Series Editor's Foreword by Dr Andre Kleyner |
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xix | |
Preface |
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xxi | |
Acknowledgments |
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xxiii | |
Introduction: What You Will Learn |
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xxv | |
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1 Design For Maintainability Paradigms |
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1 | (12) |
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1.1 Why Design for Maintainability? |
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1 | (1) |
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1 | (1) |
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1.1.2 What is Maintainability? |
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1 | (1) |
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1.1.3 What is Testability? |
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2 | (1) |
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1.2 Maintainability Factors for Design Consideration |
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2 | (3) |
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1.2.1 Part Standardization |
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3 | (1) |
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1.2.2 Structure Modularization |
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3 | (1) |
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3 | (1) |
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1.2.4 Part Interchangeability |
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3 | (1) |
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1.2.5 Human Accessibility |
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4 | (1) |
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4 | (1) |
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4 | (1) |
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1.2.8 Part Identification |
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5 | (1) |
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1.3 Reflections on the Current State of the Art |
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5 | (1) |
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1.4 Paradigms for Design for Maintainability |
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6 | (4) |
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1.4.1 Maintainability is Inversely Proportional to Reliability |
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7 | (1) |
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1.4.2 Maintainability is Directly Proportional to Testability and Prognostics and Health Monitoring |
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7 | (1) |
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1.4.3 Strive for Ambiguity Groups No Greater Than 3 |
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7 | (1) |
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1.4.4 Migrate from Scheduled Maintenance to Condition-based Maintenance |
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8 | (1) |
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1.4.5 Consider the Human as the Maintainer |
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8 | (1) |
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1.4.6 Modularity Speeds Repairs |
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8 | (1) |
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1.4.7 Maintainability Predicts Downtime During Repairs |
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8 | (1) |
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1.4.8 Understand the Maintenance Requirements |
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9 | (1) |
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1.4.9 Support Maintainability with Data |
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9 | (1) |
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10 | (1) |
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11 | (2) |
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2 History Of Maintainability |
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13 | (16) |
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13 | (1) |
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13 | (1) |
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2.3 The Difference Between Maintainability and Maintenance Engineering |
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14 | (1) |
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2.4 Early Maintainability References |
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15 | (2) |
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2.4.1 The First Maintainability Standards |
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15 | (1) |
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2.4.2 Introduction to MIL-STD-470 |
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16 | (1) |
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2.5 Original Maintainability Program Roadmap |
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17 | (4) |
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2.5.1 Task 1: The Maintainability Program Plan |
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17 | (1) |
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2.5.2 Task 2: Maintainability Analysis |
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17 | (1) |
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2.5.3 Task 3: Maintenance Inputs |
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18 | (1) |
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2.5.4 Task 4: Maintainability Design Criteria |
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18 | (1) |
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2.5.5 Task 5: Maintainability Trade Studies |
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19 | (1) |
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2.5.6 Task 6: Maintainability Predictions |
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19 | (1) |
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2.5.7 Task 7: Vendor Controls |
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19 | (1) |
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2.5.8 Task 8: Integration |
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19 | (1) |
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2.5.9 Task 9: Maintainability Design Reviews |
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20 | (1) |
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2.5.10 Task 10: Maintainability Data System |
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21 | (1) |
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2.5.11 Task 11: Maintainability Demonstration |
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21 | (1) |
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2.5.12 Task 12: Maintainability Status Reports |
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21 | (1) |
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2.6 Maintainability Evolution Over the Time Period 1966 to 1978 |
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21 | (1) |
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2.7 Improvements During the Period 1978 to 1997 |
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22 | (1) |
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2.8 Introduction of Testability |
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23 | (1) |
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2.9 Introduction of Artificial Intelligence |
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24 | (1) |
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2.10 Introduction to MIL-HDBK-470A |
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24 | (2) |
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26 | (1) |
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26 | (3) |
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3 Maintainability Program Planning And Management |
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29 | (26) |
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29 | (1) |
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3.2 System/Product Life Cycle |
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29 | (4) |
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3.3 Opportunities to Influence Design |
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33 | (4) |
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33 | (1) |
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33 | (3) |
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36 | (1) |
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3.4 Maintainability Program Planning |
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37 | (5) |
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3.4.1 Typical Maintainability Engineering Tasks |
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38 | (1) |
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3.4.2 Typical Maintainability Program Plan Outline |
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38 | (4) |
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3.5 Interfaces with Other Functions |
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42 | (2) |
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3.6 Managing Vendor/Subcontractor Maintainability Efforts |
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44 | (1) |
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45 | (2) |
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47 | (3) |
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3.9 Maintenance and Life Cycle Cost (LCC) |
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50 | (2) |
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52 | (1) |
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53 | (1) |
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54 | (1) |
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Suggestions for Additional Reading |
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54 | (1) |
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55 | (24) |
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55 | (2) |
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4.2 Developing the Maintenance Concept |
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57 | (12) |
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4.2.1 Maintainability Requirements |
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60 | (1) |
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4.2.2 Categories of Maintenance |
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61 | (1) |
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4.2.2.1 Scheduled Maintenance |
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61 | (2) |
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4.2.2.2 Unscheduled Maintenance |
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63 | (6) |
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4.3 Levels of Maintenance |
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69 | (1) |
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70 | (6) |
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71 | (1) |
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4.4.2 Design Considerations for Improved Logistics Support |
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71 | (1) |
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71 | (1) |
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72 | (1) |
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4.4.2.3 Test/Support Equipment -- Common and Special |
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72 | (1) |
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72 | (1) |
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73 | (1) |
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73 | (2) |
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4.4.2.7 Spares Provisioning |
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75 | (1) |
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75 | (1) |
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76 | (1) |
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77 | (1) |
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Suggestions for Additional Reading |
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77 | (2) |
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5 Maintainability Requirements And Design Criteria |
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79 | (18) |
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79 | (1) |
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5.2 Maintainability Requirements |
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79 | (2) |
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5.2.1 Different Maintainability Requirements for Different Markets |
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81 | (1) |
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5.3 The Systems Engineering Approach |
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81 | (3) |
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5.3.1 Requirements Analysis |
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82 | (1) |
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5.3.1.1 Types of Requirements |
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82 | (1) |
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5.3.1.2 Good Requirements |
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83 | (1) |
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5.3.2 System Design Evaluation |
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84 | (1) |
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5.3.3 Maintainability in the Systems Engineering Process |
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84 | (1) |
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5.4 Developing Maintainability Requirements |
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84 | (6) |
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5.4.1 Denning Quantitative Maintainability Requirements |
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85 | (2) |
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5.4.2 Quantitative Preventive Maintainability Requirements |
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87 | (1) |
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5.4.3 Quantitative Corrective Maintainability Requirements |
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88 | (2) |
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5.4.4 Denning Qualitative Maintainability Requirements |
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90 | (1) |
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5.5 Maintainability Design Goals |
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90 | (1) |
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5.6 Maintainability Guidelines |
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91 | (1) |
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5.7 Maintainability Design Criteria |
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91 | (2) |
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5.8 Maintainability Design Checklists |
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93 | (1) |
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5.9 Design Criteria that Provide or Improve Maintainability |
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94 | (1) |
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95 | (1) |
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95 | (1) |
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Suggestions for Additional Reading |
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96 | (1) |
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Additional Sources of Checklists |
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96 | (1) |
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6 Maintainability Analysis And Modeling |
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97 | (22) |
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97 | (1) |
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98 | (2) |
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6.2.1 Constructing a Functional Block Diagram |
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99 | (1) |
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6.2.2 Using a Functional Block Diagram |
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100 | (1) |
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6.3 Maintainability Analysis |
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100 | (1) |
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6.3.1 Objectives of Maintainability Analyses |
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101 | (1) |
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6.3.2 Typical Products of Maintainability Analyses |
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101 | (1) |
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6.4 Commonly Used Maintainability Analyses |
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101 | (16) |
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6.4.1 Equipment Downtime Analysis |
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102 | (1) |
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6.4.2 Maintainability Design Evaluation |
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102 | (1) |
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6.4.3 Testability Analysis |
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102 | (1) |
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6.4.4 Human Factors Analysis |
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102 | (1) |
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6.4.5 Maintainability Allocations |
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103 | (1) |
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6.4.5.1 Failure Rate Complexity Method |
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104 | (1) |
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6.4.5.2 Variation of the Failure Rate Complexity Method |
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104 | (1) |
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6.4.5.3 Statistically-based Allocation Method |
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104 | (2) |
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6.4.5.4 Equal Distribution Method |
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106 | (1) |
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6.4.6 Maintainability Design Trade Study |
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106 | (2) |
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6.4.7 Maintainability Models and Modeling |
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108 | (1) |
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6.4.7.1 Poisson Distribution in Maintainability Models |
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108 | (2) |
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6.4.8 Failure Modes, Effects, and Criticality Analysis - Maintenance Actions (FMECA-MA) |
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110 | (1) |
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6.4.9 Maintenance Activities Block Diagrams |
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110 | (2) |
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6.4.10 Maintainability Prediction |
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112 | (1) |
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6.4.11 Maintenance Task Analysis (MTA) |
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112 | (1) |
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6.4.12 Level of Repair Analysis (LORA) |
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113 | (1) |
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6.4.12.1 Performing a Level of Repair Analysis |
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114 | (2) |
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6.4.12.2 Managing LORA Data |
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116 | (1) |
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6.4.12.3 Level of Repair Analysis Outcomes |
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117 | (1) |
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117 | (1) |
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117 | (1) |
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Suggestion for Additional Reading |
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118 | (1) |
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7 Maintainability Predictions And Task Analysis |
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119 | (22) |
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119 | (1) |
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7.2 Maintainability Prediction Standard |
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119 | (1) |
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7.3 Maintainability Prediction Techniques |
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120 | (7) |
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7.3.1 Maintainability Prediction Procedure I |
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121 | (1) |
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7.3.1.1 Preparation Activities |
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121 | (1) |
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7.3.1.2 Failure Verification Activities |
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121 | (1) |
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7.3.1.3 Failure Location Activities |
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122 | (1) |
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7.3.1.4 Part Procurement Activities |
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122 | (1) |
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7.3.1.5 Repair Activities |
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122 | (1) |
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7.3.1.6 Final Test Activities |
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123 | (1) |
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7.3.1.7 Probability Distributions |
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123 | (1) |
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7.3.2 Maintainability Prediction Procedure II |
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123 | (1) |
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7.3.2.1 Use of Maintainability Predictions for Corrective Maintenance |
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123 | (1) |
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7.3.2.2 Use of Maintainability Predictions for Preventive Maintenance |
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124 | (1) |
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7.3.2.3 Use of Maintainability Predictions for Active Maintenance |
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124 | (1) |
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7.3.3 Maintainability Prediction Procedure III |
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124 | (1) |
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7.3.4 Maintainability Prediction Procedure IV |
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125 | (2) |
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7.3.5 Maintainability Prediction Procedure V |
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127 | (1) |
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7.4 Maintainability Prediction Results |
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127 | (2) |
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7.5 Bayesian Methodologies |
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129 | (1) |
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7.5.1 Definition of Bayesian Terms |
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130 | (1) |
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130 | (1) |
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7.6 Maintenance Task Analysis |
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130 | (9) |
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7.6.1 Maintenance Task Analysis Process and Worksheets |
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132 | (2) |
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7.6.2 Completing a Maintenance Task Analysis Sheet |
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134 | (1) |
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7.6.3 Personnel and Skill Data Entry |
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134 | (1) |
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7.6.4 Spare Parts, Supply Chain, and Inventory Management Data Entry |
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135 | (2) |
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7.6.5 Test and Support Equipment Data Entry |
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137 | (1) |
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7.6.6 Facility Requirements Data Entry |
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137 | (1) |
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7.6.7 Maintenance Manuals |
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138 | (1) |
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138 | (1) |
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139 | (1) |
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139 | (2) |
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8 Design For Machine Learning |
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141 | (16) |
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141 | (1) |
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8.2 Artificial Intelligence in Maintenance |
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142 | (2) |
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8.3 Model-based Reasoning |
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144 | (1) |
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145 | (1) |
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145 | (1) |
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145 | (1) |
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8.4 Machine Learning Process |
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145 | (7) |
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8.4.1 Supervised and Unsupervised Learning |
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147 | (1) |
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148 | (1) |
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8.4.3 Function Approximations |
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149 | (1) |
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8.4.4 Pattern Determination |
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150 | (1) |
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8.4.5 Machine Learning Classifiers |
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150 | (1) |
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8.4.6 Feature Selection and Extraction |
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151 | (1) |
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152 | (1) |
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8.5.1 Known and Unknown Anomalies |
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152 | (1) |
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8.6 Value-added Benefits of ML |
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153 | (1) |
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8.7 Digital Prescriptive Maintenance (DPM) |
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154 | (1) |
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154 | (1) |
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155 | (1) |
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155 | (2) |
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9 Condition-Based Maintenance And Design For Reduced Staffing |
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157 | (26) |
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157 | (1) |
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9.2 What is Condition-based Maintenance? |
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158 | (1) |
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9.2.1 Types of Condition-based Maintenance |
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158 | (1) |
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9.3 Condition-based Maintenance vs. Time-based Maintenance |
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159 | (4) |
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9.3.1 Time-based Maintenance |
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159 | (1) |
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9.3.2 Types of Time-based Maintenance |
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159 | (1) |
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9.3.3 Calculating Time-based Maintenance Intervals |
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160 | (1) |
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160 | (2) |
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9.3.5 Calculating Condition-based Maintenance Intervals |
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162 | (1) |
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9.4 Reduced Staffing Through CBM and Efficient TBM |
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163 | (1) |
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9.5 Integrated System Health Management |
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164 | (1) |
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165 | (5) |
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9.6.1 Essential Elements of CBM+ |
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170 | (1) |
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9.7 Digital Prescriptive Maintenance |
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170 | (2) |
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9.8 Reliability-centered Maintenance |
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172 | (8) |
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172 | (1) |
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173 | (1) |
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174 | (1) |
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9.8.4 What we Learned from RCM |
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174 | (1) |
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175 | (2) |
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9.8.5 Applying RCM in Your Organization |
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177 | (1) |
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9.8.5.1 Inner Workings of RCM |
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177 | (3) |
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180 | (1) |
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181 | (1) |
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Suggestion for Additional Reading |
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181 | (2) |
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10 Safety And Human Factors Considerations In Maintainable Design |
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183 | (24) |
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183 | (1) |
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10.2 Safety in Maintainable Design |
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183 | (12) |
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10.2.1 Safety and its Relationship to Maintainability |
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184 | (1) |
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10.2.2 Safety Design Criteria |
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184 | (3) |
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10.2.3 Overview of System Safety Engineering |
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187 | (1) |
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10.2.4 Risk Assessment and Risk Management |
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187 | (1) |
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188 | (1) |
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188 | (1) |
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189 | (1) |
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10.2.5 System Safety Analysis |
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190 | (1) |
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10.2.5.1 Operating and Support Hazard Analysis |
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191 | (2) |
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10.2.5.2 Health Hazard Analysis |
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193 | (2) |
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10.3 Human Factors in Maintainable Design |
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195 | (10) |
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10.3.1 Human Factors Engineering and its Relationship to Maintainability |
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195 | (1) |
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10.3.2 Human Systems Integration |
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196 | (1) |
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10.3.3 Human Factors Design Criteria |
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196 | (2) |
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10.3.4 Human Factors Engineering Analysis |
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198 | (1) |
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10.3.5 Maintainability Anthropometric Analysis |
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199 | (6) |
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205 | (1) |
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206 | (1) |
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Suggestion for Additional Reading |
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206 | (1) |
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11 Design For Software Maintainability |
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207 | (14) |
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207 | (1) |
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11.2 What is Software Maintainability? |
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208 | (1) |
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208 | (1) |
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11.4 Impact of Maintainability on Software Design |
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209 | (1) |
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11.5 How to Design Software that is Fault-tolerant and Requires Zero Maintenance |
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210 | (2) |
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11.6 How to Design Software that is Self-aware of its Need for Maintenance |
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212 | (1) |
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11.7 How to Develop Maintainable Software that was Not Designed for Maintainability at the Start |
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213 | (1) |
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11.8 Software Field Support and Maintenance |
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214 | (2) |
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11.8.1 Software Maintenance Process Implementation |
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214 | (1) |
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11.8.2 Software Problem Identification and Software Modification Analysis |
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215 | (1) |
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11.8.3 Software Modification Implementation |
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215 | (1) |
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11.8.4 Software Maintenance Review and Acceptance |
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215 | (1) |
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11.8.5 Software Migration |
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215 | (1) |
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11.8.6 Software Retirement |
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215 | (1) |
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11.8.7 Software Maintenance Maturity Model |
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216 | (1) |
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11.9 Software Changes and Configuration Management |
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216 | (1) |
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217 | (1) |
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218 | (1) |
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218 | (3) |
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12 Maintainability Testing And Demonstration |
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221 | (24) |
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221 | (1) |
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222 | (2) |
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224 | (12) |
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225 | (1) |
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12.3.2 Modeling or Simulation |
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225 | (2) |
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12.3.3 Analysis of the Design |
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227 | (1) |
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12.3.4 In-process Testing |
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227 | (1) |
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12.3.5 Formal Design Reviews |
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228 | (1) |
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12.3.6 Maintainability Demonstration (M-Demo) |
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228 | (1) |
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12.3.6.1 M-Demo Test Plan |
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229 | (1) |
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12.3.6.2 M-Demo Maintenance Task Sample Selection |
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230 | (3) |
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12.3.6.3 M-Demo Test Report |
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233 | (1) |
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12.3.6.4 AN/UGC-144 M-Demo Example |
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234 | (2) |
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12.3.7 Operational Maintainability Testing |
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236 | (1) |
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236 | (5) |
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241 | (1) |
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242 | (1) |
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Suggestions for Additional Reading |
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243 | (2) |
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13 Design For Test And Testability |
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245 | (20) |
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245 | (1) |
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13.2 What is Testability? |
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245 | (2) |
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13.3 DfT Considerations for Electronic Test at All Levels |
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247 | (3) |
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13.3.1 What is Electronic Test? |
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247 | (1) |
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13.3.2 Test Coverage and Effectiveness |
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248 | (1) |
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13.3.3 Accessibility Design Criteria Related to Testability |
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249 | (1) |
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13.4 DfT at System or Product Level |
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250 | (1) |
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13.4.1 Power-On Self-Test and On-Line Testing |
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251 | (1) |
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13.5 DfT at Electronic Circuit Board Level |
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251 | (2) |
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13.6 DfT at Electronic Component Level |
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253 | (8) |
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13.6.1 System in Package/Multi-chip Package Test and DfT Techniques |
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253 | (2) |
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13.6.2 VLSI and DfT Techniques |
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255 | (1) |
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13.6.3 Logic Test and Design For Test |
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255 | (1) |
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13.6.4 Memory Test and Design for Test |
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256 | (3) |
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13.6.5 Analog and Mixed-Signal Test and DfT |
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259 | (1) |
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13.6.6 Design and Test Tradeoffs |
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260 | (1) |
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13.7 Leveraging DfT for Maintainability and Sustainment |
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261 | (1) |
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13.7.1 Built-In-Test/Built-In Self-Test |
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261 | (1) |
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13.8 BITE and External Support Equipment |
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262 | (1) |
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262 | (1) |
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262 | (1) |
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Suggestions for Additional Reading |
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263 | (2) |
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265 | (16) |
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265 | (1) |
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14.2 Reliability Analysis and Modeling |
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266 | (1) |
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14.3 Reliability Block Diagrams |
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266 | (2) |
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14.4 Reliability Allocation |
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268 | (1) |
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14.5 Reliability Mathematical Model |
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269 | (1) |
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14.6 Reliability Prediction |
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269 | (1) |
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270 | (6) |
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14.7.1 What is a Fault Tree? |
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270 | (1) |
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271 | (1) |
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271 | (1) |
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271 | (2) |
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273 | (3) |
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14.7.6 Quantitative Analysis of Fault Trees |
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276 | (1) |
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14.7.7 Advantages and Disadvantages |
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276 | (1) |
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14.8 Failure Modes, Effects, and Criticality Analysis |
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276 | (3) |
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14.9 Complementary Reliability Analyses and Models |
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279 | (1) |
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279 | (1) |
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280 | (1) |
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Suggestions for Additional Reading |
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280 | (1) |
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15 Design For Availability |
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281 | (22) |
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281 | (1) |
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15.2 What is Availability? |
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281 | (2) |
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15.3 Concepts of Availability |
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283 | (6) |
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15.3.1 Elements of Availability |
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285 | (1) |
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15.3.1.1 Time-related Elements |
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286 | (1) |
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287 | (2) |
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15.4 Types of Availability |
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289 | (5) |
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15.4.1 Inherent Availability |
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289 | (1) |
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15.4.2 Achieved Availability |
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290 | (1) |
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15.4.3 Operational Availability |
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291 | (1) |
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291 | (1) |
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292 | (1) |
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292 | (1) |
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293 | (1) |
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15.5 Availability Prediction |
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294 | (6) |
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15.5.1 Data for Availability Prediction |
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295 | (1) |
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15.5.2 Calculating Availability |
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296 | (2) |
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15.5.3 Steps to Availability Prediction |
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298 | (1) |
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15.5.3.1 Define the Problem |
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299 | (1) |
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15.5.3.2 Define the System |
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299 | (1) |
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15.5.3.3 Collect the Data |
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299 | (1) |
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299 | (1) |
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15.5.3.5 Verify the Model |
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299 | (1) |
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15.5.3.6 Design the Simulation |
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299 | (1) |
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15.5.3.7 Run the Simulation |
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300 | (1) |
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15.5.3.8 Document and Use the Results |
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300 | (1) |
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300 | (1) |
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301 | (2) |
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16 Design For Supportability |
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303 | (20) |
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303 | (1) |
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16.2 Elements of Supportability |
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304 | (15) |
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16.2.1 Product Support Management |
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305 | (1) |
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306 | (1) |
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16.2.3 Sustaining Engineering |
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307 | (1) |
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308 | (1) |
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16.2.5 Maintenance Planning and Management |
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309 | (2) |
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16.2.6 Packaging, Handling, Storage, and Transportation (PHS&T) |
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311 | (1) |
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312 | (3) |
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315 | (1) |
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16.2.9 Training and Training Support |
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315 | (1) |
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16.2.10 Manpower and Personnel |
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316 | (1) |
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16.2.11 Facilities and Infrastructure |
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317 | (1) |
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16.2.12 Computer Resources |
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318 | (1) |
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16.3 Supportability Program Planning |
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319 | (2) |
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16.3.1 Supportability Analysis |
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319 | (2) |
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16.4 Supportability Tasks and the ILS Plan |
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|
321 | (1) |
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322 | (1) |
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322 | (1) |
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Suggestion for Additional Reading |
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322 | (1) |
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|
323 | (16) |
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323 | (1) |
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17.2 Reducing Active Maintenance Time with Single Minute Exchange of Dies (SMED) |
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|
323 | (7) |
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17.2.1 Incorporating Lean Methods into PM Optimization |
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|
325 | (1) |
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17.2.1.1 Understanding Waste |
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|
325 | (1) |
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17.2.1.2 Apply Lean Techniques to Eliminate Waste |
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|
326 | (3) |
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17.2.1.3 Continually Improve the PM Routine |
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329 | (1) |
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330 | (1) |
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17.3 How to use Big Data to Enable Predictive Maintenance |
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|
330 | (4) |
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331 | (1) |
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17.3.2 Predicting the Future |
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|
332 | (1) |
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333 | (1) |
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17.4 Self-correcting Circuits and Self-healing Materials for Improved Maintainability, Reliability, and Safety |
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|
334 | (3) |
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17.4.1 Self-correcting Circuits |
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|
334 | (1) |
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17.4.2 Self-healing Materials |
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|
335 | (1) |
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336 | (1) |
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17.5 Conclusion and Challenge |
|
|
337 | (1) |
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|
337 | (1) |
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Suggestions for Additional Reading |
|
|
338 | (1) |
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Appendix A System Maintainability Design Verification Checklist |
|
|
339 | (14) |
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|
339 | (1) |
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|
339 | (14) |
Index |
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353 | |