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Design for Reliability

Book Description

A unique, design-based approach to reliability engineering

Design for Reliability provides engineers and managers with a range of tools and techniques for incorporating reliability into the design process for complex systems. It clearly explains how to design for zero failure of critical system functions, leading to enormous savings in product life-cycle costs and a dramatic improvement in the ability to compete in global markets.

Readers will find a wealth of design practices not covered in typical engineering books, allowing them to think outside the box when developing reliability requirements. They will learn to address high failure rates associated with systems that are not properly designed for reliability, avoiding expensive and time-consuming engineering changes, such as excessive testing, repairs, maintenance, inspection, and logistics.

Special features of this book include:

  • A unified approach that integrates ideas from computer science and reliability engineering

  • Techniques applicable to reliability as well as safety, maintainability, system integration, and logistic engineering

  • Chapters on design for extreme environments, developing reliable software, design for trustworthiness, and HALT influence on design

  • Design for Reliability is a must-have guide for engineers and managers in R&D, product development, reliability engineering, product safety, and quality assurance, as well as anyone who needs to deliver high product performance at a lower cost while minimizing system failure.

    Table of Contents

    1. Cover
    2. Title Page
    3. Copyright
    4. Contents
    5. Contributors
    6. Foreword
    7. Preface
    8. Introduction: What You Will Learn
    9. 1 Design for Reliability Paradigms
      1. Why Design for Reliability?
      2. Reflections on the Current State of the Art
      3. The Paradigms for Design for Reliability
      4. Summary
      5. References
    10. 2 Reliability Design Tools
      1. Introduction
      2. Reliability Tools
      3. Test Data Analysis
      4. Summary
      5. References
    11. 3 Developing Reliable Software
      1. Introduction and Background
      2. Software Reliability: Definitions and Basic Concepts
      3. Software Reliability Design Considerations
      4. Operational Reliability Requires Effective Change Management
      5. Execution-Time Software Reliability Models
      6. Software Reliability Prediction Tools Prior to Testing
      7. References
    12. 4 Reliability Models
      1. Introduction
      2. Reliability Block Diagram: System Modeling
      3. Example of System Reliability Models Using RBDs
      4. Reliability Growth Model
      5. Similarity Analysis and Categories of a Physical Model
      6. Monte Carlo Models
      7. Markov Models
      8. References
    13. 5 Design Failure Modes, Effects, and Criticality Analysis
      1. Introduction to FMEA and FMECA
      2. Design FMECA
      3. Principles of FMECA-MA
      4. Design FMECA Approaches
      5. Example of a Design FMECA Process
      6. Risk Priority Number
      7. Final Thoughts
      8. References
    14. 6 Process Failure Modes, Effects, and Criticality Analysis
      1. Introduction
      2. Principles of P-FMECA
      3. Use of P-FMECA
      4. What is Required Before Starting
      5. Performing P-FMECA Step by Step
      6. Improvement Actions
      7. Reporting Results
      8. Suggestions for Additional Reading
    15. 7 FMECA Applied to Software Development
      1. Introduction
      2. Scoping an FMECA for Software Development
      3. FMECA Steps for Software Development
      4. Important Notes on Roles and Responsibilities with Software FMECA
      5. Lessons Learned from Conducting Software FMECA
      6. Conclusions
      7. References
    16. 8 Six Sigma Approach to Requirements Development
      1. Early Experiences with Design of Experiments
      2. Six Sigma Foundations
      3. The Six Sigma Three-Pronged Initiative
      4. The RASCI Tool
      5. Design for Six Sigma
      6. Requirements Development: The Principal Challenge to System Reliability
      7. The GQM Tool
      8. The Mind Mapping Tool
      9. References
    17. 9 Human Factors in Reliable Design
      1. Human Factors Engineering
      2. A Design Engineer’s Interest in Human Factors
      3. Human-Centered Design
      4. Human Factors Analysis Process
      5. Human Factors and Risk
      6. Human Error
      7. Design for Error Tolerance
      8. Checklists
      9. Testing to Validate Human Factors in Design
      10. References
    18. 10 Stress Analysis During Design to Eliminate Failures
      1. Principles of Stress Analysis
      2. Mechanical Stress Analysis or Durability Analysis
      3. Finite Element Analysis
      4. Probabilistic vs. Deterministic Methods and Failures
      5. How Stress Analysis Aids Design for Reliability
      6. Derating and Stress Analysis
      7. Stress vs. Strength Curves
      8. Software Stress Analysis and Testing
      9. Structural Reinforcement to Improve Structural Integrity
      10. References
    19. 11 Highly Accelerated Life Testing
      1. Introduction
      2. Time Compression
      3. Test Coverage
      4. Environmental Stresses of HALT
      5. Sensitivity to Stresses
      6. Design Margin
      7. Sample Size
      8. Conclusions
      9. Reference
    20. 12 Design for Extreme Environments
      1. Overview
      2. Designing for Extreme Environments
      3. Designing for Cold
      4. Designing for Heat
      5. References
    21. 13 Design for Trustworthiness
      1. Introduction
      2. Modules and Components
      3. Politics of Reuse
      4. Design Principles
      5. Design Constraints That Make Systems Trustworthy
      6. Conclusions
      7. References and Notes
    22. 14 Prognostics and Health Management Capabilities to Improve Reliability
      1. Introduction
      2. PHM Is Department of Defense Policy
      3. Condition-Based Maintenance vs. Time-Based Maintenance
      4. Monitoring and Reasoning of Failure Precursors
      5. Monitoring Environmental and Usage Loads for Damage Modeling
      6. Fault Detection, Fault Isolation, and Prognostics
      7. Sensors for Automatic Stress Monitoring
      8. References
    23. 15 Reliability Management
      1. Introduction
      2. Planning, Execution, and Documentation
      3. Closing the Feedback Loop: Reliability Assessment, Problem Solving, and Growth
      4. References
    24. 16 Risk Management, Exception Handling, and Change Management
      1. Introduction to Risk
      2. Importance of Risk Management
      3. Why Many Risks Are Overlooked
      4. Program Risk
      5. Design Risk
      6. Risk Assessment
      7. Risk Identification
      8. Risk Estimation
      9. Risk Evaluation
      10. Risk Mitigation
      11. Risk Communication
      12. Risk and Competitiveness
      13. Risk Management in the Change Process
      14. Configuration Management
      15. References
    25. 17 Integrating Design for Reliability with Design for Safety
      1. Introduction
      2. Start of Safety Design
      3. Reliability in System Safety Design
      4. Safety Analysis Techniques
      5. Establishing Safety Assessment Using the Risk Assessment Code Matrix
      6. Design and Development Process for Detailed Safety Design
      7. Verification of Design for Safety Includes Reliability
      8. Examples of Design for Safety with Reliability Data
      9. Final Thoughts
      10. References
    26. 18 Organizational Reliability Capability Assessment
      1. Introduction
      2. The Benefits of IEEE 1624-2008
      3. Organizational Reliability Capability
      4. Reliability Capability Assessment
      5. Design Capability and Performability
      6. IEEE 1624 Scoring Guidelines
      7. SEI CMMI Scoring Guidelines
      8. Organizational Reliability Capability Assessment Process
      9. Advantages of High Reliability
      10. Conclusions
      11. References
    27. Index