Maintainability, Maintenance, and Reliability for Engineers

"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."--Publisher's website 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 Covers the topics of maintainability, maintenance, and reliability. This book discusses mechanical and human reliability as well as reliability evaluation methods. It also addresses various aspects of maintainability, including tools, specific maintainability design considerations, management, and costing.