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Product Reliability, Maintainability, and Supportability Handbook 2nd edition [Hardback]

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  • Formāts: Hardback, 480 pages, height x width: 234x156 mm, weight: 839 g, 70 Tables, black and white; 149 Illustrations, black and white
  • Izdošanas datums: 16-Apr-2009
  • Izdevniecība: CRC Press Inc
  • ISBN-10: 0849398797
  • ISBN-13: 9780849398797
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Product Reliability, Maintainability, and Supportability Handbook 2nd editionPalielināt
  • Formāts: Hardback, 480 pages, height x width: 234x156 mm, weight: 839 g, 70 Tables, black and white; 149 Illustrations, black and white
  • Izdošanas datums: 16-Apr-2009
  • Izdevniecība: CRC Press Inc
  • ISBN-10: 0849398797
  • ISBN-13: 9780849398797
Citas grāmatas par šo tēmu:
Permanent link: https://www.kriso.lv/db/9780849398797.html
Keywords:
Electrical and other types of engineers explain the processes for designing reliability into a product during the development stage. Their topics include reliability concepts, confidence intervals, software reliability, system reliability modeling, the reliability of redundant and fault-tolerant products, continuous reliability improvement, product effectiveness and cost analysis, and process capability and process control. They write for colleagues seeking practical information about reliability, and for students of engineering. Annotation ©2009 Book News, Inc., Portland, OR (booknews.com)

To ensure product reliability, an organization must follow specific practices during the product development process that impact reliability. The second edition of the bestselling Product Reliability, Maintainability, and Supportability Handbook helps professionals identify the shortcomings in the reliability practices of their organizations and empowers them to take actions to overcome them.

The book begins by discussing product effectiveness and its related functions, presents the mathematical theory for reliability, and introduces statistical inference concepts as ways to analyze probabilistic models from observational data. Later chapters introduce basic types of probability distributions; present the concepts of confidence interval; focus on reliability assessment; and examine software reliability, quality, and safety.

Use FMMEA to identify failure mechanisms

Reflecting the latest developments in the field, the book introduces a new methodology known as failure modes, mechanisms, and effects analysis (FMMEA) to identify potential failure mechanisms. Shifting to a practical stance, the book delineates steps that must be taken to develop a product that meets reliability objectives. It describes how to combine reliability information from parts and subsystems to compute system level reliability, presents methods for evaluating reliability in fault-tolerant conditions, and describes methods for modeling and analyzing failures of repairable products.

The text discusses reliability growth, accelerated testing, and management of a continuous improvement program; analyzes the influence of reliability on logistics support requirements; shows how to assess overall product effectiveness; and introduces the concepts of process capability and statistical process control techniques.

New Topics in the Second Edition Include:

  • Failure Modes, Mechanisms, and Effects Analysis
  • Confidence Interval on Reliability Metrics and their Relationships with Measures of Product Quality
  • Process Control and Process Capability and their Relationship with Product Reliability
  • System Reliability, including Redundancy

Preface vii
Editor xi
Contributors xiii
Chapter 1 Product Effectiveness and Worth 1
Harold S. Balaban, Ned Criscimagna, Michael Pecht
1.1 Introduction
1
1.2 Attributes Affecting Product Effectiveness
2
1.3 Programmatic Factors Affecting Product Effectiveness
3
1.3.1 Product Effectiveness
5
1.3.2 Operational Readiness and Availability
6
1.3.3 Dependability
7
1.3.4 Capability
8
1.3.5 Reliability
8
1.3.6 Maintainability
10
1.3.7 Relationships Among Time Elements
13
1.4 Assignment of Responsibility
13
1.4.1 Administrative Time
14
1.4.2 Logistics Time
15
1.4.3 Active Repair Time and Operating Time
15
Chapter 2 Reliability Concepts 19
Diganta Das, Michael Pecht
2.1 Introduction
19
2.2 Reliability
19
2.3 Probability Density Function
23
2.4 Hazard Rate
25
2.5 Conditional Reliability
26
2.6 Time to Failure
27
Homework Problems
27
Chapter 3 Statistical Inference Concepts 31
Jun Ming Hu, Mark Kaminskiy, Igor A. Ushakov
3.1 Introduction
32
3.2 Statistical Estimation
32
3.2.1 Point Estimation
32
3.2.1.2 Method of Moments
33
3.2.1.2 Method of Maximum Likelihood
34
3.2.2 Interval Estimation
36
3.3 Hypothesis Testing
37
3.3.1 Frequency Histogram
37
3.3.2 Goodness-of-Fit Tests
38
3.3.2.1 The Chi-Square Test
38
3.3.2.2 The Kolmogorov–Smirnov Test
41
3.3.2.3 Sample Comparison
43
3.4 Reliability Regression Model Fitting
45
3.4.1 Gauss–Markov Theorem and Linear Regression
45
3.4.1.1 Regression Analysis
45
3.4.1.2 The Gauss–Markov Theorem
49
3.4.1.3 Multiple Linear Regression
49
3.4.2 Proportional Hazard (PH) and Accelerated Life (AL) Models
51
3.4.2.1 Accelerated Life (AL) Model
51
3.4.2.2 Proportional Hazard (PH) Model
52
3.4.3 Accelerated Life Regression for Constant Stress
52
3.4.4 Accelerated Life Regression for Time-Dependent Stress
54
3.5 Summary
56
References
56
Chapter 4 Practical Probability Distributions for Product Reliability Analysis 57
Diganta Das, Michael Pecht
4.1 Introduction
57
4.2 Discrete Distributions
58
4.2.1 Binomial Distribution
58
4.2.2 Poisson Distribution
62
4.2.3 Other Discrete Distributions
63
4.3 Continuous Distributions
63
4.3.1 Weibull Distribution
65
4.3.2 Exponential Distribution
68
4.3.3 The Normal Distribution
71
4.3.4 The Lognormal Distribution
73
4.4 Probability Plots
75
Chapter 5 Confidence Intervals 83
Diganta Das, Michael Pecht
5.1 Introduction
83
5.2 Concepts
84
5.2.1 Definitions
85
5.2.2 Interpretation of Confidence Level
85
5.2.3 Relationship Between Confidence Interval and Sample Size
86
5.3 Confidence Interval Estimate Methods
86
5.4 Confidence Interval for Normal Distribution
87
5.4.1 Unknown Mean with Known Variance
88
5.4.2 Unknown Mean with Unknown Variance
89
5.4.3 Differences in Two Population Means with Variances Known
90
5.5 Confidence Interval on MTBF—Exponential Distribution Assumption
91
5.6 Confidence Intervals for Proportions
92
5.7 Summary
93
Reference
94
Chapter 6 Hardware Reliability 95
Abhijit Dasgupta, Jun Ming Hu
6.1 Introduction
96
6.2 Failure Mechanisms and Damage Models
98
6.2.1 Incorrect Mechanical Performance
100
6.2.2 Incorrect Thermal Performance
101
6.2.3 Incorrect Electrical Performance
101
6.2.3.1 Electromagnetic Interference
102
6.2.3.2 Particle Radiation
102
6.2.4 Yield
103
6.2.5 Buckling
103
6.2.6 Fracture
104
6.2.7 Interfacial De-Adhesion
106
6.2.8 Fatigue
107
6.2.9 Creep
109
6.2.10 Wear
110
6.2.11 Aging due to Interdiffusion
110
6.2.12 Aging due to Particle Radiation
111
6.2.13 Other Forms of Aging
111
6.2.14 Corrosion
112
6.2.15 Metal Migration
113
6.3 Loadings, Stresses, and Material Behavior
113
6.4 Variabilities and Reliability
115
6.5 Reliability Prediction Techniques
115
6.6 Case Study: Wirebond Assembly in Microelectronic Packages
118
6.6.1 Failure Mechanisms and Stress Analysis
119
6.6.1.1 Wire Flexure
119
6.6.1.2 Shear of Bond Pad
120
6.6.1.3 Shear of Wire and Substrate
121
6.6.1.4 Axial Tension of Wire
122
6.6.2 Stochastic Modeling of Variabilities and Reliability
123
6.6.3 Fatigue Lifetime and Reliability Prediction
127
6.7 Qualification and Accelerated Testing
131
6.8 De-Rating and Logistic Implications
133
6.9 Manufacturing Issues
134
6.9.1 Process Qualification
135
6.9.2 Manufacturability, Process Variabilities, Defects, and Yields
135
6.9.3 Process Verification Testing and Statistical Process Control
136
6.10 Summary
138
References
139
Chapter 7 Software Reliability 141
Richard Kowalski, Carol Smidts
7.1 Introduction
142
7.2 Definitions
143
7.3 Software Development: The Classic Waterfall Life Cycle
147
7.3.1 Phase Descriptions
148
7.3.1.1 Software Requirements Definition and Analysis Phase
148
7.3.1.2 Preliminary and Detailed Design Phases
149
7.3.1.3 Code and Unit Testing Phase
150
7.3.1.4 Integration and System Testing Phase
151
7.3.1.5 Acceptance Testing Phase
151
7.3.1.6 Maintenance and Operation Phase
152
7.3.1.7 Retirement Phase
152
7.3.2 Software Development Standards
152
7.3.3 Distribution of Errors over the Development Life Cycle and Related Costs
152
7.4 Techniques to Improve Software Reliability
153
7.4.1 Designing Reliable Software
153
7.4.1.1 Structured Programming
153
7.4.1.2 Design Techniques
153
7.4.1.3 Design Issues
154
7.4.2 Designing Fault-Tolerant Software
155
7.4.2.1 Recovery-Block Design
156
7.4.2.2 N-Version Programming
157
7.4.2.3 Consensus Recovery Block
158
7.4.3 Testing
159
7.4.3.1 Black-Box and White-Box Testing
159
7.4.3.2 Module Testing: White-Box and Black-Box Testing Strategies
159
7.4.3.3 Integration Testing
161
7.4.4 Formal Methods (Neuhold and Paul 1991)
163
7.4.4.1 Formal Specification Methods
163
7.4.4.2 Formal Verification
163
7.4.5 Software Development Process Maturity
165
7.5 Techniques to Assess Software Reliability
166
7.5.1 Software Analysis Methods
166
7.5.1.1 Failure Mode and Effect Analysis (FMEA)
166
7.5.1.2 Fault-Tree Analysis
166
7.5.2 Software Metrics
168
7.5.2.1 Requirements Measures: The Specification Completeness Measure
168
7.5.2.2 Design Phase Measures
168
7.5.2.3 Code and Unit Test Phase Measure: Defect Density (IEEE 1989a)
172
7.5.3 Software Reliability Models
173
7.5.3.1 A Classification of Software Reliability Models
173
7.5.3.2 Jelinski and Moranda's Model
175
7.5.3.3 Musa Basic Execution Time Model (BETM)
178
7.5.3.4 Musa—Okumoto Logarithmic Poisson Execution Time Model (LPETM)
179
7.5.3.5 Mills's Fault Seeding Model (IEEE 1989b)
179
7.5.3.6 Nelson's Input-Based Domain Model
180
7.5.3.7 Derived Software Reliability Models
180
7.5.3.8 A Critique of Existing Software Reliability Models
181
7.6 Summary
181
References
182
Chapter 8 Failure Modes, Mechanisms, and Effects Analysis 185
Sony Mathew, Michael Pecht
8.1 Introduction
186
8.2 Failure Modes, Mechanisms, and Effects Analysis Methodology
188
8.2.1 System Definition, Elements, and Functions
189
8.2.2 Potential Failure Modes
189
8.2.3 Potential Failure Causes
189
8.2.4 Potential Failure Mechanisms
190
8.2.5 Failure Models
190
8.2.6 Life-Cycle Profile
191
8.2.7 Failure Mechanism Prioritization
191
8.2.8 Documentation
194
8.3 Case Study
194
8.4 Conclusions
199
References
199
Chapter 9 Design for Reliability 201
Diganta Das, Michael Pecht
9.1 Introduction
201
9.2 Product Requirements and Constraints
202
9.3 Product Life-Cycle Conditions
203
9.4 Reliability Capability
205
9.5 Parts and Materials Selection
205
9.6 Failure Modes, Mechanisms, and Effects Analysis
206
9.7 Physics of Failure
207
9.7.1 Stress Margins
207
9.7.2 Model Analysis of Failure Mechanisms
208
9.7.3 De-Rating
208
9.7.4 Protective Architectures
209
9.7.5 Redundancy
209
9.7.6 Prognostics
210
9.8 Qualification
210
9.9 Manufacture and Assembly
212
9.9.1 Manufacturability
212
9.9.2 Process Verification Testing
213
9.10 Closed-Loop, Root-Cause Monitoring
214
9.11 Summary
216
References
216
Homework Problems
216
Chapter 10 System Reliability Modeling 219
Michael Pecht
10.1 Introduction
219
10.2 Reliability Block Diagram
220
10.3 Series System
220
10.4 Products with Redundancy
222
10.4.1 Active Redundancy
223
10.4.2 Standby Systems
225
10.4.3 (k, n) Systems
226
10.4.4 Limits of Redundancy
227
10.4.5 Complex Systems
228
10.4.5.1 Complete Enumeration Method
228
10.4.5.2 Conditional Probability Method
230
10.4.5.3 Cut Set Methodology
231
10.5 Fault-Tree Analysis
232
10.6 Steps of Fault-Tree Analysis
233
References
236
Homework Problems
236
Chapter 11 Reliability Analysis of Redundant and Fault-Tolerant Products 239
Joanne Bechta Dugan
Terminology
240
Notation
241
11.1 Static Redundancy Combinatorial Modeling
241
11.1.1 Simple Redundancy
241
11.1.1.1 Series Connections
243
11.1.1.2 Parallel Connections
243
11.1.1.3 Series-Parallel Connections
243
11.1.1.4 Non-Series-Parallel Connections
244
11.1.2 Masking Redundancy
246
11.1.2.1 Triple Modular Redundancy
247
11.1.2.2 N-Modular Redundancy
248
11.1.3 Fault Trees
250
11.1.3.1 Cut Set Generation
250
11.1.3.2 Inclusion/Exclusion Method
252
11.2 Time Dependence
253
11.2.1 Mean Time to Failure
254
11.2.2 Hazard Rate
255
11.3 Dynamic Redundancy Markov Modeling
256
11.3.1 Standby Sparing
257
11.3.2 TMR/Simplex Product
260
11.3.3 Repairable Products
262
11.3.3.1 Independent Repair
263
11.3.3.2 Dependent Repair
264
11.4 Dependent Failures
266
11.4.1 Common-Mode Failures
266
11.4.2 Dependent Failure Rate
268
11.4.3 Multimode Failures
268
11.5 Coverage Modeling for Fault-Tolerant Computer Products
271
11.5.1 Terminology
272
11.5.2 The Impact of Imperfect Coverage
272
11.5.3 Some Coverage Models
273
11.5.3.1 General Structure of a Coverage Model
273
11.5.4 Near-Coincident Faults
278
11.5.5 Including the Coverage Model in the Product Model
281
11.6 Bounded Approximate Models
284
11.6.1 Truncated Exhaustive State Enumeration
287
11.6.2 Truncated Sum of Disjoint Products
289
11.6.3 Truncating a Markov Chain
291
11.7 Advanced Topics
292
11.7.1 Combining Performance with Reliability
292
11.7.2 Phased Applications
293
11.7.3 Advanced Fault-Tree Modeling
296
11.8 Summary
297
References
297
Chapter 12 Reliability Models and Data Analysis for Repairable Products 299
Harold S. Balaban
12.1 Introduction
300
12.2 Analytical Background
300
12.2.1 Age-Independent F-R Processes
301
12.2.2 Age-Persistent F-R Processes
301
12.2.3 Defining Characteristics of AI and AP Precedes
302
12.2.4 Failure Repair as Renewal and Poisson Processes
302
12.2.4.1 Renewal Processes
302
12.2.4.2 Homogeneous Poisson Processes
305
12.2.4.3 Nonhomogeneous Poisson Processes
306
12.2.4.4 F-R Process Relationships
308
12.3 Data Analysis Techniques
309
12.3.1 Graphical Trend Tests
309
12.3.2 Test for a Renewal Process
312
12.3.3 Test for a Homogeneous Poisson Process
315
12.3.4 Comparison of Two Samples
317
12.3.5 Fitting the Weibull Nonhomogeneous Poisson Process
319
12.3.5.1 Weibull Process Characteristics
319
12.3.5.2 Estimation of λ and β
320
12.3.5.3 Goodness-of-Fit Tests
322
12.3.5.4 Confidence Interval Estimates
323
12.4 Summary
324
References
324
Chapter 13 Continuous Reliability Improvement 325
Walter Tomczykowski
13.1 Introduction
326
13.2 Reliability Growth Process
326
13.2.1 Reliability Improvement Program
326
13.2.2 Failure Classification
331
13.2.3 Test Optimization
333
13.2.4 Test Cycles and Environmental Considerations
334
13.3 Stress Margin Testing
335
13.3.1 Stressed Life Test (STRIFE)
336
13.3.2 Highly Accelerated Life Test (HALT)
337
13.3.3 Inverse Power Law Model and Miner's Rule
338
13.4 Continuous Growth Monitoring
339
13.4.1 Continuous Growth Models
339
13.4.1.1 Duane Model
339
13.4.1.2 AMSAA Model
342
13.4.2 Discrete Models
349
13.4.2.1 Lloyd and Lipow Model
349
13.4.2.2 Wolman Model
350
13.5 Reliability Improvement Effectiveness and Uncertainty
350
13.5.1 Reliability Improvement Effectiveness
351
13.5.2 Reliability Improvement Uncertainty
351
13.6 Summary
354
References
354
Chapter 14 Logistics Support 357
Robert M. Hecht
14.1 Introduction
358
14.2 Logistics Elements
359
14.3 Influence of Reliability on Logistics Resources
361
14.3.1 Reliability, Maintenance Rates, and Expected Demand for Logistics Resources
361
14.3.1.1 False Alarm Rate (FAR)
364
14.3.1.2 Cannot Duplicate (CND) Rate
364
14.3.1.3 Probability of Fault Detection (DET)
364
14.3.1.4 Probability of Fault Isolation (ISO)
365
14.3.1.5 Maintenance Action Rate (MAR)
366
14.3.1.6 Demand Rate (DEM)
367
14.3.1.7 Mean Downtime (MDT)
368
14.3.2 Supply Support Provisioning of Repair Parts and Consumables
369
14.3.2.1 Optimal Reorder Quantity
370
14.3.2.2 Spares' Availability and Provisioning
373
14.3.2.3 Provisioning a Product Composed of Replaceable Parts
375
14.3.2.4 Spares' Optimization
378
14.3.3 Manpower and Personnel Staffing Levels
382
14.3.4 Support and Test Equipment Utilization and Productivity
385
14.4 Repair Level Analysis
387
14.5 Summary
389
References
390
Chapter 15 Product Effectiveness and Cost Analysis 391
Harold S. Balaban, David Weiss
15.1 Introduction
391
15.2 A Framework for Product Effectiveness Quantification Using Markov Processes
393
15.2.1 A Generalization of the Model for Multifunction Operations
394
15.2.2 Effectiveness Evaluation Example—Continuous Performance
396
15.2.3 Model Applicability
400
15.3 Factors to Consider in Analyzing Product Effectiveness
401
15.3.1 Phase I: Define Application, Product, and Logistics Support
403
15.3.2 Phase II: Select Measures of Effectiveness
403
15.3.3 Phase III: Develop the Mathematical Model
405
15.3.4 Phase IV: Obtain Data Inputs
407
15.3.5 Phase V: Exercise, Interpret, and Refine Model
407
15.4 Cost-Effectiveness Analysis
408
15.4.1 Cost Categorization
408
15.4.2 Cost Estimation
410
15.4.3 Cost Adjustments
413
15.4.4 Cost Uncertainty and Cost Sensitivity
415
15.4.5 Combining Effectiveness and Cost
416
15.5 Summary
419
Reference
419
Additional Reading
419
Chapter 16 Process Capability and Process Control 421
Diganta Das, Michael Pecht
16.1 Introduction
421
16.2 Average Outgoing Quality
421
16.3 Process Capability
423
16.4 Statistical Process Control
426
16.4.1 Control Charts: Recognizing Sources of Variation
427
16.4.1.1 Constructing a Control Chart
427
16.5 Examples of Control Chart Constants
434
References
442
Homework Problems
443
Index 447
University of Maryland, College Park, USA Calce, University of Maryland, College Park, MD, USA