Reliability Engineering
Wiley Series in Systems Engineering and Management (Series Nr. 1)
1. Edition May 2014
512 Pages, Hardcover
Wiley & Sons Ltd
Short Description
Using the authors' extensive experience in both industry and academia, this book presents an integrated approach for design, engineering and management of the reliability activities throughout the life cycle of a product which includes concept, research and development, design, manufacturing, assembly, sales and service. The coverage explains how to integrate reliability methods and techniques in the Six Sigma Process and Design for Six Sigma. It also discusses relationships between warranty and reliability, as well as legal and liability issues. This useful guide teaches readers how to effectively distribute key reliability practices throughout an organization.
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.
1 Reliability Engineering in the Twenty-First Century 1
1.1 What Is Quality? 1
1.2 What Is Reliability? 2
1.3 Quality, Customer Satisfaction, and System Effectiveness 6
1.4 Performance, Quality, and Reliability 7
1.5 Reliability and the System Life Cycle 8
1.6 Consequences of Failure 12
1.7 Suppliers and Customers 16
1.8 Summary 16
Problems 17
2 Reliability Concepts 19
2.1 Basic Reliability Concepts 19
2.2 Hazard Rate 26
2.3 Percentiles Product Life 33
2.4 Moments of Time to Failure 35
2.5 Summary 39
Problems 40
3 Probability and Life Distributions for Reliability Analysis 45
3.1 Discrete Distributions 45
3.2 Continuous Distributions 51
3.3 Probability Plots 77
3.4 Summary 83
Problems 84
4 Design for Six Sigma 89
4.1 What Is Six Sigma? 89
4.2 Why Six Sigma? 90
4.3 How Is Six Sigma Implemented? 91
4.4 Optimization Problems in the Six Sigma Process 98
4.5 Design for Six Sigma 103
4.6 Summary 108
Problems 108
5 Product Development 111
5.1 Product Requirements and Constraints 112
5.2 Product Life Cycle Conditions 113
5.3 Reliability Capability 114
5.4 Parts and Materials Selection 114
5.5 Human Factors and Reliability 115
5.6 Deductive versus Inductive Methods 117
5.7 Failure Modes, Effects, and Criticality Analysis 117
5.8 Fault Tree Analysis 119
5.9 Physics of Failure 128
5.10 Design Review 131
5.11 Qualification 132
5.12 Manufacture and Assembly 134
5.13 Analysis, Product Failure, and Root Causes 137
5.14 Summary 138
Problems 138
6 Product Requirements and Constraints 141
6.1 Defi ning Requirements 141
6.2 Responsibilities of the Supply Chain 142
6.3 The Requirements Document 144
6.4 Specifi cations 144
6.5 Requirements Tracking 146
6.6 Summary 147
Problems 147
7 Life-Cycle Conditions 149
7.1 Defining the Life-Cycle Profile 149
7.2 Life-Cycle Events 150
7.3 Loads and Their Effects 152
7.4 Considerations and Recommendations for LCP Development 160
7.5 Methods for Estimating Life-Cycle Loads 165
7.6 Summary 166
Problems 167
8 Reliability Capability 169
8.1 Capability Maturity Models 169
8.2 Key Reliability Practices 170
8.3 Summary 175
Problems 175
9 Parts Selection and Management 177
9.1 Part Assessment Process 177
9.2 Parts Management 185
9.3 Risk Management 188
9.4 Summary 190
Problems 191
10 Failure Modes, Mechanisms, and Effects Analysis 193
10.1 Development of FMMEA 193
10.2 Failure Modes, Mechanisms, and Effects Analysis 195
10.3 Case Study 201
10.4 Summary 205
Problems 206
11 Probabilistic Design for Reliability and the Factor of Safety 207
11.1 Design for Reliability 207
11.2 Design of a Tension Element 208
11.3 Reliability Models for Probabilistic Design 209
11.4 Example of Probabilistic Design and Design for a Reliability Target 211
11.5 Relationship between Reliability, Factor of Safety, and Variability 212
11.6 Functions of Random Variables 215
11.7 Steps for Probabilistic Design 219
11.8 Summary 219
Problems 220
12 Derating and Uprating 223
12.1 Part Ratings 223
12.2 Derating 225
12.3 Uprating 239
12.4 Summary 245
Problems 246
13 Reliability Estimation Techniques 247
13.1 Tests during the Product Life Cycle 247
13.2 Reliability Estimation 249
13.3 Product Qualifi cation and Testing 250
13.4 Case Study: System-in-Package Drop Test Qualifi cation 263
13.5 Basic Statistical Concepts 276
13.6 Confi dence Interval for Normal Distribution 279
13.7 Confidence Intervals for Proportions 282
13.8 Reliability Estimation and Confidence Limits for Success-Failure Testing 283
13.9 Reliability Estimation and Confidence Limits for Exponential Distribution 287
13.10 Summary 292
Problems 292
14 Process Control and Process Capability 295
14.1 Process Control System 295
14.2 Control Charts 299
14.3 Benefi ts of Control Charts 316
14.4 Average Outgoing Quality 317
14.5 Advanced Control Charts 323
14.6 Summary 325
Problems 326
15 Product Screening and Burn-In Strategies 331
15.1 Burn-In Data Observations 332
15.2 Discussion of Burn-In Data 333
15.3 Higher Field Reliability without Screening 334
15.4 Best Practices 335
15.5 Summary 336
Problems 337
16 Analyzing Product Failures and Root Causes 339
16.1 Root-Cause Analysis Processes 341
16.2 No-Fault-Found 351
16.3 Summary 373
Problems 374
17 System Reliability Modeling 375
17.1 Reliability Block Diagram 375
17.2 Series System 376
17.3 Products with Redundancy 381
17.4 Complex System Reliability 393
17.5 Summary 401
Problems 402
18 Health Monitoring and Prognostics 409
18.1 Conceptual Model for Prognostics 410
18.2 Reliability and Prognostics 412
18.3 PHM for Electronics 414
18.4 PHM Concepts and Methods 417
18.5 Monitoring and Reasoning of Failure Precursors 420
18.6 Implementation of PHM in a System of Systems 429
18.7 Summary 431
Problems 431
19 Warranty Analysis 433
19.1 Product Warranties 434
19.2 Warranty Return Information 435
19.3 Warranty Policies 436
19.4 Warranty and Reliability 437
19.5 Warranty Cost Analysis 439
19.6 Warranty and Reliability Management 448
19.7 Summary 449
Problems 449
Appendix A: Some Useful Integrals 451
Appendix B: Table for Gamma Function 453
Appendix C: Table for Cumulative Standard Normal Distribution 455
Appendix D: Values for the Percentage Points talpha,nu of the t-Distribution 457
Appendix E: Percentage Points chi2alpha ,nu of the Chi-Square Distribution 461
Appendix F: Percentage Points for the F-Distribution 467
Bibliography 473
Index 487
MICHAEL PECHT, PHD, is the founder of CALCE (Center for Advanced Life Cycle Engineering) at the University of Maryland, which is funded by over 150 of the world's leading electronics companies. He is also a Chair Professor in Mechanical Engineering and a Professor in Applied Mathematics at the University of Maryland. He consults for twenty-two major international electronics companies.
