Reliability Engineering

by Elsayed A. Elsayed

Overview

A newly revised and updated edition that details both the theoretical foundations and practical applications of reliability engineering

Reliability is one of the most important quality characteristics of components, products, and large and complex systems—but it takes a significant amount of time and resources to bring reliability to fruition. Thoroughly classroom- and industry-tested, this book helps ensure that engineers see reliability success with every product they design, test, and manufacture.

Divided into three parts, Reliability Engineering, Second Edition handily describes the theories and their practical uses while presenting readers with real-world examples and problems to solve. Part I focuses on system reliability estimation for time independent and failure dependent models, helping engineers create a reliable design. Part II aids the reader in assembling necessary components and configuring them to achieve desired reliability objectives, conducting reliability tests on components, and using field data from similar components. Part III follows what happens once a product is produced and sold, how the manufacturer must ensure its reliability objectives by providing preventive and scheduled maintenance and warranty policies.

This Second Edition includes in-depth and enhanced chapter coverage of:

• Reliability and Hazard Functions
• System Reliability Evaluation
• Time- and Failure-Dependent Reliability
• Estimation Methods of the Parameters of Failure-Time Distributions
• Parametric Reliability Models
• Models for Accelerated Life Testing
• Renewal Processes and Expected Number of Failures
• Preventive Maintenance and Inspection
• Warranty Models
• Case Studies

A comprehensive reference for practitioners and professionals in quality and reliability engineering, Reliability Engineering can also be used for senior undergraduate or graduate courses in industrial and systems, mechanical, and electrical engineering programs.

Product Details

ISBN-13:	9781118137192
Publisher:	Wiley
Publication date:	06/19/2012
Series:	Wiley Series in Systems Engineering and Management Series , #88
Edition description:	2nd ed.
Pages:	792
Product dimensions:	7.60(w) x 9.10(h) x 1.60(d)

About the Author

Elsayed A. Elsayed, PhD, is a professor in the Department of Industrial and Systems Engineering, Rutgers University, and the Director of the NSF/Industry/University Co-operative Research Center for Quality and Reliability Engineering. He is the recipient of the Institute of Industrial Engineers (IIE) Fellow Award, an ASME Fellow, the Senior Fulbright Award, and the 2011 Thomas Alva Edison Patent Award. He is a coauthor of Quality Engineering in Production Systems and the author of Reliability Engineering, which received the 1990 and 1997 IIE/Joint Publishers Book-of-the-Year Award respectively.

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Table of Contents

PREFACE xi

PRELUDE xiv

CHAPTER 1 RELIABILITY AND HAZARD FUNCTIONS 1
1.1 Introduction 1
1.2 Reliability Definition and Estimation 3
1.3 Hazard Functions 15
1.4 Multivariate Hazard Rate 55
1.5 Competing Risk Model and Mixture of Failure Rates 59
1.6 Discrete Probability Distributions 64
1.7 Mean Time to Failure 67
1.8 Mean Residual Life (MRL) 70
1.9 Time of First Failure 71

CHAPTER 2 SYSTEM RELIABILITY EVALUATION 87
2.1 Introduction 87
2.2 Reliability Block Diagrams 87
2.3 Series Systems 91
2.4 Parallel Systems 93
2.5 Parallel-Series, Series-Parallel, and Mixed-Parallel Systems 95
2.6 Consecutive-k-out-of-n:F System 104
2.7 Reliability of k-out-of-n Systems 113
2.8 Reliability of k-out-of-n Balanced Systems 115
2.9 Complex Reliability Systems 117
2.10 Special Networks 131
2.11 Multistate Models 132
2.12 Redundancy 138
2.13 Importance Measures of Components 142

CHAPTER 3 TIME- AND FAILURE-DEPENDENT RELIABILITY 170
3.1 Introduction 170
3.2 Nonrepairable Systems 170
3.3 Mean Time to Failure (MTTF) 178
3.4 Repairable Systems 187
3.5 Availability 198
3.6 Dependent Failures 207
3.7 Redundancy and Standby 212

CHAPTER 4 ESTIMATION METHODS OF THE PARAMETERS OF FAILURE-TIME DISTRIBUTIONS 233
4.1 Introduction 233
4.2 Method of Moments 234
4.3 The Likelihood Function 241
4.4 Method of Least Squares 256
4.5 Bayesian Approach 261
4.6 Generation of Failure-Time Data 265

CHAPTER 5 PARAMETRIC RELIABILITY MODELS 273
5.1 Introduction 273
5.2 Approach 1: Historical Data 273
5.3 Approach 2: Operational Life Testing 274
5.4 Approach 3: Burn-In Testing 275
5.5 Approach 4: Accelerated Life Testing 275
5.6 Types of Censoring 277
5.7 The Exponential Distribution 279
5.8 The Rayleigh Distribution 294
5.9 The Weibull Distribution 302
5.10 Lognormal Distribution 314
5.11 The Gamma Distribution 321
5.12 The Extreme Value Distribution 329
5.13 The Half-Logistic Distribution 331
5.14 Frechet Distribution 338
5.15 Birnbaum–Saunders Distribution 341
5.16 Linear Models 344
5.17 Multicensored Data 346

CHAPTER 6 MODELS FOR ACCELERATED LIFE TESTING 364
6.1 Introduction 364
6.2 Types of Reliability Testing 365
6.3 Accelerated Life Testing 368
6.4 ALT Models 372
6.5 Statistics-Based Models: Nonparametric 386
6.6 Physics-Statistics-Based Models 404
6.7 Physics-Experimental-Based Models 412
6.8 Degradation Models 415
6.9 Statistical Degradation Models 419
6.10 Accelerated Life Testing Plans 421

CHAPTER 7 RENEWAL PROCESSES AND EXPECTED NUMBER OF FAILURES 440
7.1 Introduction 440
7.2 Parametric Renewal Function Estimation 441
7.3 Nonparametric Renewal Function Estimation 455
7.4 Alternating Renewal Process 465
7.5 Approximations of M(t) 468
7.6 Other Types of Renewal Processes 469
7.7 The Variance of Number of Renewals 471
7.8 Confidence Intervals for the Renewal Function 477
7.9 Remaining Life at Time T 479
7.10 Poisson Processes 481
7.11 Laplace Transform and Random Variables 485

CHAPTER 8 PREVENTIVE MAINTENANCE AND INSPECTION 496
8.1 Introduction 496
8.2 Preventive Maintenance and Replacement Models: Cost Minimization 497
8.3 Preventive Maintenance and Replacement Models: Downtime Minimization 506
8.4 Minimal Repair Models 509
8.5 Optimum Replacement Intervals for Systems Subject to Shocks 513
8.6 Preventive Maintenance and Number of Spares 517
8.7 Group Maintenance 524
8.8 Periodic Inspection 527
8.9 Condition-Based Maintenance 535
8.10 Online Surveillance and Monitoring 537

CHAPTER 9 WARRANTY MODELS 551
9.1 Introduction 551
9.2 Warranty Models for Nonrepairable Products 553
9.3 Warranty Models for Repairable Products 574
9.4 Two-Dimensional Warranty 588
9.5 Warranty Claims 590

CHAPTER 10 CASE STUDIES 603
10.1 Case 1: A Crane Spreader Subsystem 603
10.2 Case 2: Design of a Production Line 609
10.3 Case 3: An Explosive Detection System 617
10.4 Case 4: Reliability of Furnace Tubes 623
10.5 Case 5: Reliability of Smart Cards 629
10.6 Case 6: Life Distribution of Survivors of Qualification and Certification 632
10.7 Case 7: Reliability Modeling of Telecommunication Networks for the Air Traffic Control System 639
10.8 Case 8: System Design Using Reliability Objectives 648
10.9 Case 9: Reliability Modeling of Hydraulic Fracture Pumps 658
References 663

APPENDICES

AUTHOR INDEX 759

SUBJECT INDEX 764

Preface

PREFACE: Reliability is one of the most important quality characteristics of components, products, and large and complex systems. The role of reliability is observed daily by all of us - when we turn the ignition key of a vehicle, attempt to place a phone call, or try to use a copier, computer, or fax machine. In all these instances, the user expects that the machine will provide the function it is designed for when the function is requested. As you probably have experienced, machines do not always function or deliver the desired quality of service when needed.

Engineers spend a significant amount of time and resources during the design and production phases of the product life cycle to ensure that the product or system will provide the desired service level. In doing so, engineers start with a conceptual design, select its components, test its functionality, and estimate its reliability. Then they usually make modifications and design changes and repeat these steps until the product (or service) satisfies its requirements.

Designing the product may require redundancy of components (or subsystems) or introduction of newly developed components or changes in the design configuration. These will have a major impact on the product reliability.

This book is an engineering reliability book. It is organized according to the sequence followed when engineers design a product or service. The book consists of three parts. Part I focuses on system reliability estimation for time-independent and time-dependent models. Chapter 1 focuses on the basic definitions of reliability, its measures, and methods for its calculation. Extensive coverage of different hazard functions isprovided.Chapter 2 describes, in greater detail, methods for estimating reliabilities of a variety of engineering systems configurations starting with series systems, parallel systems, series- parallel, parallel-series, consecutive k-out-of-n:F, and complex network systems. It also addresses systems with multistate devices and concludes by estimating reliabilities of redundant systems and the optimal allocation of components in a redundant system. The next step in product design is to study the effect of time on the system reliability. Hence, Chapter 3 discusses, in detail, time- and failure-dependent reliability and the calculation of mean time to failure (MTTF) of a variety of system configurations. The chapter also introduces availability as a measure of system reliability.

Once the design is "firm," the engineer assembles the components and configures them to achieve the desired reliability objectives. This may require conducting reliability tests on components or using field data from similar components. Part II of this book, starting with Chapter 4, presents the concept of constructing the likelihood function and its use in estimating the parameters of failure-time distributions. Chapter 5 provides a comprehensive coverage of parametric and nonparametric reliability models for failure data. The extensive examples and methodologies presented in this chapter will aid the engineer in appropriately modeling the test data. Confidence intervals for the parameters of the models are also discussed. More important, the book devotes a full chapter, Chapter 6, to accelerated life testing. The main objective of this chapter is to provide varieties of statistical-based models, physics-statistics-based models, and physics-experimental-based models to relate the failure time and data at accelerated conditions to the normal operating conditions at which the product is expected to operate. The computer software Reliability Analysis Software(tm) that accompanies this book provides useful tools for reliability estimation, failure-time distributions, and a wide range of accelerated life models as described in Chapters 5 and 6.

Finally, once a product is produced and sold, the manufacturer must ensure its reliability objectives by providing preventive and scheduled maintenance and warranty policies. Part III of the book focuses on these topics. Beginning with Chapter 7, different methods (exact and approximate) for estimating the expected number of system failures during a specified time interval are presented. These estimates are used in Chapter 8 to determine different warranty policies for the product, including the length of warranty and its reserve fund. Finally, Chapter 9 discusses optimal preventive maintenance schedules, optimum inspection policies, and methods for estimating the inventory levels of spares that are required to ensure predetermined reliability values.

Chapter 10 concludes the book. Its case studies use the approaches and methodologies discussed throughout the book to demonstrate how to solve real-life cases. The role of reliability during the design phase of a product or a system is particularly emphasized.

Two features contribute to the usefulness of this book: every theoretical development discussed in this book is followed by an engineering example that illustrates its application, and several problems are included at the end of each chapter. These features increase the usefulness of the book as both a comprehensive reference for practitioners and professionals in the quality and reliability engineering area and also as a text for a one- or two-semester course on reliability engineering for senior undergraduates or graduate students in industrial and systems, mechanical, and electrical engineering programs. In addition, it can be adapted for use in a life data analysis course offered in many graduate programs in statistics.

The book presumes a background in statistics and probability theory and differential calculus.

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Editorial Reviews

The well written book may be used as a reference work for practitioners and as a textbook for courses in reliability engineering, where knowledge in probability calculus and statistics is presumed.”  (Zentralblatt MATH, 1 December 2012) 

“I recommend this book for graduate courses, as it is clear and complete, and treats a vital 21st century problem.”  (Computing Reviews, 29 November 2012)

 

From the Publisher

A comprehensive, current reference on building high levels of reliability into components and products. The coverage ranges from the basic calculations for reliability estimation, to constructing and using the likelihood function in estimating the parameters of a failure time distribution, to ensuring reliability objectives through preventive maintenance. The volume emphasizes the role of reliability in the design phase of production, and covers parametric and nonparametric reliability models as well as accelerated life testing. The included software enables engineers to apply these models. Annotation c. Book News, Inc., Portland, OR (booknews.com)

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