Practical Reliability Engineering

Patrick O'Connor, Stevenage, UKSince 1995 Patrick O’Connor has worked as an independent consultant on engineering management, reliability, quality and safety. He received his engineering training at the Royal Air Force Technical College and served for 16 years in the RAF Engineer Branch, including tours on aircraft maintenance and in the Reliability and Maintainability office of the Ministry of Defence (Air). He was appointed Reliability Manager of British Aerospace Dynamics in 1980 and joined British Rail Research as Reliability Manager in 1993. Mr. O'Connor is the author of Practical Reliability Engineering, published by John Wiley (4th. edition 2002). He is also the author of the chapter on reliability and quality engineering in the Academic Press Encyclopaedia of Physical Science and Technology, and until 1999 was the UK editor of the Wiley journal Quality and Reliability Engineering International. He has written many papers and articles on quality and reliability engineering and management, and he lectures at universities and other venues on these subjects. He is editor of the Wiley book series in quality and reliability engineering.Andre Kleyner, Delphi Electronics & Safety, USAAndre Kleyner has over 25 years of engineering, research, consulting, and managerial experience specializing in reliability of electronic and mechanical systems designed to operate in severe environments. He received the doctorate in Mechanical Engineering from University of Maryland, and Master of Business Administration from Ball State University. Dr. Kleyner is a Global Reliability Engineering Leader with Delphi Electronics & Safety, and an adjunct professor at Purdue University. Andre developed and taught many training courses for reliability, quality, and design professionals. He also holds several US and foreign patents and authored professional publications on reliability, quality, and other engineering topics. Andre has is a senior member of American Society for Quality, Certified Reliability and Quality Engineer and Six-sigma black belt. He holds several US and foreign patents and hs authored many papers on the topics of warranty, lifecycle cost, reliability, and statistics. His areas of expertise are: Design for Reliability (DfR); Reliability of Electronic and Mechanical Systems; Product Test and Validation Planning; Physics of Failure; Warranty Management; Reliability Prediction and Warranty Forecasting; Weibull Analysis; Monte Carlo Simulation; Systems Engineering; Dependability analysis, and testing of energy systems for power electronics and electric/hybrid vehicles, and Training and consulting in these areas.

• Preface to the First Edition xvPreface to the Second Edition xviiPreface to the Third Edition xixPreface to the Third Edition Revised xxiPreface to the Fourth Edition xxiiiPreface to the Fifth Edition xxvAcknowledgements xxvii1 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 (Non-Repairable Items) 81.7 The Pattern of Failures with Time (Repairable Items) 91.8 The Development of Reliability Engineering 91.9 Courses, Conferences and Literature 111.10 Organizations Involved in Reliability Work 121.11 Reliability as an Effectiveness Parameter 121.12 Reliability Programme Activities 131.13 Reliability Economics and Management 14Questions 17Bibliography 182 Reliability Mathematics 192.1 Introduction 192.2 Variation 192.3 Probability Concepts 212.4 Rules of Probability 222.5 Continuous Variation 282.6 Continuous Distribution Functions 332.7 Summary of Continuous Statistical Distributions 412.8 Variation in Engineering 412.9 Conclusions 472.10 Discrete Variation 482.11 Statistical Confidence 512.12 Statistical Hypothesis Testing 532.13 Non-Parametric Inferential Methods 572.14 Goodness of Fit 592.15 Series of Events (Point Processes) 612.16 Computer Software for Statistics 642.17 Practical Conclusions 64Questions 66Bibliography 683 Life Data Analysis and Probability Plotting 703.1 Introduction 703.2 Life Data Classification 713.3 Ranking of Data 753.4 Weibull Distribution 783.5 Computerized Data Analysis and Probability Plotting 853.6 Confidence Bounds for Life Data Analysis 893.7 Choosing the Best Distribution and Assessing the Results 953.8 Conclusions 102Questions 103Bibliography 1074 Monte Carlo Simulation 1084.1 Introduction 1084.2 Monte Carlo Simulation Basics 1084.3 Additional Statistical Distributions 1084.4 Sampling a Statistical Distribution 1104.5 Basic Steps for Performing a Monte Carlo Simulation 1134.6 Monte Carlo Method Summary 115Questions 118Bibliography 1195 Load–Strength Interference 1205.1 Introduction 1205.2 Distributed Load and Strength 1205.3 Analysis of Load–Strength Interference 1235.4 Effect of Safety Margin and Loading Roughness on Reliability (Multiple Load Applications) 1245.5 Practical Aspects 131Questions 132Bibliography 1336 Reliability Prediction and Modelling 1346.1 Introduction 1346.2 Fundamental Limitations of Reliability Prediction 1356.3 Standards Based Reliability Prediction 1366.4 Other Methods for Reliability Predictions 1416.5 Practical Aspects 1436.6 Systems Reliability Models 1436.7 Availability of Repairable Systems 1476.8 Modular Design 1516.9 Block Diagram Analysis 1526.10 Fault Tree Analysis (FTA) 1576.11 State-Space Analysis (Markov Analysis) 1586.12 Petri Nets 1656.13 Reliability Apportionment 1696.14 Conclusions 170Questions 170Bibliography 1757 Design for Reliability 1777.1 Introduction 1777.2 Design for Reliability Process 1787.3 Identify 1797.4 Design 1837.5 Analyse 1967.6 Verify 1977.7 Validate 1987.8 Control 1987.9 Assessing the DfR Capability of an Organization 2017.10 Summary 201Questions 202Bibliography 2038 Reliability of Mechanical Components and Systems 2058.1 Introduction 2058.2 Mechanical Stress, Strength and Fracture 2068.3 Fatigue 2088.4 Creep 2148.5 Wear 2148.6 Corrosion 2168.7 Vibration and Shock 2168.8 Temperature Effects 2188.9 Materials 2208.10 Components 2208.11 Processes 221Questions 222Bibliography 2239 Electronic Systems Reliability 2259.1 Introduction 2259.2 Reliability of Electronic Components 2269.3 Component Types and Failure Mechanisms 2299.4 Summary of Device Failure Modes 2439.5 Circuit and System Aspects 2449.6 Reliability in Electronic System Design 2459.7 Parameter Variation and Tolerances 2549.8 Design for Production, Test and Maintenance 258Questions 259Bibliography 26010 Software Reliability 26210.1 Introduction 26210.2 Software in Engineering Systems 26310.3 Software Errors 26510.4 Preventing Errors 26710.5 Software Structure and Modularity 26810.6 Programming Style 26910.7 Fault Tolerance 26910.8 Redundancy/Diversity 27010.9 Languages 27010.10 Data Reliability 27210.11 Software Checking 27210.12 Software Testing 27410.13 Error Reporting 27510.14 Software Reliability Prediction and Measurement 27610.15 Hardware/Software Interfaces 28110.16 Conclusions 281Questions 283Bibliography 28311 Design of Experiments and Analysis of Variance 28411.1 Introduction 28411.2 Statistical Design of Experiments and Analysis of Variance 28411.3 Randomizing the Data 29611.4 Engineering Interpretation of Results 29711.5 The Taguchi Method 29711.6 Conclusions 301Questions 302Bibliography 30512 Reliability Testing 30612.1 Introduction 30612.2 Planning Reliability Testing 30712.3 Test Environments 30912.4 Testing for Reliability and Durability: Accelerated Test 31312.5 Test Planning 32212.6 Failure Reporting, Analysis and Corrective Action Systems (FRACAS) 323Questions 324Bibliography 32513 Analysing Reliability Data 32713.1 Introduction 32713.2 Pareto Analysis 32713.3 Accelerated Test Data Analysis 32813.4 Acceleration Factor 32913.5 Acceleration Models 33013.6 Field-Test Relationship 33513.7 Statistical Analysis of Accelerated Test Data 33613.8 Reliability Analysis of Repairable Systems 33913.9 CUSUM Charts 34313.10 Exploratory Data Analysis and Proportional Hazards Modelling 34613.11 Field and Warranty Data Analysis 348Questions 351Bibliography 35514 Reliability Demonstration and Growth 35714.1 Introduction 35714.2 Reliability Metrics 35714.3 Test to Success (Success Run Method) 35814.4 Test to Failure Method 35914.5 Extended Life Test 36014.6 Continuous Testing 36114.7 Degradation Analysis 36214.8 Combining Results Using Bayesian Statistics 36314.9 Non-Parametric Methods 36514.10 Reliability Demonstration Software 36614.11 Practical Aspects of Reliability Demonstration 36614.12 Standard Methods for Repairable Equipment 36714.13 Reliability Growth Monitoring 37314.14 Making Reliability Grow 382Questions 383Bibliography 38515 Reliability in Manufacture 38615.1 Introduction 38615.2 Control of Production Variability 38615.3 Control of Human Variation 39015.4 Acceptance Sampling 39115.5 Improving the Process 39515.6 Quality Control in Electronics Production 39915.7 Stress Screening 40215.8 Production Failure Reporting Analysis and Corrective Action System (FRACAS) 40415.9 Conclusions 405Questions 405Bibliography 40616 Maintainability, Maintenance and Availability 40816.1 Introduction 40816.2 Availability Measures 40916.3 Maintenance Time Distributions 41016.4 Preventive Maintenance Strategy 41116.5 FMECA and FTA in Maintenance Planning 41516.6 Maintenance Schedules 41516.7 Technology Aspects 41516.8 Calibration 41716.9 Maintainability Prediction 41716.10 Maintainability Demonstration 41816.11 Design for Maintainability 41816.12 Integrated Logistic Support 418Questions 419Bibliography 42017 Reliability Management 42117.1 Corporate Policy for Reliability 42117.2 Integrated Reliability Programmes 42117.3 Reliability and Costs 42417.4 Safety and Product Liability 42817.5 Standards for Reliability, Quality and Safety 42817.6 Specifying Reliability 43117.7 Contracting for Reliability Achievement 43217.8 Managing Lower-Level Suppliers 43417.9 The Reliability Manual 43517.10 The Project Reliability Plan 43617.11 Use of External Services 43617.12 Customer Management of Reliability 43717.13 Selecting and Training for Reliability 43917.14 Organization for Reliability 44017.15 Reliability Capability and Maturity of an Organization 44217.16 Managing Production Quality 44417.17 Quality Management Approaches 44617.18 Choosing the Methods: Strategy and Tactics 44717.19 Conclusions 448Questions 449Bibliography 450Appendix 1 The Standard Cumulative Normal Distribution Function 451Appendix 2 χ2(α, ν) Distribution Values 453Appendix 3 Kolmogorov–Smirnov Tables 455Appendix 4 Rank Tables (5 %, 95 %) 457Appendix 5 Failure Reporting, Analysis and Corrective Action System (FRACAS) 465Appendix 6 Reliability, Maintainability (and Safety) Plan Example 467Appendix 7 Matrix Algebra Revision 474Index 476

“This informative, quick read will give the reader simple explanations and an overview of the various major forms of energy and how energy is stored and transported.”  (IEEE Electrical Insulation Magazine, 1 November 2013)