineering, research, consulting, and managerial experience specializing in the reliability of engineering systems designed to operate in severe environments. He spent his career in the automotive, defense, and medical devices industries and was a part-time lecturer at Purdue University. Andre Kleyner is also the editor of the Wiley Series in Quality and Reliability Engineering.

• Preface xxiAcknowledgments xxiiiAbbreviations and Acronyms Used in this Book xxv1 Introduction to Reliability Engineering 11.1 What is Reliability Engineering? 11.2 Why Teach Reliability Engineering? 21.3 Why Do Engineering Products Fail? 41.4 Probabilistic Reliability 61.5 Repairable and Non-repairable Items 71.6 The Pattern of Failures With Time (Bathtub Curve) 81.7 The Development of Reliability Engineering 91.8 Courses, Conferences, and Literature 111.9 Organizations Involved in Reliability Work 121.10 Reliability as an Effectiveness Parameter 121.11 Reliability Program Activities 121.12 Reliability Economics and Management 14Questions 16Selected Bibliography 17Periodic Publications on Reliability 172 Reliability Mathematics 192.1 Introduction 192.2 Variation 192.3 Probability Concepts 212.4 Rules of Probability 222.5 Continuous Variation 272.6 Continuous Distribution Functions 322.7 Summary of Continuous Statistical Distributions 402.8 Variation in Engineering 402.9 Discrete Variation 462.10 Statistical Confidence 492.11 Statistical Hypothesis Testing 502.12 Non-parametric Inferential Methods 532.13 Goodness of Fit 552.14 Computer Software for Statistics 572.15 Practical Conclusions 57Questions 58Selected Bibliography 613 Life Data Analysis and Probability Plotting 633.1 Introduction 633.2 Life Data Classification 643.3 Ranking of Data 673.4 Weibull Distribution 703.5 Computerized Data Analysis and Probability Plotting 773.6 Confidence Bounds for Life Data Analysis 803.7 Choosing the Best Distribution and Assessing the Results 873.8 Conclusions 95Questions 95Selected Bibliography 1004 Repairable Systems 1014.1 Introduction 1014.2 Renewal Process 1024.3 Non-Parametric and Graphical Methods 1124.4 Conclusions 115Questions 115Selected Bibliography 1175 Monte Carlo Simulation 1195.1 Introduction 1195.2 Monte Carlo Simulation Basics 1195.3 Additional Statistical Distributions 1195.4 Sampling a Statistical Distribution 1225.5 Running a Monte Carlo Simulation 1255.6 Monte Carlo Method Summary 129Questions 130Selected Bibliography 1326 Load–Strength Interference 1336.1 Introduction 1336.2 Load and Strength Models 1336.3 Analysis of Load–Strength Interference 1386.4 Multiple Load Applications 1416.5 Dynamic Models 1426.6 Practical Aspects 144Questions 145Selected Bibliography 1477 Reliability Prediction and Modeling 1497.1 Introduction 1497.2 Fundamental Limitations of Reliability Prediction 1507.3 Standards-Based Reliability Prediction 1517.4 Other Methods for Reliability Predictions 1577.5 Practical Aspects of Reliability Prediction 1597.6 Systems Reliability Models 1607.7 Availability of Repairable Systems 1647.8 Modular Design 1687.9 Block Diagram Analysis 1697.10 Fault Tree Analysis (FTA) 1737.12 Petri Nets 1817.13 Reliability Apportionment 1847.14 Conclusions 185Questions 186Selected Bibliography 1928 Design for Reliability 1958.1 Introduction 1958.2 Design for Reliability Process 1968.3 Identify 1988.4 Design 2038.5 Analyze 2158.6 Verify 2168.7 Validate 2168.8 Control 2178.9 Assessing the DfR Capability of an Organization 2208.10 Summary 221Questions 221Selected Bibliography 2239 Reliability of Mechanical Components and Systems 2259.1 Introduction 2259.2 Mechanical Stress, Strength, and Fracture 2259.3 Fatigue 2299.4 Creep 2359.5 Wear 2369.6 Corrosion 2379.7 Vibration and Shock 2389.8 Temperature Effects 2429.9 Materials 2449.10 Components 2459.11 Processes 246Questions 247Selected Bibliography 24910 Electronic Systems Reliability 25110.1 Introduction 25110.2 Reliability of Electronic Components 25210.3 Component Types and Failure Mechanisms 25510.4 Power Electronics 27810.5 Device Failure Modes and Their Distributions 27910.6 Circuit and System Aspects 28110.7 Design for Reliability in Electronic Systems 28210.8 Parameter Variation and Tolerances 28810.9 Design for Production, Test, and Maintenance 291Questions 292Selected Bibliography 29411 Analysis of Variance (ANOVA) and Design of Experiments (DOE) 29711.1 Introduction 29711.2 Statistical Design of Experiments and Analysis of Variance 29711.3 Randomizing the Data 30811.4 Engineering Interpretation of Results 30911.5 The Taguchi Method 31011.6 Conclusions 313Questions 315Selected Bibliography 31712 Reliability Testing 31912.1 Introduction 31912.2 Planning Reliability Testing 32012.3 Test Environments 32212.4 Testing for Reliability and Durability. Accelerated Testing 33112.5 Test Planning 34012.6 Failure Reporting, Analysis, and Corrective Action Systems (FRACAS) 341Questions 343Selected Bibliography 34513 Analyzing Reliability Data and Accelerated Testing 34713.1 Introduction 34713.2 Pareto Analysis 34713.3 Accelerated Test Data Analysis 34913.4 Acceleration Factor 34913.5 Acceleration Models 35013.6 Field–Test Relationship 35513.7 Statistical Analysis of Accelerated Test Data 35613.8 Reliability Analysis of Repairable Systems 35913.9 Cusum Charts 36013.10 Exploratory Data Analysis and Proportional Hazards Modeling 36213.11 Field and Warranty Data Analysis 364Questions 368Selected Bibliography 37214 Reliability Demonstration and Growth 37514.1 Introduction 37514.2 Reliability Metrics 37514.3 Test to Success (Success-Run Method) 37614.4 Test to Failure Method 37814.5 Extended Life Test 37814.6 Continuous Testing 38114.7 Degradation Analysis 38214.8 Demonstrated Reliability vs. Population Reliability 38514.9 Combining Results Using Bayesian Statistics 38614.10 Non-parametric Methods 38814.11 Reliability Demonstration Software 38814.12 Practical Aspects of Reliability Demonstration 38914.13 Standard Methods for Repairable Systems 39014.14 Reliability Growth and Monitoring 39514.15 Making Product Reliability Grow 402Questions 404Selected Bibliography 40715 Reliability in Manufacture 40915.1 Introduction 40915.2 Control of Production Variability 40915.3 Control Charts 41115.4 Control of Human Variation 41815.5 Acceptance Sampling 41915.6 Improving the Process. Problem Solving 42415.7 Stress Screening 42815.8 Failure Reporting Analysis and Corrective Action System (FRACAS) in Production 43115.9 Conclusions 432Questions 432Selected Bibliography 43416 Human Reliability Analysis 435J. Robert Taylor and Igor Kozine16.1 Introduction 43516.2 Human Performance and Error Taxonomy 43616.3 Quantitative Methods of HEP Estimation 43916.4 Identification of Human Error Possibilities: Action Error Analysis 44516.5 Quantification of Human Error Scenarios Combined With A Technical Failure 45216.6 Causal Analysis 45216.7 Data for Human Error Probability Quantification 45716.8 Models of System Reliability Accounting for Human Error 45916.9 Conclusions 463Questions 463Selected Bibliography 46517 Maintainability, Maintenance, and Availability 46917.1 Introduction 46917.2 Availability Measures 47017.3 Maintenance Time Distributions 47317.4 Preventive Maintenance Strategy 47417.5 FMEA and FTA in Maintenance Planning 47817.6 Maintenance Schedules 47817.7 Technology Aspects 47917.8 Calibration 48117.9 Maintainability 48217.10 Integrated Logistic Support 484Questions 485Selected Bibliography 48618 Reliability Management 48918.1 Corporate Policy for Reliability 48918.2 Integrated Reliability Programs 48918.3 Specifying Reliability 49218.4 Reliability and Costs 49418.5 Safety and Product Liability 49918.6 Standards for Reliability, Quality, and Safety Programs 49918.7 Managing Lower-Tier Suppliers 50218.8 Reliability Manuals 50318.9 The Project Reliability Plan 50518.10 Use of External Services (Outsourcing) 50618.11 Customer Management of Reliability 50718.12 Product Sustainment Activities 50918.13 Reliability Training and Expertise 51118.14 Reliability Capability and Maturity of an Organization 51218.15 Managing Production Quality 51418.16 Choosing the Methods: Strategy and Tactics 51618.17 AI in Practical Reliability Engineering 51718.18 Conclusions: The Importance of Reliability Management 518Questions 520Selected Bibliography 521Appendix 1 Software Reliability 523Appendix 2 Kolmogorov–Smirnov Tables 549Appendix 3 Chi-square Distribution and MTTF/MTBF Calculations 551Appendix 4 Matrix Algebra Revision 553Appendix 5 Reliability, Maintainability, and Safety Plan Example 555Index 561