Reliability, quality, and safety for engineers

Contents 1 Introduction 1.1 Need for Reliability, Quality, and Safety 1.2 History 1.2.1 Reliability 1.2.2 Quality 1.2.3 Safety 1.3 Terms and Definitions 1.4 Useful Information on Reliability, Quality, and Safety 1.4.1 Journals 1.4.2 Standards 1.4.3 Conference Proceedings 1.4.4 Organizations 1.4.5 Books 1.5 Problems 2 Reliability, Quality, and Safety Mathematics 2.1 Introduction 2.2 Mode, Median, Range, Arithmetic Mean, Root Mean Square, Mean Deviation, and Standard Deviation 2.2.1 Mode 2.2.2 Median 2.2.3 Range 2.2.4 Arithmetic Mean 2.2.5 Root Mean Square 2.2.6 Mean Deviation 2.2.7 Standard Deviation 2.3 Boolean Algebra Laws 2.4 Probability Definition and Properties 2.5 Useful Mathematical Definitions 2.5.1 Probability Density and Cumulative Distribution Functions 2.5.2 Expected Value 2.5.3 Variance 2.5.4 Laplace Transform 2.5.5 Laplace Transform: Final-Value Theorem 2.6 Solving First Order Differential Equations with Laplace Transforms 2.7 Statistical Distributions 2.7.1 Normal Distribution 2.7.2 Binomial Distribution 2.7.3 Poisson Distribution 2.7.4 Exponential Distribution 2.7.5 Rayleigh Distribution 2.7.6 Weibull Distribution 2.8 Problems 3 Introduction to Reliability 3.1 Need for Reliability 3.2 Bathtub Hazard Rate Curve 3.3 General and Specific Hazard Rate Functions 3.3.1 Hazard Rate for Exponential Distribution 3.3.2 Hazard Rate for Weibull Distribution 3.3.3 Hazard Rate for General Distribution 3.4 General and Specific Reliability Functions 3.4.1 Reliability Function for Exponential Distribution 3.4.2 Reliability Function for Weibull Distribution 3.4.3 Reliability Function for General Distribution 3.5 Mean Time to Failure 3.5.1 Equation (3.19) Derivation 3.5.2 Equation (3.20) Derivation 3.6 Failure Rate Estimation 3.7 Failure Data Collection, Sources, and Failure Rates for Selected Items 3.7.1 Failure Rates for Selected Items 3.8 Problems 4 Static Reliability Evaluation Models 4.1 Introduction 4.2 Series Network 4.3 Parallel Network 4.4 k -Out-ofm Network 4.5 Series-Parallel Network 4.6 Parallel-Series Network 4.7 Bridge Network 4.8 Problems 5 Dynamic Reliability Evaluation Models 5.1 Introduction 5.2 Series Network 5.2.1 Series System Reliability and Mean Time to Failure with Weibull Distributed Units’ Times to Failure 5.2.2 Series System Reliability with Nonconstant Failure Rates of Units 5.3 Parallel Network 5.4 k -Out-ofm Network 5.5 Series-Parallel Network 5.6 Parallel-Series Network 5.7 Standby System 5.8 Bridge Network 5.9 Problems 6 Reliability Evaluation Methods 6.1 Introduction 6.2 Network Reduction Method 6.3 Fault Tree Analysis (FTA) Method 6.3.1 Fault Tree Symbols and Basic Steps for Developing a Fault Tree 6.3.2 Probability Evaluation of Fault Trees 6.4 Markov Method 6.5 Decomposition Method 6.6 Failure Modes and Effect Analysis (FMEA) Method 6.7 Common Cause Failure Analysis Method 6.8 Problems 7 Reliability Testing 7.1 Introduction 7.2 Types of Reliability Testing 7.3 Tests for Determining the Validity of an Item’s Exponentially Distributed Times to Failure 7.3.1 Test I 7.3.2 Test II 7.4 Confidence Limit Estimation on Mean Item Life 7.4.1 Method I 7.4.2 Method II 7.5 Economics of Testing 7.6 Problems 8 Reliablity Management and Costing 8.1 Introduction 8.2 General Management Reliability Program-Related Responsibilities and Guiding Force Associated Facts for an Effective Reliability Program 8.3 An Approach for Developing Reliability Goals and Useful Guidelines for Developing Reliability Programs 8.4 Reliability Engineering Department Responsibilities and Tasks of a Reliability Engineer 8.5 Reliability Cost 8.6 Reliability Activity Cost Estimation Models 8.6.1 Reliability Prediction Manhour Estimation Model 8.6.2 Reliability Modeling/Allocation Manhour Estimation Model 8.6.3 Reliability and Maintainability Program Plan Manhour Estimation Model 8.6.4 Reliability Testing Manhour Estimation Model 8.6.5 Failure Modes and Effect Analysis (FMEA) Manhour Estimation Model 8.6.6 Failure Reporting and Corrective Action System (FRACAS) Manhour Estimation Model 8.6.7 Reliability and Maintainability Management Manhour Estimation Model 8.7 Problems 9 Introduction to Quality 9.1 Introduction 9.2 Comparisons of Modern and Traditional Products, Direct Factors Influencing the Quality of Product and Services, and Quality Design Characteristics 9.3 Quality Goals 9.4 Quality Assurance System Elements 9.5 Design for Quality 9.6 Total Quality Management (TQM) 9.6.1 TQM Elements and Goals for TQM Process Success 9.6.2 Deming Approach to TQM 9.6.3 Obstacles to TQM Implementation 9.6.4 Selected Books on TQM and Organizations that Promote the TQM Concept 9.7 Problems 10 Quality Analysis Methods 10.1 Introduction 10.2 Quality Control Charts 10.2.1 The p -Charts 10.2.2 The R -Charts 10.2.3 The -Charts 10.2.4 The c -Charts 10.3 Pareto Diagram 10.4 Quality Function Deployment (QFD) 10.5 Scatter Diagram 10.6 Cause-and-Effect Diagram 10.7 Hoshin Kanri 10.8 Design of Experiments (DOE) X 10.9 Fault Tree Analysis (FTA) 10.10 Failure Modes and Effect Analysis (FMEA) 10.11 Problems 11 Quality Management and Costing 11.1 Introduction 11.2 Upper and Middle Management Quality-Related Roles 11.3 Quality Control Engineering Functions and Quality-Related Responsibilities Among Various Organizational Groups 11.4 Steps for Planning the Quality Control Organizational Structure and Quality Control Organizational Methods 11.5 Quality Manager Attributes, Functions, and Reasons for Failure 11.6 Quality Control Manual and Quality Auditing 11.7 Procurement Quality Control 11.7.1 Useful Guidelines for Controlling Incoming Part/Materials 11.7.2 Incoming Material Inspection 11.7.3 Formulas for Determining Accuracy and Waste of Inspectors and Vendor Quality Rating 11.8 Quality Costs 11.8.1 Classifications of Quality Costs 11.9 Quality Cost Indexes 11.9.1 Index I 11.9.2 Index II 11.9.3 Index III 11.10 Problems 12 Introduction to Safety 12.1 Need for Safety 12.2 Safety-Related Facts and Figures 12.3 Engineers and Safety 12.4 Product Hazard Classifications and Common Mechanical Injuries 12.5 Statute, Common, Administrative, and Liability Laws and Product Liability 12.6 Workers’ Compensation 12.7 Problems 13 Safety Analysis Methods 13.1 Introduction 13.2 Cause and Effect Diagram (CAED) 13.3 Fault Tree Analysis (FTA) 13.4 Control Charts 13.5 Markov Method 13.6 Failure Modes and Effect Analysis (FMEA) 13.7 Hazards and Operability Analysis (HAZOP) 13.8 Technic of Operations Review (TOR) 13.9 Interface Safety Analysis (ISA) 13.10 Job Safety Analysis (JSA) 13.11 Safety Indexes 13.11.1 Disabling Injury Severity Rate (DISR) 13.11.2 Disabling Injury Frequency Rate (DIFR) 13.12 Problems 14 Safety Management and Costing 14.1 Introduction 14.2 Safety Management Principles and Developing a Safety Program Plan 14.3 Safety Department Functions 14.4 Functions and Qualifications of Safety Professionals 14.4.1 Safety Manager 14.4.2 Safety Engineer 14.5 Safety Committees and Motivating Employees to Work Safely 14.6 A Manufacturer’s Losses or Cost due to an Accident Involving its Product 14.7 Safety Cost Estimation Methods and Models 14.7.1 The Simonds Method 14.7.2 The Heinrich Method 14.7.3 Total Safety Cost Estimation Model 14.8 Safety Cost Indexes 14.8.1 Index I 14.8.2 Index II 14.8.3 Index III 14.9 Problems 15 Robot, Software, and Medical Device Safety 15.1 Introduction 15.2 Robot Safety 15.2.1 Facts and Figures 15.2.2 Robot Safety Problems 15.2.3 Types of Robot Accidents 15.2.4 Robot Hazard Causes 15.2.5 Robot Safeguard Methods 15.3 Software Safety 15.3.1 Facts and Figures 15.3.2 Software Safety vs. Reliability 15.3.3 Software Hazard Causing Ways 15.3.4 Basic Software System Safety Tasks 15.3.5 Software Hazard Analysis Methods 15.4 Medical Device Safety 15.4.1 Facts and Figures 15.4.2 Medical Device Safety vs. Reliability 15.4.3 Types of Medical Device Safety 15.4.4 Patient Injury and Medical Device Accident Causes 15.4.5 Medical Device Safety Requirements 15.5 Problems