Applied Reliability Engineering Volume II, 5th Ed.

  • Applied Reliability Engineering - Volume II

Applied Reliability Engineering Volume II, 5th Ed.

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Volume II of the book provides a “systems view” of reliability engineering covering in chapter six the standard techniques for system reliability analysis and simulation. Chapter seven addresses techniques used in designing for reliability and maintainability. Chapter eight introduces renewal theory, condition-based maintenance and other aspects of maintainability analysis. Chapter nine provides a thorough coverage of the various aspects of development and acceptance testing as well as accelerated testing. Chapter ten then describes the design and conduct of reliability management programs.

Copyright © January 2006 by The Center for Reliability Engineering, University of Maryland, College Park, Maryland, USA.

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Product Description

Authors – Marvin Roush and Willie Webb

This book is organized to provide an introduction to reliability engineering, both for practicing engineers and for students. The emphasis throughout is on concepts and basic principles. It contains practical applications to guide the reader to appreciate the value of each topic presented. This book was not developed to be used as a handbook or reference book; such books commonly are made up of a number of self-contained modules that provide information about separate topics. Rather, this work is a carefully woven fabric of connected ideas that are progressively developed. Handbooks and other ‘how to’ books are meant to meet short term needs for carrying out a given process but do not lead to a full understanding of the subject as is the goal here. More advanced texts are cited for further reading on the mathematical and statistical aspect of reliability analysis and engineering.

The approach to engineering described here is one that has been evolving in many companies. They have moved away from an approach that only evaluated product designs through testing and data analysis to one that integrates all parts of the product design and development in a thoroughly integrated reliability program. The activities in such a program are not an end in themselves, but rather, are valuable when utilized to assist in making proper engineering and management decisions.

This book is used at the University of Maryland for a two-semester course for both upper-level undergraduate students and graduate students. By selecting the appropriate portions of the material, considerable flexibility is available for using this books as a reference for a one-semester course. The first part of the book focuses upon metrics of reliability and methods of achieving reliable components. The second half focuses upon system reliability, system analysis techniques and unique problems that arise from interactions between distinct parts of a system.

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Table of Contents

6 System Modeling and Analysis 231
  6.1 Introduction 231
    6.1.1 Definition of Functional Elements 231
  6.2 Reliability of Simple Systems 232
  6.3 Reliability Block Diagram Method 232
    6.3.1 Series System Models 232
    6.3.2 High-Level Versus Low-Level Redundancy 237
    6.3.3 M-out-of-N Redundancy 237
    6.3.5 Dependent Failures 239
    6.3.6 Conditional Probability Approach 241
  6.4 Reliability Obtained Using a Signal Flow Graph 243
    6.4.1 A Few Elements of Set Theory 244
    6.4.2 Cut-Set Method for Determining System Unreliability 247
    6.4.3 Boolean Algebra 249
  6.5 System Failure Analysis 252
  6.6 Fault Tree Analysis 253
    6.6.1 Fault Tree Building Blocks 254
    6.6.2 Fault Tree Construction 258
    6.6.3 Fault Tree Evaluation 259
  6.7 Event Tree Construction 264
    6.7.1 Sample Event Tree for Nuclear Reactor Safety Analysis 267
  6.8 Simulation Modeling for System Reliability Analysis 268
    6.8.1 Why Use Simulation? 268
    6.8.2 Advantages and Disadvantages of Simulation 269
    6.8.3 Monte Carlo Simulation 270
Exercises 277
7 Designing for Reliability, Maintainability, and Safety 289
  7.1 Establishing and Allocating Reliability Requirements 289
    7.1.1 Simplest Possible Method of Allocation 289
    7.1.2 Apportionment Based Upon Complexity 290
    7.1.3 Reliability Improvement Allocation 291
    7.1.4 Optimization of Reliability Improvement Allocation 292
    7.1.5 Albert’s Method 293
  7.2 Legal Issues 295
    7.2.1 The Changing Landscape of Liability 297
    7.2.3 Examples of Design Defect Cases 299
    7.2.4 Manufacturing Defect Cases 304
    7.2.5 Strategies for Protection against Product Liability
Lawsuits		 306
    7.2.6 Inspection and Testing Procedures 307
  7.3 Failure Mode Analysis (FMA) and FMA Follow-Up 309
    7.3.1 What is an FMA? 309
    7.3.2 FMA Follow-Up 309
    7.3.3 Purpose of the FMA 309
    7.3.4 Use of an FMA Rather Than a Failure Mode and Effect
Analysis		 309
    7.3.5 Development of the FMA 310
    7.3.6 Steps in Developing the FMA 310
  7.5 Sneak Analysis 322
    7.5.1 Sneak Circuits and Their Analysis 323
    7.5.2 Mercury Redstone Incident 326
  7.6 Topological Techniques 328
    7.6.1 Single-Line (No-Node) Topograph 330
    7.6.2 Double-Ground Node Topograph 330
    7.6.3 Double-Power Node Topograph 331
    7.6.4 “H” Pattern Topograph 331
  7.7 Sneak Circuit Guidelines 331
  7.8 Vendors of Sneak Circuit Software 332
  7.9 Sneak Label Example 332
  7.10 Maintainability Considerations 333
    7.10.2 Maintainability and Reliability 334
    7.10.3 Maintainability as a Program Element 334
    7.10.4 Maintainability Terms and Definitions 334
    7.10.6 Maintenance-Time Definitions 336
    7.10.7 Maintenance-Time Composition 337
    7.10.8 Corrective-Maintenance-Time Composition 337
    7.10.9 Delay-Time Composition 338
    7.10.10 Modification Time Defined 338
    7.10.11 Maintainability Parameters 338
Exercises 373
8 Life Models for Repairable Items 379
  8.1 Introduction 379
  8.2 Maintenance and Replacement Schemes 379
    8.2.1 Organizational Maintenance 380
  8.2 2 Intermediate Maintenance 381
    8.2.3 Supplier/Manufacturer/Depot Maintenance 381
  8.3 Repair Policy 382
    8.3.1 Nonrepairable Item 382
    8.3.2 Partially Repairable System 382
    8.3.3 Fully Repairable System 383
  8.4 The Renewal Process 384
  8.5 Reliability Centered Maintenance 387
    8.5.1 Maintenance Strategies 388
    8.5.2 The “Bathtub Curve” Fallacy 389
    8.5.3 RCM Program Development 393
  8.6 Reliability of Dynamic Systems 393
  8.7 Introduction to Markov Modeling 394
    8.7.1 A Markov Model 396
    8.7.2 Discrete Markov Chains 398
    8.7.3 Continuous Markov Processes 401
  8.8 Transition Rate Concepts 402
    8.8.1 Binary Model for a Repairable Component 403
    8.8.2 Two Dissimilar Repairable Components 404
    8.8.3 Two Identical Repairable Components 406
    8.8.4 Cumulated States 406
Exercises 409
9 Reliability Testing 413
  9.1 Introduction 413
  9.2 Reliability Testing 413
    9.2.1 Early Product Development Testing 414
    9.2.2 Reliability Development/Growth Testing 415
    9.2.3 Reliability Qualification Testing 415
    9.2.4 Production Reliability Acceptance Testing 415
    9.2.5 Environmental Stress Screening 415
  9.3 Early Product Development Testing 416
    9.3.1 Traditional Temperature/Humidity Tests 416
    9.3.2 Pressurized Humidity Testing 417
    9.3.3 Development of HAST Systems 417
    9.3.4 Dual-Vessel HAST Systems 418
  9.4 Reliability Growth 418
    9.4.1 Objectives of Reliability Growth 418
    9.4.2 Requisites of Reliability Growth 419
    9.4.3 Avoid a Common Pitfall during Reliability Growth 419
    9.4.4 Benefits of Reliability Growth 419
    9.4.5 Process of Reliability Growth 419
  9.5 Reliability Growth Models 420
    9.5.1 Discrete Reliability Growth Models 420
    9.5.2 Continuous Reliability Growth Models 421
  9.6 Accelerated Testing 424
    9.6.1 Acceleration Methods 425
  9.7 Environmental Stress Screening (ESS) 426
    9.7.1 Environmental Stresses 427
    9.7.2 Stresses Applied to Product Under Test 430
  9.8 Demonstration Testing 433
  9.9 Probability Ratio Sequential Test (PRST) 445
Exercises 457
10 Reliability Management 461
  10.1 Corporate Policy for Reliability 461
  10.2 Integrated Reliability Programs 461
Appendices 495
A Notation 497
B Definitions 501
C Rules of Boolean Algebra 509
D Statistical Tables 513
  Table D-1 Standard Normal Cumulative Distribution Function 515
  Table D-2 Critical Values of Student’s t Distribution 519
  Table D-3 Critical Values of Chi- Square χ2 α Distribution Function 521
  Table D-4 Critical Values of the Kolmogorov-Smirnov Statistic 523
  Table D-5 F-Cumulative Distribution Function, Upper 1 Percentage Points 524
  Table D-6 F-Cumulative Distribution Function, Upper 5 Percentage Points 526
  Table D-7 F-Cumulative Distribution Function, Upper 10 Percentage Points 528
E References 531
F Answers to Selected Exercises 539
Subject Index 543

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