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Practical Reliability Engineering, 5th Edition

Book Description

With emphasis on practical aspects of engineering, this bestseller has gained worldwide recognition through progressive editions as the essential reliability textbook. This fifth edition retains the unique balanced mixture of reliability theory and applications, thoroughly updated with the latest industry best practices.

Practical Reliability Engineering fulfils the requirements of the Certified Reliability Engineer curriculum of the American Society for Quality (ASQ). Each chapter is supported by practice questions, and a solutions manual is available to course tutors via the companion website.

Enhanced coverage of mathematics of reliability, physics of failure, graphical and software methods of failure data analysis, reliability prediction and modelling, design for reliability and safety as well as management and economics of reliability programmes ensures continued relevance to all quality assurance and reliability courses.

Notable additions include:

  • New chapters on applications of Monte Carlo simulation methods and reliability demonstration methods.

  • Software applications of statistical methods, including probability plotting and a wider use of common software tools.

  • More detailed descriptions of reliability prediction methods.

  • Comprehensive treatment of accelerated test data analysis and warranty data analysis.

  • Revised and expanded end-of-chapter tutorial sections to advance students' practical knowledge.

The fifth edition will appeal to a wide range of readers from college students to seasoned engineering professionals involved in the design, development, manufacture and maintenance of reliable engineering products and systems.

www.wiley.com/go/oconnor_reliability5

Table of Contents

  1. Cover Page
  2. Title Page
  3. Copyright
  4. Dedication
  5. Contents
  6. Preface to the First Edition
  7. Preface to the Second Edition
  8. Preface to the Third Edition
  9. Preface to the Third Edition Revised
  10. Preface to the Fourth Edition
  11. Preface to the Fifth Edition
  12. Acknowledgements
  13. 1: Introduction to Reliability Engineering
    1. 1.1 What is Reliability Engineering?
    2. 1.2 Why Teach Reliability Engineering?
    3. 1.3 Why Do Engineering Products Fail?
    4. 1.4 Probabilistic Reliability
    5. 1.5 Repairable and Non-Repairable Items
    6. 1.6 The Pattern of Failures with Time (Non-Repairable Items)
    7. 1.7 The Pattern of Failures with Time (Repairable Items)
    8. 1.8 The Development of Reliability Engineering
    9. 1.9 Courses, Conferences and Literature
    10. 1.10 Organizations Involved in Reliability Work
    11. 1.11 Reliability as an Effectiveness Parameter
    12. 1.12 Reliability Programme Activities
    13. 1.13 Reliability Economics and Management
  14. 2: Reliability Mathematics
    1. 2.1 Introduction
    2. 2.2 Variation
    3. 2.3 Probability Concepts
    4. 2.4 Rules of Probability
    5. 2.5 Continuous Variation
    6. 2.6 Continuous Distribution Functions
    7. 2.7 Summary of Continuous Statistical Distributions
    8. 2.8 Variation in Engineering
    9. 2.9 Conclusions
    10. 2.10 Discrete Variation
    11. 2.11 Statistical Confidence
    12. 2.12 Statistical Hypothesis Testing
    13. 2.13 Non-Parametric Inferential Methods
    14. 2.14 Goodness of Fit
    15. 2.15 Series of Events (Point Processes)
    16. 2.16 Computer Software for Statistics
    17. 2.17 Practical Conclusions
  15. 3: Life Data Analysis and Probability Plotting
    1. 3.1 Introduction
    2. 3.2 Life Data Classification
    3. 3.3 Ranking of Data
    4. 3.4 Weibull Distribution
    5. 3.5 Computerized Data Analysis and Probability Plotting
    6. 3.6 Confidence Bounds for Life Data Analysis
    7. 3.7 Choosing the Best Distribution and Assessing the Results
    8. 3.8 Conclusions
  16. 4: Monte Carlo Simulation
    1. 4.1 Introduction
    2. 4.2 Monte Carlo Simulation Basics
    3. 4.3 Additional Statistical Distributions
    4. 4.4 Sampling a Statistical Distribution
    5. 4.5 Basic Steps for Performing a Monte Carlo Simulation
    6. 4.6 Monte Carlo Method Summary
  17. 5: Load–Strength Interference
    1. 5.1 Introduction
    2. 5.2 Distributed Load and Strength
    3. 5.3 Analysis of Load–Strength Interference
    4. 5.4 Effect of Safety Margin and Loading Roughness on Reliability (Multiple Load Applications)
    5. 5.5 Practical Aspects
  18. 6: Reliability Prediction and Modelling
    1. 6.1 Introduction
    2. 6.2 Fundamental Limitations of Reliability Prediction
    3. 6.3 Standards Based Reliability Prediction
    4. 6.4 Other Methods for Reliability Predictions
    5. 6.5 Practical Aspects
    6. 6.6 Systems Reliability Models
    7. 6.7 Availability of Repairable Systems
    8. 6.8 Modular Design
    9. 6.9 Block Diagram Analysis
    10. 6.10 Fault Tree Analysis (FTA)
    11. 6.11 State-Space Analysis (Markov Analysis)
    12. 6.12 Petri Nets
    13. 6.13 Reliability Apportionment
    14. 6.14 Conclusions
  19. 7: Design for Reliability
    1. 7.1 Introduction
    2. 7.2 Design for Reliability Process
    3. 7.3 Identify
    4. 7.4 Design
    5. 7.5 Analyse
    6. 7.6 Verify
    7. 7.7 Validate
    8. 7.8 Control
    9. 7.9 Assessing the DfR Capability of an Organization
    10. 7.10 Summary
  20. 8: Reliability of Mechanical Components and Systems
    1. 8.1 Introduction
    2. 8.2 Mechanical Stress, Strength and Fracture
    3. 8.3 Fatigue
    4. 8.4 Creep
    5. 8.5 Wear
    6. 8.6 Corrosion
    7. 8.7 Vibration and Shock
    8. 8.8 Temperature Effects
    9. 8.9 Materials
    10. 8.10 Components
    11. 8.11 Processes
  21. 9: Electronic Systems Reliability
    1. 9.1 Introduction
    2. 9.2 Reliability of Electronic Components
    3. 9.3 Component Types and Failure Mechanisms
    4. 9.4 Summary of Device Failure Modes
    5. 9.5 Circuit and System Aspects
    6. 9.6 Reliability in Electronic System Design
    7. 9.7 Parameter Variation and Tolerances
    8. 9.8 Design for Production, Test and Maintenance
  22. 10: Software Reliability
    1. 10.1 Introduction
    2. 10.2 Software in Engineering Systems
    3. 10.3 Software Errors
    4. 10.4 Preventing Errors
    5. 10.5 Software Structure and Modularity
    6. 10.6 Programming Style
    7. 10.7 Fault Tolerance
    8. 10.8 Redundancy/Diversity
    9. 10.9 Languages
    10. 10.10 Data Reliability
    11. 10.11 Software Checking
    12. 10.12 Software Testing
    13. 10.13 Error Reporting
    14. 10.14 Software Reliability Prediction and Measurement
    15. 10.15 Hardware/Software Interfaces
    16. 10.16 Conclusions
  23. 11: Design of Experiments and Analysis of Variance
    1. 11.1 Introduction
    2. 11.2 Statistical Design of Experiments and Analysis of Variance
    3. 11.3 Randomizing the Data
    4. 11.4 Engineering Interpretation of Results
    5. 11.5 The Taguchi Method
    6. 11.6 Conclusions
  24. 12: Reliability Testing
    1. 12.1 Introduction
    2. 12.2 Planning Reliability Testing
    3. 12.3 Test Environments
    4. 12.4 Testing for Reliability and Durability: Accelerated Test
    5. 12.5 Test Planning
    6. 12.6 Failure Reporting, Analysis and Corrective Action Systems (FRACAS)
  25. 13: Analysing Reliability Data
    1. 13.1 Introduction
    2. 13.2 Pareto Analysis
    3. 13.3 Accelerated Test Data Analysis
    4. 13.4 Acceleration Factor
    5. 13.5 Acceleration Models
    6. 13.6 Field-Test Relationship
    7. 13.7 Statistical Analysis of Accelerated Test Data
    8. 13.8 Reliability Analysis of Repairable Systems
    9. 13.9 CUSUM Charts
    10. 13.10 Exploratory Data Analysis and Proportional Hazards Modelling
    11. 13.11 Field and Warranty Data Analysis
  26. 14: Reliability Demonstration and Growth
    1. 14.1 Introduction
    2. 14.2 Reliability Metrics
    3. 14.3 Test to Success (Success Run Method)
    4. 14.4 Test to Failure Method
    5. 14.5 Extended Life Test
    6. 14.6 Continuous Testing
    7. 14.7 Degradation Analysis
    8. 14.8 Combining Results Using Bayesian Statistics
    9. 14.9 Non-Parametric Methods
    10. 14.10 Reliability Demonstration Software
    11. 14.11 Practical Aspects of Reliability Demonstration
    12. 14.12 Standard Methods for Repairable Equipment
    13. 14.13 Reliability Growth Monitoring
    14. 14.14 Making Reliability Grow
  27. 15: Reliability in Manufacture
    1. 15.1 Introduction
    2. 15.2 Control of Production Variability
    3. 15.3 Control of Human Variation
    4. 15.4 Acceptance Sampling
    5. 15.5 Improving the Process
    6. 15.6 Quality Control in Electronics Production
    7. 15.7 Stress Screening
    8. 15.8 Production Failure Reporting Analysis and Corrective Action System (FRACAS)
    9. 15.9 Conclusions
  28. 16: Maintainability, Maintenance and Availability
    1. 16.1 Introduction
    2. 16.2 Availability Measures
    3. 16.3 Maintenance Time Distributions
    4. 16.4 Preventive Maintenance Strategy
    5. 16.5 FMECA and FTA in Maintenance Planning
    6. 16.6 Maintenance Schedules
    7. 16.7 Technology Aspects
    8. 16.8 Calibration
    9. 16.9 Maintainability Prediction
    10. 16.10 Maintainability Demonstration
    11. 16.11 Design for Maintainability
    12. 16.12 Integrated Logistic Support
  29. 17: Reliability Management
    1. 17.1 Corporate Policy for Reliability
    2. 17.2 Integrated Reliability Programmes
    3. 17.3 Reliability and Costs
    4. 17.4 Safety and Product Liability
    5. 17.5 Standards for Reliability, Quality and Safety
    6. 17.6 Specifying Reliability
    7. 17.7 Contracting for Reliability Achievement
    8. 17.8 Managing Lower-Level Suppliers
    9. 17.9 The Reliability Manual
    10. 17.10 The Project Reliability Plan
    11. 17.11 Use of External Services
    12. 17.12 Customer Management of Reliability
    13. 17.13 Selecting and Training for Reliability
    14. 17.14 Organization for Reliability
    15. 17.15 Reliability Capability and Maturity of an Organization
    16. 17.16 Managing Production Quality
    17. 17.17 Quality Management Approaches
    18. 17.18 Choosing the Methods: Strategy and Tactics
    19. 17.19 Conclusions
  30. Appendix 1: The Standard Cumulative Normal Distribution Function
  31. Appendix 2: χ 2 (α, ν) Distribution Values
  32. Appendix 3: Kolmogorov–Smirnov Tables
  33. Appendix 4: Rank Tables (5%, 95%)
  34. Appendix 5: Failure Reporting, Analysis and Corrective Action System (FRACAS)
  35. Appendix 6: Reliability, Maintainability (and Safety) Plan Example
    1. 1. RELIABILITY, MAINTAINABILITY (AND SAFETY) PLAN OVERVIEW
    2. 2. RELIABILITY AND MAINTAINABILITY ENGINEERING TASKS
    3. 3. SAFETY ENGINEERING TASKS
    4. 4. PROJECT RAMS ENGINEERING MANAGEMENT AND REPORTING
  36. Appendix 7: Matrix Algebra Revision
  37. Index