Offers a holistic approach to guiding product design, manufacturing, and after-sales support as the manufacturing industry transitions from a product-oriented model to service-oriented paradigm
This book provides fundamental knowledge and best industry practices in reliability modelling, maintenance optimization, and service parts logistics planning. It aims to develop an integrated product-service system (IPSS) synthesizing design for reliability, performance-based maintenance, and spare parts inventory. It also presents a lifecycle reliability-inventory optimization framework where reliability, redundancy, maintenance, and service parts are jointly coordinated. Additionally, the book aims to report the latest advances in reliability growth planning, maintenance contracting and spares inventory logistics under non-stationary demand condition.
Reliability Engineering and Service provides in-depth chapter coverage of topics such as: Reliability Concepts and Models; Mean and Variance of Reliability Estimates; Design for Reliability; Reliability Growth Planning; Accelerated Life Testing and Its Economics; Renewal Theory and Superimposed Renewals; Maintenance and Performance-Based Logistics; Warranty Service Models; Basic Spare Parts Inventory Models; Repairable Inventory Systems; Integrated Product-Service Systems (IPPS), and Resilience Modeling and Planning
- Guides engineers to design reliable products at a low cost
- Assists service engineers in providing superior after-sales support
- Enables managers to respond to the changing market and customer needs
- Uses end-of-chapter case studies to illustrate industry best practice
- Lifecycle approach to reliability, maintenance and spares provisioning
Reliability Engineering and Service is an important book for graduate engineering students, researchers, and industry-based reliability practitioners and consultants.
Table of Contents:
Series Editor’s Foreword xxi
Preface xxiii
Acknowledgement xxv
About the Companion Website xxvii
1 Basic Reliability Concepts and Models 1
1.1 Introduction 1
1.2 Reliability Definition and Hazard Rate 1
1.3 Mean Lifetime and Mean Residual Life 9
1.4 System Downtime and Availability 14
1.5 Discrete Random Variable for Reliability Modeling 15
1.6 Continuous Random Variable for Reliability Modeling 18
1.7 Bayesian Reliability Model 28
1.8 Markov Model and Poisson Process 30
References 34
Problems 35
2 Reliability Estimation with Uncertainty 41
2.1 Introduction 41
2.2 Reliability Block Diagram 41
2.3 Series Systems 43
2.4 Parallel Systems 47
2.5 Mixed Series and Parallel Systems 49
2.6 Systems with k-out-of-n:G Redundancy 55
2.7 Network Systems 58
2.8 Reliability Confidence Intervals 66
2.9 Reliability of Multistate Systems 68
2.10 Reliability Importance 71
References 78
Problems 81
3 Design and Optimization for Reliability 89
3.1 Introduction 89
3.2 Lifecycle Reliability Optimization 89
3.3 Reliability and Redundancy Allocation 95
3.4 Multiobjective Reliability–Redundancy Allocation 103
3.5 Failure-in-Time Based Design 108
3.6 Failure Rate Considering Uncertainty 115
3.7 Fault-Tree Method 118
3.8 Failure Mode, Effect, and Criticality Analysis 121
3.9 Case Study: Reliability Design for Six Sigma 123
References 127
Problems 129
4 Reliability Growth Planning 133
4.1 Introduction 133
4.2 Classification of Failures 133
4.3 Failure Mode Types 136
4.4 No Fault Found (NFF) Failures 138
4.5 Corrective Action Effectiveness 141
4.6 Reliability Growth Model 145
4.7 Reliability Growth and Demonstration Test 154
4.8 Lifecycle Reliability Growth Planning 159
4.9 Case Study 164
References 166
Problems 169
5 Accelerated Stress Testing and Economics 171
5.1 Introduction 171
5.2 Design of Accelerated Stress Test 171
5.3 Scale Acceleration Model and Usage Rate 178
5.4 Arrhenius Model 184
5.5 Eyring Model and Power Law Model 187
5.6 Semiparametric Acceleration Models 190
5.7 Highly Accelerated Stress Screening Testing 195
5.8 A Case Study for HASS Project 199
References 204
Problems 206
6 Renewal Theory and Superimposed Renewal 211
6.1 Introduction 211
6.2 Renewal Integral Equation 211
6.3 Exponential and Erlang Renewal 219
6.4 Generalized Exponential Renewal 221
6.5 Weibull Renewal with Decreasing Failure Rate 226
6.6 Weibull Renewal with Increasing Failure Rate 230
6.7 Renewal under Deterministic Fleet Expansion 239
6.8 Renewal under Stochastic Fleet Expansion 245
6.9 Case Study 248
References 252
Problems 255
7 Performance-Based Maintenance 259
7.1 Introduction 259
7.2 Corrective Maintenance 259
7.3 Preventive Maintenance 262
7.4 Condition-Based Maintenance 267
7.5 Inverse Gaussian Degradation Process 275
7.6 Non-Stationary Gaussian Degradation Process 278
7.7 Performance-Based Maintenance 285
7.8 Contracting for Performance-Based Logistics 293
7.9 Case Study – RUL Prediction of Electronics Equipment 295
Appendix 298
References 299
Problems 304
8 Warranty Models and Services 309
8.1 Introduction 309
8.2 Warranty Concept and Its Roles 309
8.3 Warranty Policy for Non-repairable Product 312
8.4 Warranty Models for Repairable Products 321
8.5 Warranty Service for Variable Installed Base 325
8.6 Warranty Service under Reliability Growth 329
8.7 Other Warranty Services 335
8.8 Case Study: Design for Warranty 340
References 343
Problems 346
9 Basic Spare Parts Inventory Models 349
9.1 Introduction 349
9.2 Overview of Inventory Model 349
9.3 Deterministic EOQ Model 352
9.4 The News vendor Model 357
9.5 The (q, r) Inventory System under Continuous Review 361
9.6 The (s, S, T) Policy under Periodic Review 368
9.7 Basic Supply Chain Systems 372
9.8 Spare Parts Demand Forecasting 377
References 383
Problems 387
10 Repairable Inventory System 391
10.1 Introduction 391
10.2 Characteristics of Repairable Inventory Systems 391
10.3 Single-Echelon Inventory with Uncapacitated Repair 396
10.4 Single-Echelon Inventory with Capacitated Repair 402
10.5 Repairable Inventory for a Finite Fleet Size 405
10.6 Single-Echelon Inventory with Emergency Repair 408
10.7 Repairable Inventory Planning under Fleet Expansion 412
10.8 Multi-echelon, Multi-item Repairable Inventory 417
10.9 Case Study: Teradyne’s Spare Parts Supply Chain 424
References 432
Problems 434
11 Reliability and Service Integration 439
11.1 Introduction 439
11.2 The Rise of Product-Service System 439
11.3 Allocation of Reliability and Inventory for a Static Fleet 444
11.4 Allocation of Reliability and Inventory under Fleet Expansion 451
11.5 Joint Allocation of Maintenance, Inventory, and Repair 458
11.6 Case Study: Supporting Wind Generation Using PBC 467
Appendix 470
References 475
Problems 479
12 Resilience Engineering and Management 481
12.1 Introduction 481
12.2 Resilience Concept and Measures 481
12.3 Disaster Resilience Models of Power Grid 489
12.4 Prevention, Survivability, and Recovery 500
12.5 Variable Generation System Model 508
12.6 Case Study: Design for Resilient Distribution Systems 512
References 516
Problems 520
Index 525
About the Author :
Tongdan Jin, PhD, is an Associate Professor in the Ingram School of Engineering at Texas State University. He obtained his Ph.D. in Industrial and Systems Engineering, and MS in Electrical and Computer Engineering, both from Rutgers University. His BS in Electrical and Automation Engineering is from Shaanxi University of Science and Technology, Xian, China. Prior to his academic appointment, he has five-year reliability design and management experience in Teradyne Inc., Boston. He is a recipient of best papers in several international conferences, including Evans-McElroy best paper in 2014 Reliability and Maintainability Conference. He has authored and co-authored over 140 journal and conference papers in reliability modeling and optimization with applications in manufacturing and energy systems. His research has been sponsored by NSF, the US Department of Agriculture, and the US Department of Education. He is the member of IEEE, INFORMS and IISE.
