Reliability, Maintainability, and Safety for Engineers

237 Pages·2020·8.405 MB·\237

by  B.S. Dhillon (Author)

Reliability, Maintainability,
and Safety for Engineers

Reliability, Maintainability,
and Safety for Engineers
B.S. Dhillon
First edition published 2020
by CRC Press
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Library of Congress Cataloging‑in‑Publication Data
ISBN: 978-0-367-35265-3 (hbk)
ISBN: 978-0-429-34057-4 (ebk)
Typeset in Palatino
by Cenveo® Publisher Services
Dedication
This book is affectionately dedicated
to my younger brother
Balwant S. Dhillon and his
wife Debbi Dhillon.

Contents
Preface ..............................................................................................................xiii
About the author ...........................................................................................xvii
Chapter 1 Introduction ..................................................................................1
1.1 Background ..............................................................................................1
1.2 Reliability, maintainability, and safety facts, figures,
and examples ............................................................................................2
1.3 Terms and definitions .............................................................................3
1.4 Useful sources for obtaining information on reliability,
maintainability, and safety.....................................................................5
1.5 Scope of the book .....................................................................................8
1.6 Problems ...................................................................................................9
References ............................................................................................................9
Chapter 2 Reliability, maintainability, and safety mathematics .......13
2.1 Introduction ............................................................................................13
2.2 Arithmetic mean and mean deviation ...............................................13
2.3 Boolean algebra laws .............................................................................15
2.4 Probability definition and properties .................................................16
2.5 Mathematical definitions ......................................................................18
2.6 Probability distributions .......................................................................22
2.7 Solving first-order differential equations with Laplace
transforms ...............................................................................................25
2.8 Problems .................................................................................................27
References ..........................................................................................................27
Chapter 3 Reliability, maintainability, and safety basics....................31
3.1 Introduction ............................................................................................31
3.2 Bathtub hazard rate curve ....................................................................31
3.3 General reliability formulas .................................................................33
3.4 Reliability networks ..............................................................................37
vii
viii Contents
3.5 The importance, purpose, and results of maintainability
efforts .......................................................................................................47
3.6 Maintainability versus reliability ........................................................48
3.7 Maintainability functions.....................................................................49
3.8 The role of engineers in regard to safety ...........................................51
3.9 Safety management principles and organization tasks for
product safety ........................................................................................52
3.10 Product hazard classifications .............................................................54
3.11 Accident causation theories..................................................................55
3.12 Problems .................................................................................................57
References ..........................................................................................................58
Chapter 4 Methods for performing reliability, maintainability,
and safety analysis ...................................................................61
4.1 Introduction ............................................................................................61
4.2 Fault tree analysis (FTA) .......................................................................61
4.3 Failure modes and effect analysis (FMEA) ........................................65
4.4 Markov method .....................................................................................66
4.5 Cause and effect diagram .....................................................................69
4.6 Probability tree analysis .......................................................................70
4.7 Hazard and operability analysis (HAZOP) .......................................73
4.8 Technique of operations review (TOR) ...............................................75
4.9 Job safety analysis (JSA) ........................................................................76
4.10 Interface safety analysis (ISA) ..............................................................77
4.11 Problems .................................................................................................78
References ..........................................................................................................78
Chapter 5 Reliability management ..........................................................81
5.1 Introduction ............................................................................................81
5.2 General management reliability program responsibilities and
guiding force-related facts for the general management for an
effective reliability program ................................................................81
5.3 A procedure for developing reliability goals and useful
guidelines for developing reliability programs ............................... 82
5.4 Reliability and maintainability management-related tasks
in the product life cycle ........................................................................83
5.5 Reliability management documents and tools ..................................86
5.6 Reliability engineering department responsibilities and
a reliability engineer’s tasks .................................................................88
5.7 Pitfalls in reliability program management and useful rules
for reliability professionals ..................................................................89
5.8 Problems .................................................................................................90
References ..........................................................................................................90
Contents ix
Chapter 6 Human and mechanical reliability ........................................93
6.1 Introduction ............................................................................................93
6.2 Human error occurrence facts and figures ........................................93
6.3 Human error classifications and causes .............................................94
6.4 Human stress-performance effectiveness and stress factors ..........95
6.5 Human performance reliability in continuous time and mean
time to human error (MTTHE) measure ............................................96
6.6 Human reliability analysis methods ..................................................98
6.7 Mechanical failure modes and general causes ................................102
6.8 Safety factors and safety margin .......................................................105
6.9 Stress–strength interference theory modeling ................................107
6.10 Failure rate models ..............................................................................109
6.11 Problems ................................................................................................111
References .........................................................................................................111
Chapter 7 Reliability testing and growth .............................................115
7.1 Introduction ...........................................................................................115
7.2 Reliability test classifications ..............................................................115
7.3 Success testing .......................................................................................116
7.4 Accelerated life testing .........................................................................118
7.5 Confidence interval estimates for mean time between
failures ...................................................................................................121
7.6 Reliability growth program and reliability growth process
evaluation approaches ........................................................................125
7.7 Reliability growth models ..................................................................127
7.8 Problems ...............................................................................................129
References ........................................................................................................130
Chapter 8 Maintainability management ...............................................131
8.1 Introduction ..........................................................................................131
8.2 Maintainability management functions during the product
life cycle .................................................................................................131
8.3 Maintainability organization functions ...........................................133
8.4 Maintainability program plan ...........................................................135
8.5 Maintainability design reviews .........................................................137
8.6 Maintainability-associated personnel ..............................................139
8.7 Problems ...............................................................................................140
References .........................................................................................................141
Chapter 9 Human factors in maintainability .......................................143
9.1 Introduction ..........................................................................................143
9.2 General human behaviors ..................................................................143
9.3 Human body measurements ..............................................................144
9.4 Human sensory capabilities ...............................................................146