A unique, design-based approach to reliability engineering
Design for Reliability provides engineers and managers with a range of tools and techniques for incorporating reliability into the design process for complex systems. It clearly explains how to design for zero failure of critical system functions, leading to enormous savings in product life-cycle costs and a dramatic improvement in the ability to compete in global markets.
Readers will find a wealth of design practices not covered in typical engineering books, allowing them to think outside the box when developing reliability requirements. They will learn to address high failure rates associated with systems that are not properly designed for reliability, avoiding expensive and time-consuming engineering changes, such as excessive testing, repairs, maintenance, inspection, and logistics.
Special features of this book include:
- A unified approach that integrates ideas from computer science and reliability engineering
- Techniques applicable to reliability as well as safety, maintainability, system integration, and logistic engineering
- Chapters on design for extreme environments, developing reliable software, design for trustworthiness, and HALT influence on design
Design for Reliability is a must-have guide for engineers and managers in R&D, product development, reliability engineering, product safety, and quality assurance, as well as anyone who needs to deliver high product performance at a lower cost while minimizing system failure.
Table of Contents:
Contributors xiii Foreword xv
Preface xvii
Introduction: What You Will Learn xix
1 Design for Reliability Paradigms 1
Dev Raheja
Why Design for Reliability? 1
Reflections on the Current State of the Art 2
The Paradigms for Design for Reliability 4
Summary 13
References 13
2 Reliability Design Tools 15
Joseph A. Childs
Introduction 15
Reliability Tools 19
Test Data Analysis 31
Summary 34
References 35
3 Developing Reliable Software 37
Samuel Keene
Introduction and Background 37
Software Reliability: Definitions and Basic Concepts 40
Software Reliability Design Considerations 44
Operational Reliability Requires Effective Change Management 48
Execution-Time Software Reliability Models 48
Software Reliability Prediction Tools Prior to Testing 49
References 51
4 Reliability Models 53
Louis J. Gullo
Introduction 53
Reliability Block Diagram: System Modeling 56
Example of System Reliability Models Using RBDs 57
Reliability Growth Model 60
Similarity Analysis and Categories of a Physical Model 60
Monte Carlo Models 62
Markov Models 62
References 64
5 Design Failure Modes, Effects, and Criticality Analysis 67
Louis J. Gullo
Introduction to FMEA and FMECA 67
Design FMECA 68
Principles of FMECA-MA 71
Design FMECA Approaches 72
Example of a Design FMECA Process 74
Risk Priority Number 82
Final Thoughts 86
References 86
6 Process Failure Modes, Effects, and Criticality Analysis 87
Joseph A. Childs
Introduction 87
Principles of P-FMECA 87
Use of P-FMECA 88
What Is Required Before Starting 90
Performing P-FMECA Step by Step 91
Improvement Actions 98
Reporting Results 100
Suggestions for Additional Reading 101
7 FMECA Applied to Software Development 103
Robert W. Stoddard
Introduction 103
Scoping an FMECA for Software Development 104
FMECA Steps for Software Development 106
Important Notes on Roles and Responsibilities with Software FMECA 116
Lessons Learned from Conducting Software FMECA 117
Conclusions 119
References 120
8 Six Sigma Approach to Requirements Development 121
Samuel Keene
Early Experiences with Design of Experiments 121
Six Sigma Foundations 124
The Six Sigma Three-Pronged Initiative 126
The RASCI Tool 128
Design for Six Sigma 129
Requirements Development: The Principal Challenge to System Reliability 130
The GQM Tool 131
The Mind Mapping Tool 132
References 135
9 Human Factors in Reliable Design 137
Jack Dixon
Human Factors Engineering 137
A Design Engineer’s Interest in Human Factors 138
Human-Centered Design 138
Human Factors Analysis Process 144
Human Factors and Risk 150
Human Error 150
Design for Error Tolerance 153
Checklists 154
Testing to Validate Human Factors in Design 154
References 154
10 Stress Analysis During Design to Eliminate Failures 157
Louis J. Gullo
Principles of Stress Analysis 157
Mechanical Stress Analysis or Durability Analysis 158
Finite Element Analysis 158
Probabilistic vs. Deterministic Methods and Failures 159
How Stress Analysis Aids Design for Reliability 159
Derating and Stress Analysis 160
Stress vs. Strength Curves 161
Software Stress Analysis and Testing 166
Structural Reinforcement to Improve Structural Integrity 167
References 167
11 Highly Accelerated Life Testing 169
Louis J. Gullo
Introduction 169
Time Compression 173
Test Coverage 174
Environmental Stresses of HALT 175
Sensitivity to Stresses 176
Design Margin 178
Sample Size 180
Conclusions 180
Reference 181
12 Design for Extreme Environments 183
Steven S. Austin
Overview 183
Designing for Extreme Environments 183
Designing for Cold 184
Designing for Heat 186
References 191
13 Design for Trustworthiness 193
Lawrence Bernstein and C. M. Yuhas
Introduction 193
Modules and Components 196
Politics of Reuse 200
Design Principles 201
Design Constraints That Make Systems Trustworthy 204
Conclusions 210
References and Notes 211
14 Prognostics and Health Management Capabilities to Improve Reliability 213
Louis J. Gullo
Introduction 213
PHM Is Department of Defense Policy 216
Condition-Based Maintenance vs. Time-Based Maintenance 216
Monitoring and Reasoning of Failure Precursors 217
Monitoring Environmental and Usage Loads for Damage Modeling 218
Fault Detection, Fault Isolation, and Prognostics 218
Sensors for Automatic Stress Monitoring 220
References 221
15 Reliability Management 223
Joseph A. Childs
Introduction 223
Planning, Execution, and Documentation 229
Closing the Feedback Loop: Reliability Assessment, Problem Solving, and Growth 232
References 233
16 Risk Management, Exception Handling, and Change Management 235
Jack Dixon
Introduction to Risk 235
Importance of Risk Management 236
Why Many Risks Are Overlooked 237
Program Risk 239
Design Risk 241
Risk Assessment 242
Risk Identification 243
Risk Estimation 244
Risk Evaluation 245
Risk Mitigation 247
Risk Communication 248
Risk and Competitiveness 249
Risk Management in the Change Process 249
Configuration Management 249
References 251
17 Integrating Design for Reliability with Design for Safety 253
Brian Moriarty
Introduction 253
Start of Safety Design 254
Reliability in System Safety Design 255
Safety Analysis Techniques 255
Establishing Safety Assessment Using the Risk Assessment Code Matrix 260
Design and Development Process for Detailed Safety Design 261
Verification of Design for Safety Includes Reliability 261
Examples of Design for Safety with Reliability Data 262
Final Thoughts 266
References 266
18 Organizational Reliability Capability Assessment 267
Louis J. Gullo
Introduction 267
The Benefits of IEEE 1624-2008 269
Organizational Reliability Capability 270
Reliability Capability Assessment 271
Design Capability and Performability 271
IEEE 1624 Scoring Guidelines 276
SEI CMMI Scoring Guidelines 277
Organizational Reliability Capability Assessment Process 278
Advantages of High Reliability 282
Conclusions 283
References 284
Index 285
