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Practical Reliability Engineering and Analysis for System Design and Life-Cycle Sustainment

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Table of Contents

Preface The Author List of Tables List of Figures Requirements for Reliability Engineering: Design for Reliability, Reliability Systems Integration, and Reliability-Based System Sustainment Introduction Part Reliability Failure Mechanisms Failure Modes Failure Effects-Local Failure Effects-Next Higher Failure Effects-System (End Effect) Failure Modes and Effects Analysis Criticality Analysis System End Effects P-F Interval Operator Awareness of Degradation Maintainability and Maintainability Engineering Fault Detection Fault Isolation Part Mean Time to Repair Administrative and Logistical Downtime Part and System Availability Reliability in an Organization The Need for Change in Conventional Organizational Structure Proposed Organization Structure Design for Reliability: Reliability Engineering Requirements for Part Design Design Requirement for a System Systems Engineering Work Breakdown Structure Lowest Replaceable Unit, LRU, Reliability Allocations Conditions of Use, Mission Duration, and Maintainability Allocations Functional Design Analysis Functional Reliability Block Diagram Functional LRU Failure Modes and Effects Analysis Functional LRU Criticality/Consequences Analysis and Critical Items List Design Trade Studies LRU Nondestructive Examination and Math Modeling Preliminary LRU Failure Mechanisms: Modes and Effects Analysis Preliminary LRU Criticality/Consequences Analysis and Critical Items List Preliminary Design Bills of Materials and Drawings Preliminary Reliability Block Diagram and Math Modeling Preliminary LRU Reliability, Maintainability, and Availability Estimates Design Tests and Evaluation Reliability Experiments and Math Modeling Design LRU Failure Mechanisms Modes and Effects Analysis Design LRU Criticality/Consequences Analysis and Critical Items List Final Design Analysis, Bills of Materials, and Drawings Final Design Reliability Block Diagram and Math Modeling Final LRU Failure Mechanisms Modes and Effects Analysis Design Reviews Reliability Systems Engineering Requirements for System Integration Part/LRU-to-Assembly Integration Part/LRU-to-Assembly Reliability, Maintainability, and Availability Model Assembly Design Review Design Modification Reliability Growth Assembly-to-Subsystem Integration Assembly-to-Subsystem Reliability, Maintainability, and Availability Model Design Review Design Modification Reliability Growth Subsystem-to-System Integration Subsystem-to-System Reliability, Maintainability, and Availability Model Design Review Design Modification Reliability Growth System Demonstration Reliability and Maintainability Demonstration System Baseline Configuration Management Reliability Engineering Requirements for System Sustainment System Sustainment Repair Maintenance Logistical Support Database Requirements Notes Part/LRU Reliability Modeling for Time-to Failure Data Introduction Part Candidate for Reliability Engineering and Analysis Hypothesize Part Failure Mechanisms Part Failure Modes Analysis Part Failure Effects Analysis Critical Items List Part/LRU Reliability Analysis: Understanding Failure of a Part/LRU Qualitative Part/LRU Investigation Part/LRU Design Parameters Fall in One of Three Criteria Quantitative Part/LRU Investigation TTF and TTR Frequency Distribution and Probability Density Function of Part/LRU Failure Cumulative Frequency Distribution TTF Survival Function of a Part/LRU TTF Instantaneous Part/LRU Failure Rate: The Hazard Function.3 TTF Reliability Function of a Part/LRU Part/LRU Time-to-Failure Characterization of Reliability Parameters Part/LRU Historical Part Failure Data Part/LRU Reliability Experiments Time-Censored Experimental Part/LRU Failure Data Interval-Censored Experiment Failure-Censored Experimental Part/LRU Failure Data Failure-Free Experimental Part Data Maintainability Analysis Functions of a Part/LRU Resource Requirements for a Part/LRU Inherent Availability of a Part/LRU Notes Reliability Failure Modeling Based on Time-to-Failure Data Introduction Part Reliability Failure Modeling Candidate for Reliability Engineering and Analysis Experimental Design for TTF Exponential Probability Distribution Approach Spreadsheet Approach Exponential Distribution: Minitab Weibull Distribution Approach Spreadsheet Approach Weibull Distribution: Minitab Weibull Distribution: MathCAD Approach Pump Failure Math Model Triangular Distribution Notes Part Maintainability and Availability Introduction Part Mean Time to Repair Maintenance Experiment Excel Spreadsheet Approach Minitab Approach MathCAD Approach Empirical Data Part and System Availability Inherent Availability Instantaneous Availability Operational Availability Achieved Availability Notes Part Reliability Based on Stress-Strength Analysis Introduction Part Stress Part Failure Time-to-Failure Reliability Functions Example TTF Reliability Functions for Hex Bolt Exponential Failure Distribution Approach Single Failure Mechanism Weibull Model Approach Multiple Failure Mechanism Weibull Model Approach Comparative Evaluation of Exponential, Single Weibull, and Multiple Failure Mechanism Weibull Model Approaches Using TTF Data Part Stress and Strength: Interference Theory Normal Stress-Normal Strength Normal Stress-Weibull Strength Weibull Stress-Weibull Strength Triangular Stress-Weibull Strength Stress-Strength Reliability of the Bolt in Tension and Shear Nondeterministic, Variable Approach Advantages and Disadvantages for Stress-Strength Analysis Approach Notes Reliability Engineering Functions from Stress-Strength Analysis Introduction Frequency Distributions of the Mechanisms of Failure Design for Reliability Phase I: 1-Operational-Day Test Simulation Period Phase II: 1-Operational-Year Test Simulation Period Phase III: 2-Operational-Year Test Simulation Period Design for Reliability by Analysis Material in Tension Notes Failure Modeling Based on Failure Mechanisms Introduction Normal Distribution Stress-Normal Distribution Strength1 Normal Distribution Stress-Weibull Distribution Strength Weibull Distributed Stress-Weibull Distribution Strength Triangular Distribution Stress-Triangular Distribution Strength Notes Reliability Modeling for Assembly Design Levels Introduction Reliability Allocation Reliability Math Model Math Modeling for Design Configurations of Assemblies Series Design Configuration Parallel Design Configuration n-Provided, r-Required Redundancy Standby Redundancy Equal Reliability: Perfect Switch Unequal Reliability: Perfect Switch Equal Reliability: Imperfect Switch Unequal Reliability: Imperfect Switch Shared Load Redundancy7 Notes Reliability Analysis for System of Systems Introduction Multiple-Missions System of System Simple Single-Mission System of Systems Complex Single-Mission System of Systems System of Systems Compared Notes Reliability-Centered Maintenance Introduction Implementation of Reliability-Centered Maintenance Notes Reliability-Centered Failure Analysis Introduction Nondestructive Examination, Design, and Destruct Limits Condition-Based Maintenance NDE Time-Directed Maintenance NDE Finite Element Math Model, Simulation and Analysis, Design Loads and Material Design Properties, Statistically Significant Failure Mechanisms No Maintenance Solution CBM Solution TDM Solution Physical Test Highly Accelerated Life Test MIL-STD-810 Method 501: High Temperature Method 502: Low Temperature Method 503: Temperature Shock Method 507: Humidity Method 514: Vibration Method 520: Combined Environments (Temperature, Vibration, and Humidity) Accelerated Life Testing Time Compression Accelerated Life Testing Life-versus-Stress Analysis Accelerated Life Test Condition-Based Maintenance Introduction CBM Logic Maintainability Demonstration Test, Validate Part Fault Detection, and P-F Interval Develop and Implement Maintenance Procedures and Practices.20 Notes Time-Directed Maintenance Introduction Characterize Hazard Function Define Hazard Threshold Maintainability Demonstration Test, Validate Hazard Function Develop and Implement Maintenance Procedures and Practices Bibliography Index

About the Author

University of Alabama, Huntsville, USA

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