Maintainability, Maintenance, And Reliability for Engineers

by Dhillon; B.S.

• ISBN13: 9780849372438
• ISBN10: 0849372437
• Edition: 1st
• Format: Hardcover
• Copyright: 2006-03-27
• Publisher: CRC Press

Summary

This book covers the topics of maintainability, maintenance, and reliability for the first time within a single source. It discusses mechanical and human reliability as well as reliability evaluation methods. It addresses various aspects of maintainability, including tools, specific maintainability design considerations, management, and costing, and explores human factors in maintainability, maintenance engineering objectives, corrective and preventive maintenance, and reliability centered maintenance. The author offers historical aspects, terms, definitions, and useful mathematical concepts while providing examples, solutions, and problems at the end of each chapter.

Author Biography

B. S. Dhillon is a professor of mechanical engineering at the University of Ottawa.

Table of Contents

Introduction	p. 1
Need for Maintainability, Maintenance, and Reliability	p. 1
History	p. 2
Maintainability	p. 2
Maintenance	p. 2
Reliability	p. 2
Maintainability, Maintenance, and Reliability Terms and Definitions	p. 3
Useful Information on Maintainability, Maintenance, and Reliability	p. 4
Journals and Magazines	p. 4
Books	p. 5
Data Information Sources	p. 5
Organizations	p. 6
Problems	p. 6
References	p. 7
Maintainability, Maintenance, and Reliability Mathematics	p. 9
Introduction	p. 9
Boolean Algebra Laws and Probability Properties	p. 9
Useful Definitions and Probability Distributions	p. 12
Probability	p. 12
Cumulative Distribution Function	p. 12
Probability Density Function	p. 13
Reliability Function	p. 13
Continuous Random Variable Expected Value	p. 13
Discrete Random Variable Expected Value	p. 13
Exponential Distribution	p. 13
Rayleigh Distribution	p. 14
Weibull Distribution	p. 15
Gamma Distribution	p. 15
Normal Distribution	p. 16
Lognormal Distribution	p. 16
Binomial Distribution	p. 17
Laplace Transforms and Their Applications to Differential Equations	p. 17
Laplace Transforms: Initial and Final Value Theorems	p. 18
Laplace Transform Application to Differential Equations	p. 19
Problems	p. 20
References	p. 21
Introduction to Engineering Reliability	p. 23
Need for Reliability	p. 23
Bathtub Hazard Rate Concept	p. 23
General Reliability Analysis Formulas	p. 25
Failure Density Function	p. 25
Hazard Rate Function	p. 25
General Reliability Function	p. 26
Mean Time to Failure	p. 27
Reliability Networks	p. 28
Series Network	p. 29
Parallel Network	p. 30
M-Out-of-N Network	p. 32
Standby System	p. 33
Bridge Network	p. 35
Reliability Allocation	p. 36
Hybrid Method	p. 37
Problems	p. 38
References	p. 38
Reliability Evaluation Tools	p. 41
Introduction	p. 41
Failure Modes and Effect Analysis (FMEA)	p. 41
Network Reduction Method	p. 42
Decomposition Method	p. 44
Delta-Star Method	p. 46
Markov Method	p. 49
Supplementary Variables Method	p. 51
Problems	p. 53
References	p. 54
Reliability Management	p. 55
Introduction	p. 55
General Management Reliability Program Responsibilities	p. 55
A Method for Establishing Reliability Goals and Guidelines for Developing Reliability Programs	p. 55
Reliability and Maintainability Management Tasks in System Life Cycle	p. 57
Concept and Definition Phase	p. 57
Acquisition Phase	p. 58
Operation and Maintenance Phase	p. 59
Disposal Phase	p. 59
Reliability Management Tools and Documents	p. 59
Configuration Management	p. 60
Value Engineering	p. 60
Critical Path Method	p. 60
Reliability Manual	p. 61
Reliability Department Functions and Tasks of Reliability Engineer	p. 61
Pitfalls in Reliability Program Management	p. 62
Problems	p. 63
References	p. 63
Mechanical and Human Reliability	p. 65
Introduction	p. 65
General Mechanical Failure Causes and Modes	p. 65
Safety Factors	p. 67
Safety Factor 1	p. 67
Safety Factor 2	p. 67
Safety Factor 3	p. 68
Stress-Strength Interference Theory Modeling	p. 68
Model 1	p. 69
Model 2	p. 70
Graphical Method for Estimating Mechanical Item's Reliability	p. 71
Human Error Occurrence Facts and Figures	p. 74
Human Error Categories and Causes	p. 75
Human Stress-Performance Effectiveness and Stress Factors	p. 76
Human Performance Reliability in Continuous Time and Mean Time to Human Error Measure	p. 77
Methods for Performing Human Reliability Analysis	p. 78
Fault Tree Analysis	p. 78
Markov Method	p. 81
Problems	p. 83
References	p. 83
Introduction to Engineering Maintainability	p. 87
Need for Maintainability	p. 87
Engineering Maintainability versus Engineering Maintenance	p. 87
Maintainability versus Reliability	p. 88
Maintainability Functions	p. 88
Maintainability Function for Exponential Distribution	p. 89
Maintainability Function for Rayleigh Distribution	p. 90
Maintainability Function for Weibull Distribution	p. 90
Maintainability Function for Gamma Distribution	p. 91
Maintainability Function for Erlangian Distribution	p. 92
Maintainability Function for Normal Distribution	p. 92
Maintainability Function for Lognormal Distribution	p. 93
Problems	p. 94
References	p. 94
Maintainability Tools and Specific Maintainability Design Considerations	p. 97
Introduction	p. 97
Fault Tree Analysis	p. 97
Cause and Effect Diagram	p. 101
Failure Modes, Effects, and Criticality Analysis (FMECA)	p. 101
Total Quality Management	p. 103
Maintainability Design Factors	p. 104
Standardization and Modularization	p. 105
Simplification and Accessibility	p. 107
Interchangeability and Identification	p. 107
Problems	p. 108
References	p. 109
Maintainability Management and Costing	p. 111
Introduction	p. 111
Maintainability Management Tasks during Product Life Cycle	p. 111
Maintainability Organization Functions	p. 113
Maintainability Program Plan	p. 114
Maintainability Design Reviews	p. 115
Maintainability Investment Cost Elements	p. 116
Life Cycle Costing	p. 116
Life Cycle Cost Estimation Models	p. 117
Life Cycle Cost Estimation Model 1	p. 118
Life Cycle Cost Estimation Model 2	p. 118
Life Cycle Cost Estimation Model 3	p. 119
Problems	p. 123
References	p. 124
Human Factors in Maintainability	p. 125
Introduction	p. 125
General Human Behaviors	p. 125
Human Sensory Capabilities and Body Measurements	p. 126
Touch	p. 126
Sight	p. 126
Hearing	p. 127
Body Measurements	p. 127
Auditory and Visual Warnings in Maintenance Work	p. 128
Human Factors-Related Formulas	p. 129
The Decibel	p. 130
Character Height Estimation Formulas	p. 130
Formula 1	p. 130
Formula 2	p. 131
Lifting Load Estimation	p. 131
Glare Constant Estimation	p. 132
Problems	p. 132
References	p. 132
Introduction to Engineering Maintenance	p. 135
Need for Maintenance	p. 135
Facts and Figures Related to Engineering Maintenance	p. 135
Maintenance Engineering Objectives	p. 136
Maintenance-Related Data Information Sources	p. 136
Maintenance Measures	p. 136
Index 1	p. 137
Index 2	p. 137
Index 3	p. 137
Index 4	p. 138
Index 5	p. 138
Index 6	p. 138
Index 7	p. 138
Index 8	p. 139
Index 9	p. 139
Safety in Maintenance	p. 139
Quality in Maintenance	p. 140
Problems	p. 141
References	p. 141
Corrective and Preventive Maintenance	p. 143
Introduction	p. 143
Types of Corrective Maintenance	p. 143
Corrective Maintenance Steps, Downtime Components, and Time-Reduction Strategies at System Level	p. 144
Corrective Maintenance Measures	p. 145
Mean Corrective Maintenance Time	p. 145
Median Active Corrective Maintenance Time	p. 146
Mathematical Models for Performing Corrective Maintenance	p. 146
Mathematical Model 1	p. 146
Mathematical Model II	p. 149
Preventive Maintenance Components and Principle for Choosing Items for Preventive Maintenance	p. 152
Steps for Developing Preventive Maintenance Program	p. 152
Preventive Maintenance Measures	p. 153
Mean Preventive Maintenance Time	p. 153
Median Preventive Maintenance Time	p. 154
Mathematical Models for Performing Preventive Maintenance	p. 154
Model 1	p. 154
Model 2	p. 155
Preventive Maintenance Benefits and Drawbacks	p. 158
Problems	p. 158
References	p. 159
Reliability-Centered Maintenance	p. 161
Introduction	p. 161
RCM Goals and Principles	p. 161
RCM Process-Associated Questions and RCM Process	p. 163
Key RCM Program Elements	p. 164
Reactive Maintenance	p. 164
Predictive Testing and Inspection	p. 165
Proactive Maintenance	p. 166
Preventive Maintenance	p. 166
Determining Preventive Maintenance Tasks and Monitoring Periodicities	p. 167
RCM Program Measures	p. 167
Index 1	p. 168
Index 2	p. 168
Index 3	p. 168
Index 4	p. 169
Index 5	p. 169
RCM Benefits and Causes for RCM Methodology Failures	p. 169
Problems	p. 170
References	p. 170
Maintenance Management and Costing	p. 173
Introduction	p. 173
Maintenance Management Principles	p. 173
Maintenance Department Organization and Functions	p. 174
Effective Maintenance Management Elements	p. 175
Questions for Evaluating Maintenance Program Effectiveness	p. 177
Maintenance Costing Reasons and Maintenance Cost Influences	p. 178
Cost Data Collection and Sources	p. 179
Maintenance Labor Cost Estimation Models	p. 179
Corrective-Maintenance Labor Cost Estimation Model	p. 179
Total Maintenance Labor Cost Estimation Model	p. 180
Maintenance Cost Estimation Models for Specific Equipment or Facility	p. 181
Model 1	p. 181
Model 2	p. 181
Model 3	p. 181
Problems	p. 182
References	p. 182
Human Error in Engineering Maintenance	p. 185
Introduction	p. 185
Maintenance Error-Related Facts and Figures	p. 185
Reasons for Human Error in Maintenance	p. 186
Major Human Failures in Maintenance and Classifications of Maintenance Errors and Their Occurrence Frequency	p. 187
Human Error in Maintenance Prediction Models	p. 188
Model 1	p. 188
Model 2	p. 190
Useful Guidelines for Reducing Maintenance Errors	p. 193
Design	p. 193
Tools and Equipment	p. 194
Towing Aircraft	p. 194
Procedures	p. 194
Training	p. 194
Human Error Risk Management	p. 194
Maintenance Incident Feedback	p. 194
Supervision	p. 195
Communication	p. 195
Shift Handover	p. 195
Problems	p. 195
References	p. 196
Software Maintenance, Robotic Maintenance, and Medical Equipment Maintenance	p. 197
Introduction	p. 197
Software Maintenance Facts and Figures	p. 197
Software Maintenance Types	p. 198
Software Maintenance Tools and Guidelines for Reducing Software Maintenance	p. 198
Impact Analysis	p. 198
Software Configuration Management	p. 198
Software Maintenance Cost Estimation Models	p. 199
Model 1	p. 200
Model 2	p. 200
Robot Maintenance Requirements and Types	p. 202
Robot Parts and Tools for maintenance and Repair	p. 203
Robot Inspection	p. 203
Guidelines for Safeguarding Robot Maintenance Personnel	p. 204
Model for Maximizing Income of Robot Subject to Repair	p. 205
Medical Equipment Classification and Indexes for Maintenance and Repair	p. 207
Index 1	p. 208
Index 2	p. 208
Index 3	p. 208
Computerized Maintenance Management System for Medical Equipment and Its Selection	p. 209
Models for Medical Equipment Maintenance	p. 209
Model 1	p. 210
Model 2	p. 211
Problems	p. 212
References	p. 212
Index	p. 215
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