Accelerated quality and reliability solutions

PREFACE, Lev M. Klyatis xiii INTRODUCTION, Lev M. Klyatis xix CHAPTER 1. ACCURATE PHYSICAL SIMULATION OF FIELD INPUT INFLUENCES ON THE ACTUAL PRODUCT, Lev M. Klyatis 1 1 INTRODUCTION 1 1.1 General 1 1.2 Elements of history of physical simulation development 1 1.3 Simulation for accelerated quality development and improvement through accelerated reliability testing and experimental research 4 2 THE STRATEGY FOR DEVELOPMENT OF ACCURATE PHYSICAL SIMULATION OF FIELD INPUT INFLUENCES 7 2.1 Basic concepts 7 2.2 Accuracy of the simulation 13 2.3 Degradation (failure) mechanism of the product as a criterion for an accurate simulation of field input influences 15 2.4 Obtaining accurate initial information from the field 19 2.5 A methodology for selecting a representative input region for accurate simulation of the field conditions 22 2.5.1 Introduction 22 2.5.2 Methodology for selecting a representative region 23 2.5.3 Example of selecting a representative region 26 2.6 References 32 3 CLIMATE AND RELIABILITY 33 3.1 Introduction 33 3.2 The climate characteristics as external conditions of machinery use 33 3.2.1 The classifications and characteristics of world climate for technical goals 33 3.2.2 The characteristics of the radiation regime 35 3.2.3 The characteristics of the air thermal regime 40 3.2.4 Daily variations of air temperature 40 3.2.5 Air humidity and rains 41 3.2.6 Characteristics of wind speed 41 3.2.7 Atmospheric phenomena 41 3.2.8 Characteristics of environmental factors in combination 42 3.2.9 Biological factors 42 3.3 The influence of climatic factors and atmospheric phenomena on the properties of the materials and on the system "operator-machine-subject of the machine influence" 42 3.3.1 Influence of solar radiation 43 3.3.2 Influence of high temperatures 48 3.3.3 Influence of daily and yearly fluctuations of air temperatures and rapid changes of other climatic factors 50 3.3.4 Influence of water (moisture), air humidity, fog, and dew 52 3.3.5 The characteristics of complex influences of basic climatic factors 54 3.4 References 62 Contents viii 4 THE SYSTEM OF CONTROL FOR PHYSICAL SIMULATION OF THE RANDOM INPUT INFLUENCES* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 4.1 Principles for simulation of random input influences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 4.2 The mechanisms for control of simulation of the field random input influences . . . . . . . . . . . . . 71 4.3 Example of physical simulation of random input influences on the trailer . . . . . . . . . . . . . . . . . . 76 4.4 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 5 SUBSTITUTION OF ARTIFICIAL MEDIA FOR NATURAL (TECHNOLOGICAL) MEDIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 5.1 Basic concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83 5.2 Example of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 5.3 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 CHAPTER 2. USEFUL ACCELERATED RELIABILITY TESTING PERFORMANCE, Lev M. Klyatis, Eugene L. Klyatis . . . . . . . . . . . . . . . . . . . . . . . . 93 6 GENERAL REVIEW OF ACCELERATED TESTING METHODS . . . . . . . . . . . . . . . . . . . . . . . 93 7 SPECIFIC ACCELERATED RELIABILITY TESTING TECHNOLOGY . . . . . . . . . . . . . . . . . 105 7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 7.2 Analysis of different approaches to accelerated reliability testing. . . . . . . . . . . . . . . . . . . . . . . . 106 7.3 Basic concepts of useful accelerated reliability testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 7.4 Reliability (dependability) and life cycle costing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 7.5 Useful accelerated reliability testing (UART) as a combination of accelerated laboratory testing and special field testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 7.6 Accelerated laboratory testing technology which provides simultaneous combination of environmental, mechanical, electrical, and other types of testing . . . . . . . . . . . 126 7.7 Equipment for accelerated reliability testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 7.8 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 8 TECHNOLOGY OF STEP-BY-STEP USEFUL ACCELERATED RELIABILITY TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 8.1 Step 1: Collection of the initial information from the field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 8.2 Step 2: Analysis of the above information as a random process with an evaluation of the statistical characteristics of the studied parameters. . . . . . . . . . . . . 137 8.3 Step 3: Establishing concepts and statistical criteria for the physical simulation of the input influences on the product selected for useful accelerated reliability testing. . . . . . 138 8.4 Step 4: Development and use of the test equipment which simulates the field input influences on the actual product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 8.5 Step 5: Determining the number and types of test parameters for analysis during useful accelerated reliability testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 8.6 Step 6: Selecting a representative input region for useful accelerated reliability testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 8.7 Step 7: Procedure for useful accelerated reliability testing preparation. . . . . . . . . . . . . . . . . . . . 143 8.8 Step 8: Use of statistical criteria for comparison of accelerated reliability testing results and field results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 8.9 Step 9: Collection, calculation, and statistical analysis of useful accelerated reliability testing data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150 Contents 4 THE SYSTEM OF CONTROL FOR PHYSICAL SIMULATION OF THE RANDOM INPUT INFLUENCES* 65 4.1 Principles for simulation of random input influences 65 4.2 The mechanisms for control of simulation of the field random input influences 71 4.3 Example of physical simulation of random input influences on the trailer 76 4.4 References 81 5 SUBSTITUTION OF ARTIFICIAL MEDIA FOR NATURAL (TECHNOLOGICAL) MEDIA 83 5.1 Basic concepts 83 5.2 Example of use 86 5.3 References 92 CHAPTER 2. USEFUL ACCELERATED RELIABILITY TESTING PERFORMANCE, Lev M. Klyatis, Eugene L. Klyatis 93 6 GENERAL REVIEW OF ACCELERATED TESTING METHODS 93 7 SPECIFIC ACCELERATED RELIABILITY TESTING TECHNOLOGY 105 7.1 Introduction 105 7.2 Analysis of different approaches to accelerated reliability testing 106 7.3 Basic concepts of useful accelerated reliability testing 110 7.4 Reliability (dependability) and life cycle costing 116 7.5 Useful accelerated reliability testing (UART) as a combination of accelerated laboratory testing and special field testing 120 7.6 Accelerated laboratory testing technology which provides simultaneous combination of environmental, mechanical, electrical, and other types of testing 126 7.7 Equipment for accelerated reliability testing 127 7.8 References 132 8 TECHNOLOGY OF STEP-BY-STEP USEFUL ACCELERATED RELIABILITY TESTING 135 8.1 Step 1: Collection of the initial information from the field 135 8.2 Step 2: Analysis of the above information as a random process with an evaluation of the statistical characteristics of the studied parameters 137 8.3 Step 3: Establishing concepts and statistical criteria for the physical simulation of the input influences on the product selected for useful accelerated reliability testing 138 8.4 Step 4: Development and use of the test equipment which simulates the field input influences on the actual product 140 8.5 Step 5: Determining the number and types of test parameters for analysis during useful accelerated reliability testing 141 8.6 Step 6: Selecting a representative input region for useful accelerated reliability testing 143 8.7 Step 7: Procedure for useful accelerated reliability testing preparation 143 8.8 Step 8: Use of statistical criteria for comparison of accelerated reliability testing results and field results 143 8.9 Step 9: Collection, calculation, and statistical analysis of useful accelerated reliability testing data 150 Contents ix 8.10 Step 10: Evaluation and prediction of the dynamics of the test subject’s reliability, durability, and maintainability during its service life . . . . . . . . . . . . . . . . . . . . . . . . . 151 8.11 Step 11: Using accelerated reliability testing results for rapid and cost-effective test subject development and improvement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 8.12 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 9 ACCELERATED MULTIPLE ENVIRONMENTAL TESTING TECHNOLOGY . . . . . . . . . . 156 9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 9.2 The strategy of the establishment of accelerated multiple environmental testing conditions. . . 160 9.3 Basic environmental influences on the product and the main scheme of accelerated multiple environmental testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 9.4 Mechanism of the influences of solar radiation on the destruction of polymers and rubber. Simulation of these influences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 9.4.1 Influence of radiation on the diminution of plastic’s quality . . . . . . . . . . . . . . . . . . . . . . . . . . 165 9.4.2 Chemical factors in the destruction of plastics and rubbers. . . . . . . . . . . . . . . . . . . . . . . . . . . 167 9.4.3 Sources of light for solar radiation simulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 9.4.4 Equipment for lighting technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 9.4.5 Basic principles of development of lighting module elements . . . . . . . . . . . . . . . . . . . . . . . . 169 9.5 Accelerated weathering testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 9.6 Trends in the development of environmental testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 9.7 Accelerated corrosion testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 9.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 9.7.2 Current accelerated corrosion testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 9.7.3 Development of the technique of accelerated corrosion testing . . . . . . . . . . . . . . . . . . . . . . . 185 9.7.4 Accelerated corrosion testing for the complete product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 9.7.5 Anaerobic microbial corrosion of steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 9.8 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 10 ACCELERATED VIBRATION TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 10.1 Analysis of the current situation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 10.2 Development of accelerated vibration testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 10.3 System of control for vibration testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 10.4 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 11 ACCELERATED DYNAMOMETER TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 11.1 Product overview on the market . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 11.2 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 12 ACCELERATED TESTING OF FARM AND OFF-HIGHWAY MACHINERY. . . . . . . . . . . 242 12.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 12.2 Some aspects of accelerated stress testing technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 12.3 Special equipment for accelerated testing of farm machinery . . . . . . . . . . . . . . . . . . . . . . . . . 258 12.4 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 13 DETERMINATION OF THE NUMBER OF TESTED PRODUCT . . . . . . . . . . . . . . . . . . . . . 272 13.1 Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 13.2 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 Contents 8.10 Step 10: Evaluation and prediction of the dynamics of the test subject's reliability, durability, and maintainability during its service life 151 8.11 Step 11: Using accelerated reliability testing results for rapid and cost-effective test subject development and improvement 152 8.12 References 155 9 ACCELERATED MULTIPLE ENVIRONMENTAL TESTING TECHNOLOGY 156 9.1 Introduction 156 9.2 The strategy of the establishment of accelerated multiple environmental testing conditions. . . 160 9.3 Basic environmental influences on the product and the main scheme of accelerated multiple environmental testing 161 9.4 Mechanism of the influences of solar radiation on the destruction of polymers and rubber. Simulation of these influences 165 9.4.1 Influence of radiation on the diminution of plastic's quality 165 9.4.2 Chemical factors in the destruction of plastics and rubbers 167 9.4.3 Sources of light for solar radiation simulation 167 9.4.4 Equipment for lighting technology 169 9.4.5 Basic principles of development of lighting module elements 169 9.5 Accelerated weathering testing 170 9.6 Trends in the development of environmental testing 175 9.7 Accelerated corrosion testing 178 9.7.1 Introduction 178 9.7.2 Current accelerated corrosion testing 181 9.7.3 Development of the technique of accelerated corrosion testing 185 9.7.4 Accelerated corrosion testing for the complete product 198 9.7.5 Anaerobic microbial corrosion of steel 200 9.8 References 202 10 ACCELERATED VIBRATION TESTING 205 10.1 Analysis of the current situation 205 10.2 Development of accelerated vibration testing 216 10.3 System of control for vibration testing 222 10.4 References 233 11 ACCELERATED DYNAMOMETER TESTING 236 11.1 Product overview on the market 236 11.2 References 241 12 ACCELERATED TESTING OF FARM AND OFF-HIGHWAY MACHINERY 242 12.1 Introduction 242 12.2 Some aspects of accelerated stress testing technique 242 12.3 Special equipment for accelerated testing of farm machinery 258 12.4 References 270 13 DETERMINATION OF THE NUMBER OF TESTED PRODUCT 272 13.1 Solution 272 13.2 References 275 Contents x 14 TRENDS IN THE DEVELOPMENT OF USEFUL ACCELERATED RELIABILITY TESTING TECHNOLOGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276 14.1 Analysis of current situation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 14.2 Trends in the development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 14.3 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 CHAPTER 3. ACCURATE PREDICTION OF RELIABILITY, DURABILITY, AND MAINTAINABILITY ON THE BASIS OF USEFUL ACCELERATED RELIABILITY TESTING RESULTS, Lev M. Klyatis. . . . . . 285 15 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 16 CRITERIA OF ACCURATE PREDICTION OF RELIABILITY AND MAINTAINABILITY BY RESULTS OF USEFUL ACCELERATED RELIABILITY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 16.1 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 17 DEVELOPMENT OF TECHNIQUES FOR PRODUCT RELIABILITY PREDICTION ON THE BASIS OF USEFUL ACCELERATED RELIABILITY TESTING RESULTS . . . . . 306 17.1 Basic concepts of reliability prediction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 17.2 Prediction of the reliability function without finding the accurate analytical or graphical forms of the failures’ distribution law . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 17.3 Prediction using the mathematical models with indication of the dependence between product reliability and different factors of manufacturing and field . . . . . . . . . . . . . . 309 17.4 Practical example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 18 PREDICTION OF SYSTEM RELIABILITY FROM ACCELERATED TESTING RESULTS OF THE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .318 18.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 18.2 Confidence bounds for simple Weibull model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 18.3 Multi-variate Weibull model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322 18.4 Practical examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 18.5 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 19 DURABILITY PREDICTION WITH CONSIDERATION OF EXPENSES AND LOSSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 19.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329 19.2 Principal scheme of optimal durability prediction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329 19.3 Practical example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335 19.4 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 20 BASIC PRINCIPLES OF MAINTENANCE PREDICTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 20.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 20.2 Basic principles of prediction of optimal intervals between maintenances . . . . . . . . . . . . . . . . 337 20.3 Basic principles of spare parts number prediction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 20.4 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360 Contents 14 TRENDS IN THE DEVELOPMENT OF USEFUL ACCELERATED RELIABILITY TESTING TECHNOLOGY 276 14.1 Analysis of current situation 276 14.2 Trends in the development 278 14.3 References 283 CHAPTER 3. ACCURATE PREDICTION OF RELIABILITY, DURABILITY, AND MAINTAINABILITY ON THE BASIS OF USEFUL ACCELERATED RELIABILITY TESTING RESULTS, Lev M. Klyatis 285 15 INTRODUCTION 285 16 CRITERIA OF ACCURATE PREDICTION OF RELIABILITY AND MAINTAINABILITY BY RESULTS OF USEFUL ACCELERATED RELIABILITY TESTING 288 16.1 References 304 17 DEVELOPMENT OF TECHNIQUES FOR PRODUCT RELIABILITY PREDICTION ON THE BASIS OF USEFUL ACCELERATED RELIABILITY TESTING RESULTS 306 17.1 Basic concepts of reliability prediction 306 17.2 Prediction of the reliability function without finding the accurate analytical or graphical forms of the failures' distribution law 307 17.3 Prediction using the mathematical models with indication of the dependence between product reliability and different factors of manufacturing and field 309 17.4 Practical example 313 18 PREDICTION OF SYSTEM RELIABILITY FROM ACCELERATED TESTING RESULTS OFTHE COMPONENTS 318 18.1 Introduction 318 18.2 Confidence bounds for simple Weibull model 318 18.3 Multi-variate Weibull model 322 18.4 Practical examples 324 18.5 References 327 19 DURABILITY PREDICTION WITH CONSIDERATION OF EXPENSES AND LOSSES 329 19.1 Introduction 329 19.2 Principal scheme of optimal durability prediction 329 19.3 Practical example 335 19.4 References 336 20 BASIC PRINCIPLES OF MAINTENANCE PREDICTION 337 20.1 Introduction 337 20.2 Basic principles of prediction of optimal intervals between maintenances 337 20.3 Basic principles of spare parts number prediction 348 20.4 References 360 Contents xi CHAPTER 4. PRACTICAL ACCELERATED QUALITY DEVELOPMENT AND IMPROVEMENT IN MANUFACTURING AND DESIGN, Eugene L. Klyatis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363 21 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363 22 BASIC CONCEPTS OF QUALITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 22.1 Development of the quality system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.4 Quality system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371 22.4.1 Objectives of the quality function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371 22.4.2 Developing a quality plan in the company (organization) . . . . . . . . . . . . . . . . . . . . . . . . . . . 374 22.4.3 Review the effectiveness of the quality systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375 22.4.4 Continuous improvement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378 22.4.5 Process improvement models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379 23 BASIC CONCEPTS AND PRACTICAL STRATEGY OF ACCELERATED QUALITY IMPROVEMENT IN MANUFACTURING AND DESIGN. . . . . . . . . . . . . . . . . . 381 23.1 Why accelerated quality improvement? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381 23.2 The basic components of current practical quality systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 381 23.3 Analyzing the current quality system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384 23.4 The basic concepts of practical quality system improvement. . . . . . . . . . . . . . . . . . . . . . . . . . 386 23.5 The basic functions of the quality assurance department in developing the quality system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388 23.6 The basic steps for sufficient practical quality systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389 24 IMPLEMENTATION OF ACCELERATED QUALITY IMPROVEMENT. . . . . . . . . . . . . . . 392 24.1 The main direction of practical quality improvement during manufacture . . . . . . . . . . . . . . . 392 24.2 Complex analysis of the factors that influence product quality . . . . . . . . . . . . . . . . . . . . . . . . 392 24.3 Procedure of the practical complex analysis of these factors in an actual example . . . . . . . . . 398 24.4 Generalized example of the classification of the characteristics which may lead to a defective product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402 24.5 Total result of use of the complex analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407 24.6 Practical accelerated quality improvement and establishment of the company’s situation in the market . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408 25 REFERENCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411 CHAPTER 5. BASIC CONCEPTS OF SAFETY RISK ASSESSMENT Lev M. Klyatis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 26 GLOSSARY AND TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 27 SAFETY ASPECTS OF RISK CONTROL AND ASSESSMENT, RELATIONS TO TRANSPORTATION PROBLEMS. CURRENT SITUATION. . . . . . . . . . . . . . . . . . . . . . 429 28 BASIC PRINCIPLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433 Contents CHAPTER 4. PRACTICAL ACCELERATED QUALITY DEVELOPMENT AND IMPROVEMENT IN MANUFACTURING AND DESIGN, Eugene L. Klyatis 363 21 INTRODUCTION 363 22 BASIC CONCEPTS OF QUALITY 365 22.1 Development of the quality system 365 22.2 Quality basics: quality function, three managerial processes for managing quality 366 22.3 General concepts of quality assurance 370 22.4 Quality system 371 22.4.1 Objectives of the quality function 371 22.4.2 Developing a quality plan in the company (organization) 374 22.4.3 Review the effectiveness of the quality systems 375 22.4.4 Continuous improvement 378 22.4.5 Process improvement models 379 23 BASIC CONCEPTS AND PRACTICAL STRATEGY OF ACCELERATED QUALITY IMPROVEMENT IN MANUFACTURING AND DESIGN 381 23.1 Why accelerated quality improvement? 381 23.2 The basic components of current practical quality systems 381 23.3 Analyzing the current quality system 384 23.4 The basic concepts of practical quality system improvement 386 23.5 The basic functions of the quality assurance department in developing the quality system 388 23.6 The basic steps for sufficient practical quality systems 389 24 IMPLEMENTATION OF ACCELERATED QUALITY IMPROVEMENT 392 24.1 The main direction of practical quality improvement during manufacture 392 24.2 Complex analysis of the factors that influence product quality 392 24.3 Procedure of the practical complex analysis of these factors in an actual example 398 24.4 Generalized example of the classification of the characteristics which may lead to a defective product 402 24.5 Total result of use of the complex analysis 407 24.6 Practical accelerated quality improvement and establishment of the company's situation in the market 408 25 REFERENCES 411 CHAPTER 5. BASIC CONCEPTS OF SAFETY RISK ASSESSMENT Lev M. Klyatis 413 26 GLOSSARY AND TERMS 413 27 SAFETY ASPECTS OF RISK CONTROL AND ASSESSMENT, RELATIONS TO TRANSPORTATION PROBLEMS. CURRENT SITUATION 429 28 BASIC PRINCIPLES 433 Contents xii 28.1 Analysis of current situation in international standardization of the area . . . . . . . . . . . . . . . . . 433 28.2 Necessity for risk assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436 28.3 Basic concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438 28.4 Information for risk assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439 29 ASSESSMENT OF A MACHINE’S LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 30 RISK ESTIMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441 30.1 Components of risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441 30.2 Requirements for taking decision involving components of risk. . . . . . . . . . . . . . . . . . . . . . . . 444 31 RISK EVALUATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .445 31.1 Achievement of risk reduction objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .445 31.2 Comparison of risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445 32 HAZARD ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447 32.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447 32.2 Hazard analysis concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447 32.3 Hazard analysis process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449 32.4 Hazard analysis implementation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450 32.5 Hazard analysis steps and tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451 32.6 Techniques for hazard analysis and estimating risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451 32.7 Hazard identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452 33 RISK MANAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457 33.1 Concepts of risk management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457 33.2 The risk management process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457 33.3 Risk management implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .459 34 ABOUT SAFETY, CRASH SIMULATORS, AND COMPLIANCE TECHNIQUES . . . . . . . . 462 35 TRENDS IN THE DEVELOPMENT OF SOME SAFETY PROBLEMS SOLUTION . . . . . . . 464 36 INTRODUCTION TO HUMAN FACTORS . .