A key reference for reliability professionals worldwide and widely adopted as a textbook by universities across many countries. This material also aligns with the Certified Reliability Engineer (CRE) curriculum set by the American Society for Quality (ASQ), making it a valuable resource for those preparing for the CRE certification. With a strong focus on practical engineering applications, the Sixth Edition of Practical Reliability Engineering continues to offer a balanced blend of reliability theory and real-world applications. This edition has been comprehensively updated to reflect the latest advancements in industry practices and state-of-the-art reliability engineering. Each chapter includes practical examples, and course instructors have access to a Solutions Manual and PowerPoint slides for training support available from the author at kleyner.consulting@sbcglobal.net. The sixth edition introduces several significant updates. Every chapter has been refreshed with new material, and two new chapters — Repairable Systems and Human Reliability — have been added. This edition also covers emerging topics in reliability engineering, such as prognostics and health management (PHM), Agile hardware development, the reliability challenges posed by the ongoing miniaturization of integrated circuits, and many more, ensuring that the content remains relevant to modern technological developments. Written by two highly qualified reliability professionals, each with decades of experience, this book covers nearly every aspect of reliability science and practice, making it a comprehensive reference guide. Practical Reliability Engineering has, over the years, helped to train multiple generations of reliability engineers and continues to be an essential resource for both emerging professionals and seasoned experts alike.

Table of Contents:
Preface xxi Acknowledgments xxiii Abbreviations and Acronyms Used in this Book xxv 1 Introduction to Reliability Engineering 1 1.1 What is Reliability Engineering? 1 1.2 Why Teach Reliability Engineering? 2 1.3 Why Do Engineering Products Fail? 4 1.4 Probabilistic Reliability 6 1.5 Repairable and Non-repairable Items 7 1.6 The Pattern of Failures With Time (Bathtub Curve) 8 1.7 The Development of Reliability Engineering 9 1.8 Courses, Conferences, and Literature 11 1.9 Organizations Involved in Reliability Work 12 1.10 Reliability as an Effectiveness Parameter 12 1.11 Reliability Program Activities 12 1.12 Reliability Economics and Management 14 Questions 16 Selected Bibliography 17 Periodic Publications on Reliability 17 2 Reliability Mathematics 19 2.1 Introduction 19 2.2 Variation 19 2.3 Probability Concepts 21 2.4 Rules of Probability 22 2.5 Continuous Variation 27 2.6 Continuous Distribution Functions 32 2.7 Summary of Continuous Statistical Distributions 40 2.8 Variation in Engineering 40 2.9 Discrete Variation 46 2.10 Statistical Confidence 49 2.11 Statistical Hypothesis Testing 50 2.12 Non-parametric Inferential Methods 53 2.13 Goodness of Fit 55 2.14 Computer Software for Statistics 57 2.15 Practical Conclusions 57 Questions 58 Selected Bibliography 61 3 Life Data Analysis and Probability Plotting 63 3.1 Introduction 63 3.2 Life Data Classification 64 3.3 Ranking of Data 67 3.4 Weibull Distribution 70 3.5 Computerized Data Analysis and Probability Plotting 77 3.6 Confidence Bounds for Life Data Analysis 80 3.7 Choosing the Best Distribution and Assessing the Results 87 3.8 Conclusions 95 Questions 95 Selected Bibliography 100 4 Repairable Systems 101 4.1 Introduction 101 4.2 Renewal Process 102 4.3 Non-Parametric and Graphical Methods 112 4.4 Conclusions 115 Questions 115 Selected Bibliography 117 5 Monte Carlo Simulation 119 5.1 Introduction 119 5.2 Monte Carlo Simulation Basics 119 5.3 Additional Statistical Distributions 119 5.4 Sampling a Statistical Distribution 122 5.5 Running a Monte Carlo Simulation 125 5.6 Monte Carlo Method Summary 129 Questions 130 Selected Bibliography 132 6 Load–Strength Interference 133 6.1 Introduction 133 6.2 Load and Strength Models 133 6.3 Analysis of Load–Strength Interference 138 6.4 Multiple Load Applications 141 6.5 Dynamic Models 142 6.6 Practical Aspects 144 Questions 145 Selected Bibliography 147 7 Reliability Prediction and Modeling 149 7.1 Introduction 149 7.2 Fundamental Limitations of Reliability Prediction 150 7.3 Standards-Based Reliability Prediction 151 7.4 Other Methods for Reliability Predictions 157 7.5 Practical Aspects of Reliability Prediction 159 7.6 Systems Reliability Models 160 7.7 Availability of Repairable Systems 164 7.8 Modular Design 168 7.9 Block Diagram Analysis 169 7.10 Fault Tree Analysis (FTA) 173 7.12 Petri Nets 181 7.13 Reliability Apportionment 184 7.14 Conclusions 185 Questions 186 Selected Bibliography 192 8 Design for Reliability 195 8.1 Introduction 195 8.2 Design for Reliability Process 196 8.3 Identify 198 8.4 Design 203 8.5 Analyze 215 8.6 Verify 216 8.7 Validate 216 8.8 Control 217 8.9 Assessing the DfR Capability of an Organization 220 8.10 Summary 221 Questions 221 Selected Bibliography 223 9 Reliability of Mechanical Components and Systems 225 9.1 Introduction 225 9.2 Mechanical Stress, Strength, and Fracture 225 9.3 Fatigue 229 9.4 Creep 235 9.5 Wear 236 9.6 Corrosion 237 9.7 Vibration and Shock 238 9.8 Temperature Effects 242 9.9 Materials 244 9.10 Components 245 9.11 Processes 246 Questions 247 Selected Bibliography 249 10 Electronic Systems Reliability 251 10.1 Introduction 251 10.2 Reliability of Electronic Components 252 10.3 Component Types and Failure Mechanisms 255 10.4 Power Electronics 278 10.5 Device Failure Modes and Their Distributions 279 10.6 Circuit and System Aspects 281 10.7 Design for Reliability in Electronic Systems 282 10.8 Parameter Variation and Tolerances 288 10.9 Design for Production, Test, and Maintenance 291 Questions 292 Selected Bibliography 294 11 Analysis of Variance (ANOVA) and Design of Experiments (DOE) 297 11.1 Introduction 297 11.2 Statistical Design of Experiments and Analysis of Variance 297 11.3 Randomizing the Data 308 11.4 Engineering Interpretation of Results 309 11.5 The Taguchi Method 310 11.6 Conclusions 313 Questions 315 Selected Bibliography 317 12 Reliability Testing 319 12.1 Introduction 319 12.2 Planning Reliability Testing 320 12.3 Test Environments 322 12.4 Testing for Reliability and Durability. Accelerated Testing 331 12.5 Test Planning 340 12.6 Failure Reporting, Analysis, and Corrective Action Systems (FRACAS) 341 Questions 343 Selected Bibliography 345 13 Analyzing Reliability Data and Accelerated Testing 347 13.1 Introduction 347 13.2 Pareto Analysis 347 13.3 Accelerated Test Data Analysis 349 13.4 Acceleration Factor 349 13.5 Acceleration Models 350 13.6 Field–Test Relationship 355 13.7 Statistical Analysis of Accelerated Test Data 356 13.8 Reliability Analysis of Repairable Systems 359 13.9 Cusum Charts 360 13.10 Exploratory Data Analysis and Proportional Hazards Modeling 362 13.11 Field and Warranty Data Analysis 364 Questions 368 Selected Bibliography 372 14 Reliability Demonstration and Growth 375 14.1 Introduction 375 14.2 Reliability Metrics 375 14.3 Test to Success (Success-Run Method) 376 14.4 Test to Failure Method 378 14.5 Extended Life Test 378 14.6 Continuous Testing 381 14.7 Degradation Analysis 382 14.8 Demonstrated Reliability vs. Population Reliability 385 14.9 Combining Results Using Bayesian Statistics 386 14.10 Non-parametric Methods 388 14.11 Reliability Demonstration Software 388 14.12 Practical Aspects of Reliability Demonstration 389 14.13 Standard Methods for Repairable Systems 390 14.14 Reliability Growth and Monitoring 395 14.15 Making Product Reliability Grow 402 Questions 404 Selected Bibliography 407 15 Reliability in Manufacture 409 15.1 Introduction 409 15.2 Control of Production Variability 409 15.3 Control Charts 411 15.4 Control of Human Variation 418 15.5 Acceptance Sampling 419 15.6 Improving the Process. Problem Solving 424 15.7 Stress Screening 428 15.8 Failure Reporting Analysis and Corrective Action System (FRACAS) in Production 431 15.9 Conclusions 432 Questions 432 Selected Bibliography 434 16 Human Reliability Analysis 435 J. Robert Taylor and Igor Kozine 16.1 Introduction 435 16.2 Human Performance and Error Taxonomy 436 16.3 Quantitative Methods of HEP Estimation 439 16.4 Identification of Human Error Possibilities: Action Error Analysis 445 16.5 Quantification of Human Error Scenarios Combined With A Technical Failure 452 16.6 Causal Analysis 452 16.7 Data for Human Error Probability Quantification 457 16.8 Models of System Reliability Accounting for Human Error 459 16.9 Conclusions 463 Questions 463 Selected Bibliography 465 17 Maintainability, Maintenance, and Availability 469 17.1 Introduction 469 17.2 Availability Measures 470 17.3 Maintenance Time Distributions 473 17.4 Preventive Maintenance Strategy 474 17.5 FMEA and FTA in Maintenance Planning 478 17.6 Maintenance Schedules 478 17.7 Technology Aspects 479 17.8 Calibration 481 17.9 Maintainability 482 17.10 Integrated Logistic Support 484 Questions 485 Selected Bibliography 486 18 Reliability Management 489 18.1 Corporate Policy for Reliability 489 18.2 Integrated Reliability Programs 489 18.3 Specifying Reliability 492 18.4 Reliability and Costs 494 18.5 Safety and Product Liability 499 18.6 Standards for Reliability, Quality, and Safety Programs 499 18.7 Managing Lower-Tier Suppliers 502 18.8 Reliability Manuals 503 18.9 The Project Reliability Plan 505 18.10 Use of External Services (Outsourcing) 506 18.11 Customer Management of Reliability 507 18.12 Product Sustainment Activities 509 18.13 Reliability Training and Expertise 511 18.14 Reliability Capability and Maturity of an Organization 512 18.15 Managing Production Quality 514 18.16 Choosing the Methods: Strategy and Tactics 516 18.17 AI in Practical Reliability Engineering 517 18.18 Conclusions: The Importance of Reliability Management 518 Questions 520 Selected Bibliography 521 Appendix 1 Software Reliability 523 Appendix 2 Kolmogorov–Smirnov Tables 549 Appendix 3 Chi-square Distribution and MTTF/MTBF Calculations 551 Appendix 4 Matrix Algebra Revision 553 Appendix 5 Reliability, Maintainability, and Safety Plan Example 555 Index 561