B.S. Dhillon0849314658, 9780849314650
Table of contents :
Design Reliability: Fundamentals and Applications……Page 1
Preface……Page 4
The Author……Page 6
Contents……Page 7
1.2 NEED OF RELIABILITY IN PRODUCT DESIGN……Page 16
1.4 RELIABILITY SPECIALIZED AND APPLICATION AREAS……Page 17
1.5 TERMS AND DEFINITIONS……Page 18
1.6 RELIABILITY INFORMATION SOURCES……Page 19
1.7 MILITARY AND OTHER RELIABILITY DOCUMENTS……Page 21
1.8 PROBLEMS……Page 22
1.9 REFERENCES……Page 23
Commutative Law:……Page 25
Idempotent Law……Page 26
2.3 PROBABILITY PROPERTIES……Page 27
2.4.2 Cumulative Distribution Function……Page 28
2.4.5 Hazard Rate Function……Page 29
Example 2.2……Page 30
2.4.8 Expected Value……Page 31
2.5.2 Poisson Distribution……Page 32
2.5.4 Rayleigh Distribution……Page 33
2.5.5 Weibull Distribution……Page 34
2.5.7 Normal Distribution……Page 35
2.6.2 Rayleigh Distribution……Page 36
2.7.1 Partial Fraction Method……Page 37
Example 2.3……Page 38
Quadratic Equation……Page 39
Cubic Equation……Page 40
Example 2.4……Page 41
2.9 PROBLEMS……Page 42
2.10REFERENCES……Page 43
3.1 INTRODUCTION……Page 44
3.2.1 Design Failures and Their Common Reasons……Page 45
3.2.2 The Design Process and Functions……Page 46
3.2.4 Design Reviews……Page 47
Design Review Related Information and Topics……Page 48
3.2.6 Designing for Reliability and Design Reliability Check List Items……Page 49
3.3.1 General Management Reliability Program Related Responsibilities and Guiding Force Associated Facts for an Effective Rel……Page 51
3.3.2 Military Specification Guidelines for Developing Reliability Programs and a Procedure to Establish Reliability Goals……Page 52
3.3.3 Reliability and Maintainability Management Tasks in the Product Life Cycle……Page 53
The Operation and Maintenance Phase……Page 54
3.3.4 Documents and Tools for Reliability Management……Page 55
3.3.5 Reliability Auditing and Pitfalls in Reliability Program Management……Page 56
Maintainability Engineering Department Responsibilities……Page 57
Rules for Reliability Professionals……Page 58
Training of Reliability Manpower……Page 59
3.4 PROBLEMS……Page 60
3.5 REFERENCES……Page 61
4.2 FAILURE DATA USES……Page 63
4.4 FAILURE REPORTING AND DOCUMENTATION SYSTEM DESIGN GUIDELINES AND FAILURE DATA COLLECTION FORMS……Page 64
4.5 EXTERNAL FAILURE DATA SOURCES……Page 65
4.7 HAZARD PLOTTING METHOD……Page 67
4.7.1 Hazard Plotting Mathematical Theory……Page 68
Exponential Distribution……Page 70
Bathtub Hazard Rate Distribution……Page 71
Weibull Distribution……Page 72
Hazard Plotting Steps……Page 74
4.8.1 Bartlett Test……Page 77
Example 4.2……Page 78
4.8.2 General Exponential Test……Page 79
Example 4.3……Page 80
4.8.3 Kolmogorov–Smirnov Test……Page 81
Example 4.4……Page 82
4.9 MAXIMUM LIKELIHOOD ESTIMATION METHOD……Page 85
4.9.1 Exponential Distribution……Page 86
4.9.2 Normal Distribution……Page 87
4.9.3 Weibull Distribution……Page 88
4.10PROBLEMS……Page 89
4.11REFERENCES……Page 91
5.2 BATHTUB HAZARD RATE CURVE……Page 94
5.3.3 General Reliability Function……Page 96
Example 5.1……Page 97
Example 5.3……Page 98
5.4.1 Series Network……Page 99
Example 5.4……Page 101
5.4.2 Parallel Network……Page 102
Example 5.5……Page 103
Example 5.6……Page 104
Example 5.7……Page 105
5.4.4 Standby Redundancy……Page 106
5.4.5 Bridge Network……Page 107
Example 5.9……Page 108
Example 5.10……Page 109
Example 5.11……Page 111
5.5.3 Delta-Star Method……Page 113
Example 5.12……Page 114
5.5.4 Parts Count Method……Page 115
Failure Rate Estimation of an Electronic Part……Page 116
Example 5.13……Page 117
5.6.1 Hybrid Method……Page 120
5.6.2 Failure Rate Allocation Method……Page 121
Example 5.14……Page 122
5.7 PROBLEMS……Page 124
5.8 REFERENCES……Page 125
6.2 TERMS AND DEFINITIONS……Page 126
6.3.1 Design-Level FMEA……Page 127
6.4 STEPS FOR PERFORMING FMEA……Page 128
6.4.2 Establish Ground Rules……Page 129
6.4.6 Document the Analysis……Page 130
6.5.1 RPN Technique……Page 132
6.5.2 Military Standard Technique……Page 133
6.7 FMEA IMPLEMENTATION RELATED FACTORS AND GENERAL GUIDELINES……Page 138
6.10REFERENCES……Page 139
7.2 FTA PURPOSES AND PREREQUISITES……Page 141
7.3 FAULT TREE SYMBOLS……Page 142
7.5 BOOLEAN ALGEBRA RULES……Page 143
AND Gate……Page 145
7.6.1 Repeated Fault Events……Page 146
Example 7.3……Page 147
7.6.2 Algorithm for Obtaining Minimal Cut Sets……Page 148
Example 7.4……Page 149
7.7 PROBABILITY EVALUATION OF FAULT TREES WITH REPAIRABLE AND NONREPAIRABLE COMPONENTS……Page 150
OR Gate……Page 151
Example 7.4……Page 152
7.7.2 Probability Evaluation of Fault Trees with Repairable Components……Page 153
Example 7.5……Page 155
7.8 FAULT TREE DUALITY AND FTA APPROACH BENEFITS AND DRAWBACKS……Page 156
7.9 PROBLEMS……Page 157
7.10REFERENCES……Page 158
8.1 INTRODUCTION……Page 159
8.2 COMMON CAUSE FAILURES……Page 160
Parallel Network……Page 161
k-out-of-m Network……Page 164
Example 8.2……Page 165
8.2.2 Fault Tree Method……Page 166
Example 8.3……Page 167
8.2.3 Markov Method……Page 168
Model I……Page 169
Example 8.5……Page 171
Model II……Page 172
Model III……Page 175
8.3.1 Reliability Evaluation of a Series Network……Page 177
Example 8.6……Page 180
8.3.2 Reliability Evaluation of a Parallel Network……Page 181
8.3.3 Reliability Optimization of a Series Network……Page 183
8.3.4 Reliability Optimization of a Parallel Network……Page 184
8.4 PROBLEMS……Page 185
8.5 REFERENCES……Page 186
9.2 REASONS FOR THE DISCIPLINE OF MECHANICAL RELIABILITY AND MECHANICAL FAILURE MODES……Page 188
9.3 GENERAL AND GEAR FAILURE CAUSES……Page 191
9.4.1 Safety Factor……Page 192
Definition II……Page 193
Example 9.1……Page 194
9.5 “DESIGN BY RELIABILITY” METHODOLOGY AND STRESS-STRENGTH MODELS……Page 195
Model I……Page 197
Example 9.2……Page 198
Model II……Page 199
Model III……Page 200
Example 9.4……Page 201
9.6 MELLIN TRANSFORM METHOD……Page 202
Example 9.5……Page 203
9.7.1 Break System Failure Rate Model……Page 204
9.7.2 Clutch System Failure Rate Model……Page 206
9.7.3 Pump Failure Rate Model……Page 207
9.7.5 Compressor System Failure Rate Model……Page 208
9.7.6 Bearing Failure Rate Model……Page 209
9.8 FAILURE DATA SOURCES FOR MECHANICAL PARTS……Page 210
9.9.1 Equipment Replacement Model……Page 211
9.9.2 Equipment Maintenance Model……Page 212
Example 9.7……Page 213
9.11REFERENCES……Page 214
10.2 TERMS AND DEFINITIONS……Page 217
10.4 HUMAN ERROR OCCURRENCE CLASSIFICATION AND ITS TYPES AND CAUSES……Page 218
10.5 HUMAN PERFORMANCE AND STRESS……Page 220
10.5.1 Stress Factors and Operator Stress Characteristics……Page 221
10.6 HUMAN PERFORMANCE RELIABILITY IN CONTINUOUS TIME AND MEAN TIME TO HUMAN ERROR (MTTHE) MEASURE……Page 222
Example 10.1……Page 224
10.7 HUMAN RELIABILITY EVALUATION METHODS……Page 225
Example 10.3……Page 226
Example 10.4……Page 227
Example 10.5……Page 228
Example 10.6……Page 229
10.7.3 Markov Method……Page 231
10.8.1 Reliability Analysis of a System with Human Error……Page 233
10.8.2 Reliability Analysis of a Human Performing a Time- Continuous Task Under Fluctuating Envir………Page 235
10.9 HUMAN ERROR DATA……Page 238
10.9.1 Specific Human Error Data Banks and Sources……Page 239
10.10PROBLEMS……Page 240
10.11REFERENCES……Page 242
11.2 RELIABILITY TESTING……Page 245
11.2.2 SUCCESS TESTING……Page 246
Example 11.1……Page 247
11.2.3 CONFIDENCE INTERVAL ESTIMATES FOR MEAN TIME BETWEEN FAILURES……Page 248
Example 11.2……Page 250
Example 11.3……Page 251
Example 11.4……Page 252
Relationship Between the Accelerated and Normal Conditions……Page 253
Acceleration Model……Page 255
Example 11.5……Page 256
11.3.1 RELIABILITY GROWTH PROGRAM……Page 257
11.4.1 DUANE MODEL……Page 258
11.4.2 ARMY MATERIAL SYSTEM ANALYSIS ACTIVITY (AMSAA) MODEL……Page 259
11.5 PROBLEMS……Page 260
11.6 REFERENCES……Page 261
12.2 TERMS AND DEFINITIONS……Page 263
12.4 COMPUTER FAILURE CAUSES……Page 264
12.5 SOFTWARE LIFE CYCLE PHASES AND ASSOCIATED ERROR SOURCES……Page 266
12.6.1 RELIABLE SOFTWARE DESIGN METHODS……Page 267
12.6.2 FAULT-TOLERANT SOFTWARE DESIGN METHODS……Page 268
12.6.4 TESTING……Page 269
12.7.1 ANALYTICAL APPROACHES……Page 270
Code and Unit Test Phase Measure……Page 271
12.7.3 SOFTWARE RELIABILITY MODELS……Page 272
Example 12.1……Page 273
Musa Model……Page 274
Shooman Model……Page 275
Power Model……Page 277
Air Force Model……Page 279
12.8.1 TRIPLE MODULAR REDUNDANCY (TMR)……Page 280
Example 12.3……Page 282
TMR System Time Dependent Reliability and Mean Time to Failure (MTTF)……Page 283
Example 12.5……Page 284
TMR System with Repair and Perfect Voter Reliability Analysis……Page 285
Example 12.7……Page 287
12.9 PROBLEMS……Page 288
12.10 REFERENCES……Page 289
13.1 INTRODUCTION……Page 292
13.2.1 Robot Accidents……Page 293
13.2.2 Robot Hazards and Safety Problems……Page 294
Installation Phase……Page 295
Warning Signs……Page 296
13.2.5 Human Factor Issues in Robotic Safety……Page 297
13.3.1 Causes and Classifications of Robot Failures……Page 299
Example 13.1……Page 300
Example 13.3……Page 301
Example 13.4……Page 302
13.3.4 Reliability and Availability Analyses of a Robot System Failing with Human Error……Page 303
13.3.5 Reliability Analysis of a Repairable/Non-Repairable Robot System……Page 307
Example 13.6……Page 312
13.4 PROBLEMS……Page 313
13.5 REFERENCES……Page 314
14.2 FACTS AND FIGURES, GOVERNMENT CONTROL AND LIABILITY……Page 316
14.4 MEDICAL DEVICE RECALLS……Page 319
14.5 MEDICAL DEVICE DESIGN QUALITY ASSURANCE……Page 320
14.5.3 Design Review……Page 321
14.5.5 Parts/Materials Quality Control……Page 322
14.5.9 Certification……Page 323
14.6 HUMAN ERROR OCCURRENCE AND RELATED HUMAN FACTORS……Page 324
14.6.2 Medical Device Maintainability Related Human Factor Problems……Page 325
14.6.3 Human Factor Pointers for Already Being Used/to be Purchased Medical Devices……Page 326
14.7 MEDICAL DEVICE SOFTWARE……Page 327
Manual Software Testing……Page 328
Automated Software Testing……Page 329
14.8 SOURCES FOR ADVERSE MEDICAL DEVICE REPORTABLE EVENTS AND FAILURE INVESTIGATION DOCUMENTATION……Page 330
14.9 A SMALL INSTRUMENT MANUFACTURER’S APPROACH TO PRODUCE RELIABLE AND SAFE MEDICAL DEVICES……Page 331
14.10 AEROSPACE AND MEDICAL EQUIPMENT RELIABILITY AND RELIABILITY APPROACH COMPARISONS……Page 332
14.11 GUIDELINES FOR RELIABILITY AND OTHER PROFESSIONALS ASSOCIATED WITH HEALTH CARE……Page 333
14.13 REFERENCES……Page 334
15.1 INTRODUCTION……Page 338
Reliability……Page 339
Safety……Page 340
Human Factors……Page 341
15.2.2 Design Reviews……Page 342
Mean Time to Repair……Page 343
Median Corrective Maintenance Time……Page 344
Mean Preventive Maintenance Time……Page 345
Exponential……Page 346
Lognormal……Page 347
Normal……Page 348
15.3 RELIABILITY CENTERED MAINTENANCE……Page 349
15.3.2 RCM Process Related Maintenance Task Classification Areas and Steps……Page 350
Conduct Fault Tree Analysis……Page 351
Use Decision Logic to Important Failure Modes……Page 352
15.3.3 RCM Advantages……Page 353
15.3.4 Reasons for the RCM Methodology Application Failures……Page 354
15.5 REFERENCES……Page 355
16.1 INTRODUCTION……Page 357
16.2.1 Traditional Quality Assurance Vs. TQM……Page 358
16.2.2 TQM Principles and Elements……Page 359
Juran Steps……Page 361
16.2.4 TQM Methods……Page 362
Pareto Analysis……Page 363
Cause-and-Effect Diagram……Page 365
Quality Function Deployment (QFD)……Page 366
16.2.5 Designing for Quality and Goals for TQM Process Success……Page 367
16.2.6 Deming’s “Deadly Diseases” of American Management and Common Errors During the Starting Quality Initiative Phase……Page 368
16.3.2 Risk Analysis Objectives in Hazardous System Life Cycle……Page 369
16.3.3 Risk Analysis Process Steps……Page 370
Hazard and Operability Study (HAZOP)……Page 372
Event Tree Analysis (ETA)……Page 373
16.4 PROBLEMS……Page 374
16.5 REFERENCES……Page 375
17.2 REASONS AND USES OF LIFE CYCLE COSTING AND REQUIRED INPUTS……Page 377
17.3 LIFE CYCLE COSTING STEPS AND ACTIVITIES……Page 378
17.4 SKILL REQUIREMENT AREAS OF A LIFE CYCLE COSTING ANALYST AND HIS/HER ASSOCIATED PROFESSIONALS……Page 379
17.5 LIFE CYCLE COSTING PROGRAM EVALUATION AREAS AND LIFE CYCLE COST ESTIMATE REPORT……Page 380
17.6.2 Single Payment Present Value Formula……Page 381
17.6.3 Uniform Periodic Payment Present Value Formula……Page 382
17.6.4 Uniform Periodic Payment Future Amount Formula……Page 383
General Life Cycle Cost Model I……Page 384
General Life Cycle Cost Model III……Page 385
Switching Power Supply Life Cycle Cost Model……Page 386
Early Warning Radar Life Cycle Cost Model……Page 387
Example 17.5……Page 388
Example 17.6……Page 391
17.8.3 Corrective Maintenance Labor Cost Estimation Model……Page 392
17.9.1 Cost Data Sources……Page 393
17.11PROBLEMS……Page 394
17.12REFERENCES……Page 395
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