Maintainability, Maintenance, and Reliability for Engineers

✍ Scribed by B.S. Dhillon

• Publisher: CRC/Taylor & Francis
• Year: 2006
• Tongue: English
• Leaves: 221
• Edition: 1
• Category: Library

✦ Synopsis

The demands of the global economy require manufacturers to produce highly reliable and easily maintainable engineering products. Recent studies indicate that for many large and sophisticated products or systems, maintenance, and support account for as much as 60 to 75 percent of their life cycle costs. Therefore, the role of maintainability, maintenance, and reliability has become increasingly significant. Satisfying the pressing need for a volume that addresses these subjects with an interdiscilinary approach, Maintainability, Maintenance, and Reliability for Engineers distills knowledge specific to each discipline into one comprehensive resource. After reviewing the history of all three fields and their interrelationships, the book covers mathematical concepts such as Boolean algebra laws, probability properties, mathematical definitions, and probability distributions. It includes reliability evaluation methods such as fault tree analysis, network reduction method, delta-method, Markov method, supplementary variables method, and reliabitity management, both mechanical and human. Highlihting maintainibility tools and functions, the author discusses topics in maintainibility management and costing including tasks during product life cycle, program plan, organization functions, design reviews, life cycle costing, investment cost elements, and life cycle cost estimation models. The author also includes coverage of maintenance engineering, focusing on safety, quality, corrective, and preventive maintenance. The book concludes with coverage of maintenance management costing and human errror in engineering maintenance and contains 60 illustrations, 16 tables, and more than 200 equations. There is a definite need to considermaintainibility, maintenance, and reliability during product/system design and other phases. To achieve this goal effectively, it is absoulutely imperative to have a certain degree of understanding of each of these disciplines. Although many books cover one or two of these topics, this is the first to cover all three in a manner useful to engineering professionals.

✦ Table of Contents

7243_c000......Page 1
Maintainability, Maintenance, and Reliability for Engineers......Page 2
Preface......Page 5
Author......Page 7
Contents......Page 8
1.1 NEED FOR MAINTAINABILITY, MAINTENANCE, AND RELIABILITY......Page 16
Table of Contents......Page 0
1.2.3 RELIABILITY......Page 17
1.3 MAINTAINABILITY, MAINTENANCE, AND RELIABILITY TERMS AND DEFINITIONS......Page 18
1.4.1 JOURNALS AND MAGAZINES......Page 19
1.4.3 DATA INFORMATION SOURCES......Page 20
1.5 PROBLEMS......Page 21
REFERENCES......Page 22
2.2 BOOLEAN ALGEBRA LAWS AND PROBABILITY PROPERTIES......Page 24
2.3.2 CUMULATIVE DISTRIBUTION FUNCTION......Page 27
2.3.7 EXPONENTIAL DISTRIBUTION......Page 28
2.3.8 RAYLEIGH DISTRIBUTION......Page 29
2.3.10 GAMMA DISTRIBUTION......Page 30
2.3.12 LOGNORMAL DISTRIBUTION......Page 31
2.4 LAPLACE TRANSFORMS AND THEIR APPLICATIONS TO DIFFERENTIAL EQUATIONS......Page 32
2.4.1 LAPLACE TRANSFORMS: INITIAL AND FINAL VALUE THEOREMS......Page 33
2.4.2 LAPLACE TRANSFORM APPLICATION TO DIFFERENTIAL EQUATIONS......Page 34
2.5 PROBLEMS......Page 35
REFERENCES......Page 36
3.2 BATHTUB HAZARD RATE CONCEPT......Page 37
3.3.2 HAZARD RATE FUNCTION......Page 39
3.3.3 GENERAL RELIABILITY FUNCTION......Page 40
3.3.4 MEAN TIME TO FAILURE......Page 41
3.4 RELIABILITY NETWORKS......Page 42
3.4.1 SERIES NETWORK......Page 43
3.4.2 PARALLEL NETWORK......Page 44
3.4.3 M-OUT-OF-N NETWORK......Page 46
3.4.4 STANDBY SYSTEM......Page 47
3.4.5 BRIDGE NETWORK......Page 49
3.5 RELIABILITY ALLOCATION......Page 50
3.5.1 HYBRID METHOD......Page 51
REFERENCES......Page 52
4.2 FAILURE MODES AND EFFECT ANALYSIS (FMEA)......Page 54
4.3 NETWORK REDUCTION METHOD......Page 55
4.4 DECOMPOSITION METHOD......Page 57
4.5 DELTA–STAR METHOD......Page 59
4.6 MARKOV METHOD......Page 62
4.7 SUPPLEMENTARY VARIABLES METHOD......Page 64
4.8 PROBLEMS......Page 66
REFERENCES......Page 67
5.3 A METHOD FOR ESTABLISHING RELIABILITY GOALS AND GUIDELINES FOR DEVELOPING RELIABILITY PROGRAMS......Page 68
5.4.1 CONCEPT AND DEFINITION PHASE......Page 70
5.4.2 ACQUISITION PHASE......Page 71
5.5 RELIABILITY MANAGEMENT TOOLS AND DOCUMENTS......Page 72
5.5.3 CRITICAL PATH METHOD......Page 73
5.6 RELIABILITY DEPARTMENT FUNCTIONS AND TASKS OF RELIABILITY ENGINEER......Page 74
5.7 PITFALLS IN RELIABILITY PROGRAM MANAGEMENT......Page 75
REFERENCES......Page 76
6.2 GENERAL MECHANICAL FAILURE CAUSES AND MODES......Page 78
6.3.2 SAFETY FACTOR 2......Page 80
6.4 STRESS–STRENTH INTERFERENCE THEORY MODELING......Page 81
6.4.1 MODEL 1......Page 82
6.4.2 MODEL 2......Page 83
6.5 GRAPHICAL METHOD FOR ESTIMATING MECHANICAL ITEMÌS RELIABILITY......Page 84
6.6 HUMAN ERROR OCCURRENCE FACTS AND FIGURES......Page 87
6.7 HUMAN ERROR CATEGORIES AND CAUSES......Page 88
6.8 HUMAN STRESS–PERFORMANCE EFFECTIVENESS AND STRESS FACTORS......Page 89
6.9 HUMAN PERFORMANCE RELIABILITY IN CONTINUOUS TIME AND MEAN TIME TO HUMAN ERROR MEASURE......Page 90
6.10.1 FAULT TREE ANALYSIS......Page 91
6.10.2 MARKOV METHOD......Page 94
REFERENCES......Page 96
7.2 ENGINEERING MAINTAINABILITY VERSUS ENGINEERING MAINTENANCE......Page 99
7.4 MAINTAINABILITY FUNCTIONS......Page 100
7.4.1 MAINTAINABILITY FUNCTION FOR EXPONENTIAL DISTRIBUTION......Page 101
7.4.3 MAINTAINABILITY FUNCTION FOR WEIBULL DISTRIBUTION......Page 102
7.4.4 MAINTAINABILITY FUNCTION FOR GAMMA DISTRIBUTION......Page 103
7.4.6 MAINTAINABILITY FUNCTION FOR NORMAL DISTRIBUTION......Page 104
7.4.7 MAINTAINABILITY FUNCTION FOR LOGNORMAL DISTRIBUTION......Page 105
REFERENCES......Page 106
8.2 FAULT TREE ANALYSIS......Page 108
8.4 FAILURE MODES, EFFECTS, AND CRITICALITY ANALYSIS (FMECA)......Page 112
8.5 TOTAL QUALITY MANAGEMENT......Page 114
8.6 MAINTAINABILITY DESIGN FACTORS......Page 115
8.7 STANDARDIZATION AND MODULARIZATION......Page 116
8.9 INTERCHANGEABILITY AND IDENTIFICATION......Page 118
8.10 PROBLEMS......Page 119
REFERENCES......Page 120
9.2 MAINTAINABILITY MANAGEMENT TASKS DURING THE PRODUCT LIFE CYCLE......Page 121
9.3 MAINTAINABILITY ORGANIZATION FUNCTIONS......Page 123
9.4 MAINTAINABILITY PROGRAM PLAN......Page 124
9.5 MAINTAINABILITY DESIGN REVIEWS......Page 125
9.7 LIFE CYCLE COSTING......Page 126
9.8 LIFE CYCLE COST ESTIMATION MODELS......Page 127
9.8.2 LIFE CYCLE COST ESTIMATION MODEL 2......Page 128
9.8.3 LIFE CYCLE COST ESTIMATION MODEL 3......Page 129
9.9 PROBLEMS......Page 133
REFERENCES......Page 134
10.2 GENERAL HUMAN BEHAVIORS......Page 135
10.3.2 SIGHT......Page 136
10.3.4 BODY MEASUREMENTS......Page 137
10.4 AUDITORY AND VISUAL WARNINGS IN MAINTENANCE WORK......Page 138
10.5 HUMAN FACTORS-RELATED FORMULAS......Page 139
10.5.2.1 Formula 1......Page 140
10.5.3 LIFTING LOAD ESTIMATION......Page 141
REFERENCES......Page 142
11.2 FACTS AND FIGURES RELATED TO ENGINEERING MAINTENANCE......Page 144
11.5 MAINTENANCE MEASURES......Page 145
11.5.3 INDEX 3......Page 146
11.5.7 INDEX 7......Page 147
11.6 SAFETY IN MAINTENANCE......Page 148
11.7 QUALITY IN MAINTENANCE......Page 149
REFERENCES......Page 150
12.2 TYPES OF CORRECTIVE MAINTENANCE......Page 152
12.3 CORRECTIVE MAINTENANCE STEPS, DOWNTIME COMPONENTS, AND TIME-REDUCTION STRATEGIES AT SYSTEM LEVEL......Page 153
12.4.1 MEAN CORRECTIVE MAINTENANCE TIME......Page 154
12.5.1 MATHEMATICAL MODEL 1......Page 155
12.5.2 MATHEMATICAL MODEL 2......Page 158
12.7 STEPS FOR DEVELOPING PREVENTIVE MAINTENANCE PROGRAM......Page 161
12.8.1 MEAN PREVENTIVE MAINTENANCE TIME......Page 162
12.9.1 MODEL 1......Page 163
12.9.2 MODEL 2......Page 164
12.11 PROBLEMS......Page 167
REFERENCES......Page 168
13.2 RCM GOALS AND PRINCIPLES......Page 170
13.3 RCM PROCESS-ASSOCIATED QUESTIONS AND RCM PROCESS......Page 172
13.4.1 REACTIVE MAINTENANCE......Page 173
13.4.2 PREDICTIVE TESTING AND INSPECTION......Page 174
13.4.4 PREVENTIVE MAINTENANCE......Page 175
13.5 RCM PROGRAM MEASURES......Page 176
13.5.3 INDEX 3......Page 177
13.6 RCM BENEFITS AND CAUSES FOR RCM METHODOLOGY FAILURES......Page 178
REFERENCES......Page 179
14.2 MAINTENANCE MANAGEMENT PRINCIPLES......Page 181
14.3 MAINTENANCE DEPARTMENT ORGANIZATION AND FUNCTIONS......Page 182
14.4 EFFECTIVE MAINTENANCE MANAGEMENT ELEMENTS......Page 183
14.5 QUESTIONS FOR EVALUATING MAINTENANCE PROGRAM EFFECTIVENESS......Page 185
14.6 MAINTENANCE COSTING REASONS AND MAINTENANCE COST INFLUENCES......Page 186
14.8.1 CORRECTIVE-MAINTENANCE LABOR-COST ESTIMATION MODEL......Page 187
14.8.2 TOTAL MAINTENANCE LABOR COST ESTIMATION MODEL......Page 188
14.9.3 MODEL 3......Page 189
REFERENCES......Page 190
15.2 MAINTENANCE ERROR-RELATED FACTS AND FIGURES......Page 192
15.3 REASONS FOR HUMAN ERROR IN MAINTENANCE......Page 193
15.4 MAJOR HUMAN FAILURES IN MAINTENANCE AND CLASSIFICATIONS OF MAINTENANCE ERRORS AND THEIR OCCURRENCE FREQUENCY......Page 194
15.5.1 MODEL 1......Page 195
15.5.2 MODEL 2......Page 197
15.6.1 DESIGN......Page 200
15.6.7 MAINTENANCE INCIDENT FEEDBACK......Page 201
15.7 PROBLEMS......Page 202
REFERENCES......Page 203
16.2 SOFTWARE MAINTENANCE FACTS AND FIGURES......Page 204
16.4.2 SOFTWARE CONFIGURATION MANAGEMENT......Page 205
16.5 SOFTWARE MAINTENANCE COST ESTIMATION MODELS......Page 206
16.5.2 MODEL 2......Page 207
16.6 ROBOT MAINTENANCE REQUIREMENTS AND TYPES......Page 209
16.8 ROBOT INSPECTION......Page 210
16.9 GUIDELINES FOR SAFEGUARDING ROBOT MAINTENANCE PERSONNEL......Page 211
16.10 MODEL FOR MAXIMIZING INCOME OF ROBOT SUBJECT TO REPAIR......Page 212
16.11 MEDICAL EQUIPMENT CLASSIFICATION AND INDEXES FOR MAINTENANCE AND REPAIR......Page 214
16.11.3 INDEX 3......Page 215
16.13 MODELS FOR MEDICAL EQUIPMENT MAINTENANCE......Page 216
16.13.1 MODEL 1......Page 217
16.13.2 MODEL 2......Page 218
REFERENCES......Page 219