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.

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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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Format	Download, Hardcopy

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