Reliability, quality, and safety for engineers

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Title:

Personal Author:

Dhillon, Balbir S.

Publication Information:

Boca Raton, FL : CRC Press, 2004

ISBN:

9780849330681

Subject Term:

Reliability (Engineering)

Engineering design

Industrial safety

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Library	Item Barcode	Call Number	Material Type	Item Category 1	Status
Searching... PSZ JB	30000010082562	TS173 D44 2004	Open Access Book	Book	Searching... Unknown

Due to global competition, safety regulations, and other factors, manufacturers are increasingly pressed to create products that are safe, highly reliable, and of high quality. Engineers and quality assurance professionals need a cross-disciplinary understanding of these topics in order to ensure high standards in the design and manufacturing processes. Reliability, Quality, and Safety for Engineers is the first publication to integrate this information in a single source.

The text begins with an introduction that discusses the need for reliability, quality and safety as well as historical information, terms, and definitions. Subsequent chapters discuss relevant mathematics, evaluation models and methods, testing, management, and costing. The author treats each topic in a comprehensive manner that requires no prior knowledge of the subject in order to understand the contents.

The author includes numerous examples, problems, and solutions to test the reader's comprehension. He also lists important journals, organizations, standards, and books for further study, creating a comprehensive resource for design, system, safety and manufacturing engineers as well as reliability specialists and quality assurance professionals.

Author Notes

B.S. Dhillon received his Ph.D. in industrial engineering from the University of Windsor. He received his M.S. in mechanical engineering and B.S. in electrical and electronic engineering from the University of Wales.

Dr. Dhillon is a professor of engineering management in mechanical engineering at the University of Ottawa.

050

1 Introduction	p. 1
1.1 Need for Reliability, Quality, and Safety	p. 1
1.2 History	p. 2
1.2.1 Reliability	p. 2
1.2.2 Quality	p. 2
1.2.3 Safety	p. 3
1.3 Terms and Definitions	p. 3
1.4 Useful Information on Reliability, Quality, and Safety	p. 5
1.4.1 Journals	p. 5
1.4.2 Standards	p. 6
1.4.3 Conference Proceedings	p. 7
1.4.4 Organizations	p. 8
1.4.5 Books	p. 8
1.5 Problems	p. 9
2 Reliability, Quality, and Safety Mathematics	p. 13
2.1 Introduction	p. 13
2.2 Mode, Median, Range, Arithmetic Mean, Root Mean Square, Mean Deviation, and Standard Deviation	p. 13
2.2.1 Mode	p. 14
2.2.2 Median	p. 14
2.2.3 Range	p. 15
2.2.4 Arithmetic Mean	p. 15
2.2.5 Root Mean Square	p. 16
2.2.6 Mean Deviation	p. 16
2.2.7 Standard Deviation	p. 17
2.3 Boolean Algebra Laws	p. 18
2.4 Probability Definition and Properties	p. 18
2.5 Useful Mathematical Definitions	p. 20
2.5.1 Probability Density and Cumulative Distribution Functions	p. 20
2.5.2 Expected Value	p. 21
2.5.3 Variance	p. 21
2.5.4 Laplace Transform	p. 22
2.5.5 Laplace Transform: Final-Value Theorem	p. 22
2.6 Solving First Order Differential Equations with Laplace Transforms	p. 23
2.7 Statistical Distributions	p. 25
2.7.1 Normal Distribution	p. 25
2.7.2 Binomial Distribution	p. 25
2.7.3 Poisson Distribution	p. 26
2.7.4 Exponential Distribution	p. 27
2.7.5 Rayleigh Distribution	p. 27
2.7.6 Weibull Distribution	p. 28
2.8 Problems	p. 28
3 Introduction to Reliability	p. 31
3.1 Need for Reliability	p. 31
3.2 Bathtub Hazard Rate Curve	p. 32
3.3 General and Specific Hazard Rate Functions	p. 33
3.3.1 Hazard Rate for Exponential Distribution	p. 33
3.3.2 Hazard Rate for Weibull Distribution	p. 34
3.3.3 Hazard Rate for General Distribution	p. 34
3.4 General and Specific Reliability Functions	p. 35
3.4.1 Reliability Function for Exponential Distribution	p. 36
3.4.2 Reliability Function for Weibull Distribution	p. 36
3.4.3 Reliability Function for General Distribution	p. 36
3.5 Mean Time to Failure	p. 36
3.5.1 Equation (3.19) Derivation	p. 37
3.5.2 Equation (3.20) Derivation	p. 38
3.6 Failure Rate Estimation	p. 40
3.7 Failure Data Collection, Sources, and Failure Rates for Selected Items	p. 42
3.7.1 Failure Rates for Selected Items	p. 43
3.8 Problems	p. 43
4 Static Reliability Evaluation Models	p. 47
4.1 Introduction	p. 47
4.2 Series Network	p. 47
4.3 Parallel Network	p. 49
4.4 k-Out-of-m Network	p. 51
4.5 Series-Parallel Network	p. 52
4.6 Parallel-Series Network	p. 54
4.7 Bridge Network	p. 56
4.8 Problems	p. 58
5 Dynamic Reliability Evaluation Models	p. 61
5.1 Introduction	p. 61
5.2 Series Network	p. 61
5.2.1 Series System Reliability and Mean Time to Failure with Weibull Distributed Units' Times to Failure	p. 63
5.2.2 Series System Reliability with Nonconstant Failure Rates of Units	p. 64
5.3 Parallel Network	p. 65
5.4 k-Out-of-m Network	p. 67
5.5 Series-Parallel Network	p. 70
5.6 Parallel-Series Network	p. 71
5.7 Standby System	p. 72
5.8 Bridge Network	p. 74
5.9 Problems	p. 75
6 Reliability Evaluation Methods	p. 79
6.1 Introduction	p. 79
6.2 Network Reduction Method	p. 79
6.3 Fault Tree Analysis (FTA) Method	p. 82
6.3.1 Fault Tree Symbols and Basic Steps for Developing a Fault Tree	p. 82
6.3.2 Probability Evaluation of Fault Trees	p. 83
6.4 Markov Method	p. 86
6.5 Decomposition Method	p. 87
6.6 Failure Modes and Effect Analysis (FMEA) Method	p. 90
6.7 Common Cause Failure Analysis Method	p. 91
6.8 Problems	p. 95
7 Reliability Testing	p. 99
7.1 Introduction	p. 99
7.2 Types of Reliability Testing	p. 99
7.3 Tests for Determining the Validity of an Item's Exponentially Distributed Times to Failure	p. 101
7.3.1 Test I	p. 101
7.3.2 Test II	p. 103
7.4 Confidence Limit Estimation on Mean Item Life	p. 105
7.4.1 Method I	p. 106
7.4.2 Method II	p. 107
7.5 Economics of Testing	p. 109
7.6 Problems	p. 110
8 Reliability Management and Costing	p. 113
8.1 Introduction	p. 113
8.2 General Management Reliability Program-Related Responsibilities and Guiding Force Associated Facts for an Effective Reliability Program	p. 113
8.3 An Approach for Developing Reliability Goals and Useful Guidelines for Developing Reliability Programs	p. 115
8.4 Reliability Engineering Department Responsibilities and Tasks of a Reliability Engineer	p. 116
8.5 Reliability Cost	p. 117
8.6 Reliability Activity Cost Estimation Models	p. 118
8.6.1 Reliability Prediction Manhour Estimation Model	p. 119
8.6.2 Reliability Modeling/Allocation Manhour Estimation Model	p. 119
8.6.3 Reliability and Maintainability Program Plan Manhour Estimation Model	p. 119
8.6.4 Reliability Testing Manhour Estimation Model	p. 120
8.6.5 Failure Modes and Effect Analysis (FMEA) Manhour Estimation Model	p. 120
8.6.6 Failure Reporting and Corrective Action System (FRACAS) Manhour Estimation Model	p. 120
8.6.7 Reliability and Maintainability Management Manhour Estimation Model	p. 121
8.7 Problems	p. 121
9 Introduction to Quality	p. 123
9.1 Introduction	p. 123
9.2 Comparisons of Modern and Traditional Products, Direct Factors Influencing the Quality of Product and Services, and Quality Design Characteristics	p. 123
9.3 Quality Goals	p. 124
9.4 Quality Assurance System Elements	p. 125
9.5 Design for Quality	p. 126
9.6 Total Quality Management (TQM)	p. 127
9.6.1 TQM Elements and Goals for TQM Process Success	p. 128
9.6.2 Deming Approach to TQM	p. 129
9.6.3 Obstacles to TQM Implementation	p. 130
9.6.4 Selected Books on TQM and Organizations that Promote the TQM Concept	p. 131
9.7 Problems	p. 132
10 Quality Analysis Methods	p. 135
10.1 Introduction	p. 135
10.2 Quality Control Charts	p. 135
10.2.1 The p-Charts	p. 136
10.2.2 The R-Charts	p. 138
10.2.3 The X-Charts	p. 141
10.2.4 The c-Charts	p. 143
10.3 Pareto Diagram	p. 146
10.4 Quality Function Deployment (QFD)	p. 146
10.5 Scatter Diagram	p. 147
10.6 Cause-and-Effect Diagram	p. 149
10.7 Hoshin Kanri	p. 150
10.8 Design of Experiments (DOE)	p. 151
10.9 Fault Tree Analysis (FTA)	p. 151
10.10 Failure Modes and Effect Analysis (FMEA)	p. 153
10.11 Problems	p. 153
11 Quality Management and Costing	p. 155
11.1 Introduction	p. 155
11.2 Upper and Middle Management Quality-Related Roles	p. 155
11.3 Quality Control Engineering Functions and Quality-Related Responsibilities Among Various Organizational Groups	p. 156
11.4 Steps for Planning the Quality Control Organizational Structure and Quality Control Organizational Methods	p. 157
11.5 Quality Manager Attributes, Functions, and Reasons for Failure	p. 159
11.6 Quality Control Manual and Quality Auditing	p. 160
11.7 Procurement Quality Control	p. 160
11.7.1 Useful Guidelines for Controlling Incoming Part/Materials	p. 161
11.7.2 Incoming Material Inspection	p. 161
11.7.3 Formulas for Determining Accuracy and Waste of Inspectors and Vendor Quality Rating	p. 162
11.8 Quality Costs	p. 164
11.8.1 Classifications of Quality Costs	p. 164
11.9 Quality Cost Indexes	p. 165
11.9.1 Index I	p. 165
11.9.2 Index II	p. 166
11.9.3 Index III	p. 166
11.10 Problems	p. 166
12 Introduction to Safety	p. 169
12.1 Need for Safety	p. 169
12.2 Safety-Related Facts and Figures	p. 169
12.3 Engineers and Safety	p. 170
12.4 Product Hazard Classifications and Common Mechanical Injuries	p. 171
12.5 Statute, Common, Administrative, and Liability Laws and Product Liability	p. 173
12.6 Workers' Compensation	p. 175
12.7 Problems	p. 175
13 Safety Analysis Methods	p. 177
13.1 Introduction	p. 177
13.2 Cause and Effect Diagram (CAED)	p. 177
13.3 Fault Tree Analysis (FTA)	p. 178
13.4 Control Charts	p. 180
13.5 Markov Method	p. 181
13.6 Failure Modes and Effect Analysis (FMEA)	p. 184
13.7 Hazards and Operability Analysis (HAZOP)	p. 184
13.8 Technic of Operations Review (TOR)	p. 184
13.9 Interface Safety Analysis (ISA)	p. 186
13.10 Job Safety Analysis (JSA)	p. 187
13.11 Safety Indexes	p. 187
13.11.1 Disabling Injury Severity Rate (DISR)	p. 187
13.11.2 Disabling Injury Frequency Rate (DIFR)	p. 188
13.12 Problems	p. 188
14 Safety Management and Costing	p. 191
14.1 Introduction	p. 191
14.2 Safety Management Principles and Developing a Safety Program Plan	p. 191
14.3 Safety Department Functions	p. 193
14.4 Functions and Qualifications of Safety Professionals	p. 193
14.4.1 Safety Manager	p. 193
14.4.2 Safety Engineer	p. 194
14.5 Safety Committees and Motivating Employees to Work Safely	p. 195
14.6 A Manufacturer's Losses or Cost due to an Accident Involving its Product	p. 196
14.7 Safety Cost Estimation Methods and Models	p. 197
14.7.1 The Simonds Method	p. 197
14.7.2 The Heinrich Method	p. 198
14.7.3 Total Safety Cost Estimation Model	p. 198
14.8 Safety Cost Indexes	p. 199
14.8.1 Index I	p. 199
14.8.2 Index II	p. 199
14.8.3 Index III	p. 199
14.9 Problems	p. 200
15 Robot, Software, and Medical Device Safety	p. 203
15.1 Introduction	p. 203
15.2 Robot Safety	p. 204
15.2.1 Facts and Figures	p. 204
15.2.2 Robot Safety Problems	p. 204
15.2.3 Types of Robot Accidents	p. 205
15.2.4 Robot Hazard Causes	p. 205
15.2.5 Robot Safeguard Methods	p. 206
15.3 Software Safety	p. 207
15.3.1 Facts and Figures	p. 207
15.3.2 Software Safety vs. Reliability	p. 208
15.3.3 Software Hazard Causing Ways	p. 208
15.3.4 Basic Software System Safety Tasks	p. 208
15.3.5 Software Hazard Analysis Methods	p. 209
15.4 Medical Device Safety	p. 210
15.4.1 Facts and Figures	p. 210
15.4.2 Medical Device Safety vs. Reliability	p. 210
15.4.3 Types of Medical Device Safety	p. 211
15.4.4 Patient Injury and Medical Device Accident Causes	p. 212
15.4.5 Medical Device Safety Requirements	p. 212
15.5 Problems	p. 212
Index	p. 217

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