An Introduction To Reliability And Maintainability Engineering

by Ebeling, Charles E.

• ISBN13: 9781577663867
• ISBN10: 1577663861
• Format: Paperback
• Copyright: 2005-02-28
• Publisher: Waveland Pr Inc

Summary

This practical and modern approach to reliability deals with core concepts, major models, and proven techniques. The computer software packaged in the Instructor's Manual allows students to focus on concepts and analysis instead of tedius numerical calculations. Relevant to all departments of engineering, particularly industrial, this text provides an introduction to probability and statistical techniques that is necessary to support the development of reliability and maintainability concepts.

Table of Contents

Preface	xv
Course Software	xvii
Introduction	1	(22)
The Study of Reliability and Maintainability	3	(2)
Reliability Improvement
Random versus Deterministic Failure Phenomena
Concepts, Terms, and Definitions	5	(2)
Applications	7	(3)
A Brief History	10	(1)
Scope of the Text	11	(12)
Appendix 1A A Probability Primer	13	(10)
Random Events
Bayes' Formula
Random Variables
Discrete Distributions
Binomial Distribution
Poisson Distribution
Continuous Distributions
PART 1 Basic Reliability Models
The Failure Distribution	23	(18)
The Reliability Function	23	(3)
Mean Time to Failure	26	(2)
Hazard Rate Function	28	(3)
Bathtub Curve	31	(1)
Conditional Reliability	32	(2)
Summary	34	(7)
Appendix 2A Derivation of Equation (2.8)	35	(1)
Appendix 2B Derivation of Equation (2.12)	36	(1)
Appendix 2C Conditional Reliability and Failure Rates	36	(1)
Appendix 2D Intermediate Calculations for the Linear Bathtub Curve	37	(1)
Appendix 2E Table of Integrals	38	(1)
Indefinite Integrals
Definite Integrals
Exercises	38	(3)
Constant Failure Rate Model	41	(17)
The Exponential Reliability Function	41	(4)
Failure Modes	45	(2)
Failure Modes with CFR Model
Failures on Demand
Applications	47	(4)
Renewal Process
Repetitive Loading
Reliability Bounds
The Two-Parameter Exponential Distribution	51	(1)
Poisson Process	52	(2)
Redundancy and the CFR Model	54	(4)
Exercises	55	(3)
Time-Dependent Failure Models	58	(25)
The Weibull Distribution	58	(11)
Design Life, Median, and Mode
Burn-In Screening for Weibull
Failure Modes
Identical Weibull Components
The Three-Parameter Weibull
Redundancy with Weibull Failures
The Normal Distribution	69	(4)
The Lognormal Distribution	73	(10)
Appendix 4A Derivation of the MTTF for the Weibull Distribution	77	(1)
Appendix 4B Derivation of the Mode for the Weibull Distribution	78	(1)
Appendix 4C Minimum Extreme-Value Distribution	78	(1)
Appendix 4D Hazard Rate for the Two-Component Weibull Redundant System	79	(1)
Exercises	79	(4)
Reliability of Systems	83	(25)
Serial Configuration	83	(2)
Parallel Configuration	85	(2)
Combined Series-Parallel Systems	87	(6)
High-Level versus Low-Level Redundancy
k-out-of-n Redundancy
Complex Configurations
System Structure Function, Minimal Cuts, and Minimal Paths (Optional)	93	(4)
Coherent Systems
Minimal Path and Cut Sets
System Bounds
Common-Mode Failures	97	(1)
Three-State Devices	98	(10)
Series Structure
Parallel Structure
Low-Level Redundancy
High-Level Redundancy
Exercises	102	(6)
State-Dependent Systems	108	(16)
Markov Analysis	108	(3)
Load-Sharing System	111	(1)
Standby Systems	112	(5)
Identical Standby Units
Standby System with Switching Failures
Three-Component Standby System
Degraded Systems	117	(1)
Three-State Devices	118	(6)
Appendix 6A Solution to Two-Component Redundant System	119	(1)
Appendix 6B Solution to Load-Sharing System	120	(1)
Appendix 6C Solution to Standby System Model	120	(1)
Exercises	121	(3)
Physical Reliability Models	124	(21)
Covariate Models	124	(4)
Proportional Hazards Models
Location-Scale Models
Static Models	128	(7)
Random Stress and Constant Strength
Constant Stress and Random Strength
Random Stress and Random Strength
Dynamic Models	135	(2)
Periodic Loads
Random Loads
Random Fixed Stress and Strength
Physics-of-Failure Models	137	(8)
Exercises	141	(4)
Design for Reliability	145	(44)
Reliability Specification and System Measurements	147	(4)
System Effectiveness
Economic Analysis and Life-Cycle Costs
Reliability Allocation	151	(6)
Exponential Case
Optimal Allocations
ARINC Method
AGREE Method
Redundancies
Design Methods	157	(9)
Parts and Material Selection
Derating
Stress-Strength Analysis
Complexity and Technology
Redundancy
Failure Analysis	166	(6)
System Definition
Identification of Failure Modes
Determination of Cause
Assessment of Effect
Classification of Severity
Estimation of Probability of Occurrence
Computation of Criticality Index
Determination of Corrective Action
System Safety and Fault Tree Analysis	172	(17)
Fault Tree Analysis
Minimal Cut Sets
Quantitative Analysis
Exercises	183	(6)
Maintainability	189	(29)
Analysis of Downtime	189	(2)
The Repair-Time Distribution	191	(3)
Exponential Repair Times
Lognormal Repair Times
Stochastic Point Processes	194	(8)
Renewal Process
Minimal Repair Process
Overhaul and Cycle Time
System Repair Time	202	(2)
Reliability under Preventive Maintenance	204	(3)
State-Dependent Systems with Repair	207	(11)
Appendix 9A The MTTF for the Preventive Maintenance Model	211	(1)
Appendix 9B Solution to the Active Redundant System with Repair	211	(1)
Appendix 9C Solution to Standby System with Repair	212	(1)
Exercises	213	(5)
Design for Maintainability	218	(36)
Maintenance Requirements	219	(6)
Measurements and Specifications
Maintenance Concepts and Procedures
Component Reliability and Maintainability
Design Methods	225	(10)
Fault Isolation and Self-Diagnostics
Parts Standardization and Interchangeability
Modularization and Accessibility
Repair versus Replacement
Proactive Maintenance
Human Factors and Ergonomics	235	(2)
Maintenance and Spares Provisioning	237	(7)
Finite Population Queuing Model with Spares
Component Sparing
Maintainability Prediction and Demonstration	244	(10)
Maintainability Prediction
Maintainability Demonstration
Appendix 10A Birth-Death Queuing Model	248	(2)
Exercises	250	(4)
Availability	254	(29)
Concepts and Definitions	254	(3)
Inherent Availability
Achieved Availability
Operational Availability
Generalized Operational Availability
Exponential Availability Model	257	(1)
System Availability	258	(6)
Availability with Standby Systems
Steady-State Availability
Matrix Approach
Inspection and Repair Availability Model	264	(2)
Design Trade-Off Analysis	266	(17)
Maintainability Allocation
Economic Analysis
Concave Costs
Convex Cost Functions
Profit and Life-Cycle Cost Trade-Offs
Appendix 11A Solution to Single Unit with Repair Model	275	(1)
Exercises	275	(8)
PART 2 The Analysis of Failure Data
Data Collection and Empirical Methods	283	(25)
Data Collection	283	(3)
Empirical Methods	286	(16)
Ungrouped Complete Data
Grouped Complete Data
Ungrouped Censored Data
Grouped Censored Data
Static Life Estimation	302	(6)
Exercises	303	(5)
Reliability Testing	308	(34)
Product Testing	308	(1)
Reliability Life Testing	309	(1)
Test Time Calculations	310	(2)
Length of Test
Burn-In Testing	312	(3)
Acceptance Testing	315	(8)
Binomial Acceptance Testing
Sequential Tests
Accelerated Life Testing	323	(8)
Number of Units on Test
Accelerated Cycling
Constant-Stress Models
Other Acceleration Models
Experimental Design	331	(4)
Competing Failure Modes	335	(7)
Appendix 13A Derivation of Expected Test Time	336	(1)
Appendix 13B Expected Test Time (Type II Testing)	337	(1)
Exercises	338	(4)
Reliability Growth Testing	342	(16)
Reliability Growth Process	342	(1)
Idealized Growth Curve	343	(2)
Duane Growth Model	345	(4)
AMSAA Model	349	(4)
Parameter Estimation for the Power Law Intensity Function
Other Growth Models	353	(5)
Exercises	355	(3)
Identifying Failure and Repair Distributions	358	(34)
Identifying Candidate Distributions	359	(3)
Probability Plots and Least-Squares Curve-Fitting	362	(12)
Exponential Plots
Weibull Plots
Normal Plots
Lognormal Plots
Multiply Censored Time Plots
Parameter Estimation	374	(8)
Maximum Likelihood Estimator
Exponential MLE
Weibull MLE
Normal and Lognormal MLEs
Maximum Likelihood Estimation with Multiply Censored Data
Location Parameter Estimation
Confidence Intervals	382	(3)
Confidence Intervals for the Constant Failure Rate Model
Confidence Intervals for Other Distributions
Parameter Estimation for Covariate Models	385	(7)
Appendix 15A Weibull Maximum Likelihood Estimator	387	(1)
Appendix 15B Weibull MLE with Multiply Censored Data	388	(1)
Appendix 15C MLE for Normal and Lognormal Distributions with Censored Data	388	(1)
Exercises	389	(3)
Goodness-of-Fit Tests	392	(21)
Chi-Square Goodness-of-Fit Test	393	(6)
Bartlett's Test for the Exponential Distribution	399	(1)
Mann's Test for the Weibull Distribution	400	(2)
Kolmogorov-Smirnov Test for Normal and Lognormal Distributions	402	(2)
Tests for the Power-Law Process Model	404	(3)
On Fitting Distributions	407	(6)
Exercises	408	(5)
PART 3 Application
Reliability Estimation and Application	413	(16)
Case 1: Redundancy	413	(2)
Case 2: Burn-In Testing	415	(3)
Case 3: Preventive Maintenance Analysis	418	(3)
Case 4: Reliability Allocation	421	(2)
Case 5: Reliability Growth Testing	423	(1)
Case 6: Repairable System Analysis	424	(2)
Case 7: Multiply Censored Data	426	(3)
Exercise	428	(1)
Implementation	429	(20)
Objectives, Functions, and Processes	429	(1)
The Economics of Reliability and Maintainability and System Design	430	(7)
Life-Cycle Cost Model
Minimal Repair
Organizational Considerations	437	(2)
Data Sources and Data Collection Methods	439	(6)
Field Data
Process Reliability and Operational Failures
External Data Sources
Product Liability, Warranties, and Related Matters	445	(2)
Software Reliability	447	(2)
References	449	(6)
Appendix	455	(24)
Index	479