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Reliability Engineering

Book Description

An Integrated Approach to Product Development

Reliability Engineering presents an integrated approach to the design, engineering, and management of reliability activities throughout the life cycle of a product, including concept, research and development, design, manufacturing, assembly, sales, and service. Containing illustrative guides that include worked problems, numerical examples, homework problems, a solutions manual, and class-tested materials, it demonstrates to product development and manufacturing professionals how to distribute key reliability practices throughout an organization.

The authors explain how to integrate reliability methods and techniques in the Six Sigma process and Design for Six Sigma (DFSS). They also discuss relationships between warranty and reliability, as well as legal and liability issues. Other topics covered include:

  • Reliability engineering in the 21st Century

  • Probability life distributions for reliability analysis

  • Process control and process capability

  • Failure modes, mechanisms, and effects analysis

  • Health monitoring and prognostics

  • Reliability tests and reliability estimation

  • Reliability Engineering provides a comprehensive list of references on the topics covered in each chapter. It is an invaluable resource for those interested in gaining fundamental knowledge of the practical aspects of reliability in design, manufacturing, and testing. In addition, it is useful for implementation and management of reliability programs.

    Table of Contents

    1. Wiley Series in Systems Engineering and Management
    2. Title page
    3. Copyright page
    4. Preface
    5. 1: Reliability Engineering in the Twenty-First Century
      1. 1.1 What Is Quality?
      2. 1.2 What Is Reliability?
      3. 1.3 Quality, Customer Satisfaction, and System Effectiveness
      4. 1.4 Performance, Quality, and Reliability
      5. 1.5 Reliability and the System Life Cycle
      6. 1.6 Consequences of Failure
      7. 1.7 Suppliers and Customers
      8. 1.8 Summary
      9. Problems
      10. Notes
    6. 2: Reliability Concepts
      1. 2.1 Basic Reliability Concepts
      2. 2.2 Hazard Rate
      3. 2.3 Percentiles Product Life
      4. 2.4 Moments of Time to Failure
      5. 2.5 Summary
      6. Problems
    7. 3: Probability and Life Distributions for Reliability Analysis
      1. 3.1 Discrete Distributions
      2. 3.2 Continuous Distributions
      3. 3.3 Probability Plots
      4. 3.4 Summary
      5. Problems
    8. 4: Design for Six Sigma
      1. 4.1 What Is Six Sigma?
      2. 4.2 Why Six Sigma?
      3. 4.3 How Is Six Sigma Implemented?
      4. 4.4 Optimization Problems in the Six Sigma Process
      5. 4.5 Design for Six Sigma
      6. 4.6 Summary
      7. Problems
      8. Notes
    9. 5: Product Development
      1. 5.1 Product Requirements and Constraints
      2. 5.2 Product Life Cycle Conditions
      3. 5.3 Reliability Capability
      4. 5.4 Parts and Materials Selection
      5. 5.5 Human Factors and Reliability
      6. 5.6 Deductive versus Inductive Methods
      7. 5.7 Failure Modes, Effects, and Criticality Analysis
      8. 5.8 Fault Tree Analysis
      9. 5.9 Physics of Failure
      10. 5.10 Design Review
      11. 5.11 Qualification
      12. 5.12 Manufacture and Assembly
      13. 5.13 Analysis, Product Failure, and Root Causes
      14. 5.14 Summary
      15. Problems
      16. Notes
    10. 6: Product Requirements and Constraints
      1. 6.1 Defining Requirements
      2. 6.2 Responsibilities of the Supply Chain
      3. 6.3 The Requirements Document
      4. 6.4 Specifications
      5. 6.5 Requirements Tracking
      6. 6.6 Summary
      7. Problems
    11. 7: Life-Cycle Conditions
      1. 7.1 Defining the Life-Cycle Profile
      2. 7.2 Life-Cycle Events
      3. 7.3 Loads and Their Effects
      4. 7.4 Considerations and Recommendations for LCP Development
      5. 7.5 Methods for Estimating Life-Cycle Loads
      6. 7.6 Summary
      7. Problems
      8. Notes
    12. 8: Reliability Capability
      1. 8.1 Capability Maturity Models
      2. 8.2 Key Reliability Practices
      3. 8.3 Summary
      4. Problems
    13. 9: Parts Selection and Management
      1. 9.1 Part Assessment Process
      2. 9.2 Parts Management
      3. 9.3 Risk Management
      4. 9.4 Summary
      5. Problems
      6. Notes
    14. 10: Failure Modes, Mechanisms, and Effects Analysis
      1. 10.1 Development of FMMEA
      2. 10.2 Failure Modes, Mechanisms, and Effects Analysis
      3. 10.3 Case Study
      4. 10.4 Summary
      5. Problems
      6. Note
    15. 11: Probabilistic Design for Reliability and the Factor of Safety
      1. 11.1 Design for Reliability
      2. 11.2 Design of a Tension Element
      3. 11.3 Reliability Models for Probabilistic Design
      4. 11.4 Example of Probabilistic Design and Design for a Reliability Target
      5. 11.5 Relationship between Reliability, Factor of Safety, and Variability
      6. 11.6 Functions of Random Variables
      7. 11.7 Steps for Probabilistic Design
      8. 11.8 Summary
      9. Problems
    16. 12: Derating and Uprating
      1. 12.1 Part Ratings
      2. 12.2 Derating
      3. 12.3 Uprating
      4. 12.4 Summary
      5. Problems
      6. Notes
    17. 13: Reliability Estimation Techniques
      1. 13.1 Tests during the Product Life Cycle
      2. 13.2 Reliability Estimation
      3. 13.3 Product Qualification and Testing
      4. 13.4 Case Study: System-in-Package Drop Test Qualification
      5. 13.5 Basic Statistical Concepts
      6. 13.6 Confidence Interval for Normal Distribution
      7. 13.7 Confidence Intervals for Proportions
      8. 13.8 Reliability Estimation and Confidence Limits for Success–Failure Testing
      9. 13.9 Reliability Estimation and Confidence Limits for Exponential Distribution
      10. 13.10 Summary
      11. Problems
    18. 14: Process Control and Process Capability
      1. 14.1 Process Control System
      2. 14.2 Control Charts
      3. 14.3 Benefits of Control Charts
      4. 14.4 Average Outgoing Quality
      5. 14.5 Advanced Control Charts
      6. 14.6 Summary
      7. Problems
    19. 15: Product Screening and Burn-In Strategies
      1. 15.1 Burn-In Data Observations
      2. 15.2 Discussion of Burn-In Data
      3. 15.3 Higher Field Reliability without Screening
      4. 15.4 Best Practices
      5. 15.5 Summary
      6. Problems
    20. 16: Analyzing Product Failures and Root Causes
      1. 16.1 Root-Cause Analysis Processes
      2. 16.2 No-Fault-Found
      3. 16.3 Summary
      4. Problems
    21. 17: System Reliability Modeling
      1. 17.1 Reliability Block Diagram
      2. 17.2 Series System
      3. 17.3 Products with Redundancy
      4. 17.4 Complex System Reliability
      5. 17.5 Summary
      6. Problems
    22. 18: Health Monitoring and Prognostics
      1. 18.1 Conceptual Model for Prognostics
      2. 18.2 Reliability and Prognostics
      3. 18.3 PHM for Electronics
      4. 18.4 PHM Concepts and Methods
      5. 18.5 Monitoring and Reasoning of Failure Precursors
      6. 18.6 Implementation of PHM in a System of Systems
      7. 18.7 Summary
      8. Problems
      9. Notes
    23. 19: Warranty Analysis
      1. 19.1 Product Warranties
      2. 19.2 Warranty Return Information
      3. 19.3 Warranty Policies
      4. 19.4 Warranty and Reliability
      5. 19.5 Warranty Cost Analysis
      6. 19.6 Warranty and Reliability Management
      7. 19.7 Summary
      8. Problems
      9. Notes
    24. Appendix A: Some Useful Integrals
    25. Appendix B: Table for Gamma Function
    26. Appendix C: Table for Cumulative Standard Normal Distribution
    27. Appendix D: Values for the Percentage Points t<sub xmlns="http://www.w3.org/1999/xhtml" xmlns:m="http://www.w3.org/1998/Math/MathML" xmlns:svg="http://www.w3.org/2000/svg" xmlns:xlink="http://www.w3.org/1999/xlink" xmlns:ibooks="http://vocabulary.itunes.apple.com/rdf/ibooks/vocabulary-extensions-1.0" xmlns:epub="http://www.idpf.org/2007/ops">&#945;,&#957;</sub> of the t-Distribution of the t-Distribution
    28. Appendix E: Percentage Points <img xmlns="http://www.w3.org/1999/xhtml" xmlns:m="http://www.w3.org/1998/Math/MathML" xmlns:svg="http://www.w3.org/2000/svg" xmlns:xlink="http://www.w3.org/1999/xlink" xmlns:ibooks="http://vocabulary.itunes.apple.com/rdf/ibooks/vocabulary-extensions-1.0" xmlns:epub="http://www.idpf.org/2007/ops" alt="math001" src="images/math001.jpg"></img> of the Chi-Square Distribution of the Chi-Square Distribution
    29. Appendix F: Percentage Points for the F-Distribution
    30. Bibliography
    31. Index
    32. End User License Agreement