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Reliability Engineering Handbook
by Bryan Dodson &
Dennis Nolan
Preface ix
1. Introduction 1
1.1 Life cycle costs 1
1.2 Reliability data sources 3
1.3 Data Collection, Analysis, and Reporting 5
1.4 Customer expectations 17
1.5 Exercises 26
1.6 References 28
2. Distributions 33
2.1 Distribution characteristics 33
2.2 Normal and lognormal distributions 40
2.3 Exponential, Poisson, binomial, hypergeometric, and geometric distributions 49
2.4 The Weibull distribution 59
2.5 The gamma and beta distributions 64
2.6 Chi-square, F, and t-distributions 72
2.7 Bayes' probability analysis 77
2.8 Propagation of errors 81
2.9 Exercises 90
2.10 References 93
3. Parameter Estimation 95
3.1 Censored data 96
3.2 Maximum likelihood estimation 97
3.3 Hazard plotting 97
3.4 Probability plotting 98
3.5 Moment estimation 98
3.6 Exponential distribution 99
3.7 Normal distribution 108
3.8 Lognormal distribution 118
3.9 Weibull distribution 118
3.10 Goodness of fit 125
3.11 Exercises 128
3.12 References 129
4. Statistical Inference 131
4.1 Confidence intervals for the mean and variance 131
4.2 Confidence Intervals for proportions 133
4.3 Tolerance Intervals 136
4.4 Hypothesis testing 137
4.5 Exercises 142
4.6 References 143
5. Reliability Modeling 145
5.1 Models with standard data 145
5.2 Mathematical models 147
5.3 Fault trees 162
5.4 Monte Carlo Simulation 172
5.5 Markov analysis 187
5.6 Reliability allocation 191
5.7 Software reliability 196
5.8 Reliability growth 201
5.9 Sneak analysis 207
5.10 Exercises 211
5.11 References 219
6. Reliability Testing 221
6.1 Accelerated testing 222
6.2 Sequential testing 232
6.3 Exercises 249
6.4 References 251
7. Maintainability and Availability 253
7.1 Quantifying maintainability and availability 256
7.2 Preventive maintenance 263
7.3 Designing for maintainability 269
7.4 System effectiveness 270
7.5 Exercises 272
7.6 References 273
8. Failure Mode, Effects and Criticality Analysis 275
8.1 Criticality analysis 275
8.2 Environmental requirements and influence 285
8.3 Differences between part function, part failure mechanism, failure effect, failure detection, and failure mode 285
8.4 Exercises 290
8.5 References 293
9. Part Selection and Derating 295
9.1 Evaluation of parts for reliability 295
9.2 Reliability testing for parts 297
9.3 Vendor evaluation of part reliability 301
9.4 Derating principles 301
9.5 Summary 304
9.6 Exercises 304
9.7 References 307
10. Reliability Design and Management Control 309
10.1 Reliability program management principles 309
10.2 Design review teams 315
10.3 Follow-up and corrective-action 315
10.4 Reliability needs 318
10.5 Managing the program 320
10.6 General considerations 321
10.7 Summary 322
10.8 Exercises 323
10.9 References 323
11. Product Safety 325
11.1 Contingency analysis 325
11.2 Malfunction and multiple failure analysis 332
11.3 Exercises 336
11.4 References 339
12. Human Factors In Reliability 341
12.1 Human factors in design and design principles 342
12.2 Man-machine function allocation 356
12.3 Human factors in production 361
12.4 Human factos in field testing 366
12.5 Training and education 367
12.6 Exercises 401
12.7 References 403
13. Statistical Process Control 407
13.1 Sources of variation 408
13.2 Types of control charts 409
13.3 Advanced control charts 430
13.4 Implementation 437
13.5 Tampering effects and diagnostics 448
13.6 Process capability studies and indices 450
13.7 Exercises 455
13.8 References 456
14. Experimentation 461
14.1 Experimental design 461
14.2 Analyzing experimental data 471
14.3 Regression 485
14.4 Surface response methodology 500
14.5 Exercises 509
14.6 References 516
Appendix A Area Under the Standard Normal Curve 519
Appendix B The Gamma Function 523
Appendix C Rank Tables 525
Appendix D Beta Table 541
Appendix E The F Distribution 545
Appendix F Critical Values of the t-Distribution 551
Appendix G Poisson Probability Sums 553
Appendix H Critical Values of the Chi-Square Distribution 557
Appendix I Tolerance Interval Factors 561
Appendix J Useful Integrals 565
Appendix K Government Documents 567
Appendix L Financial Formulas 569
Appendix M For Further Information 571
Appendix N Glossary 573
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