Reliability, Quality, and Safety for Engineers

Due to global competition, safety regulations, and other factors, manufacturers are increasingly pressed to create products that are safe, highly reliable, and of high quality. Engineers and quality assurance professionals need a cross-disciplinary understanding of these topics in order to ensure high standards in the design and manufacturing processes. Reliability, Quality, and Safety for Engineers is the first publication to integrate this information in a single source.

The text begins with an introduction that discusses the need for reliability, quality and safety as well as historical information, terms, and definitions. Subsequent chapters discuss relevant mathematics, evaluation models and methods, testing, management, and costing. The author treats each topic in a comprehensive manner that requires no prior knowledge of the subject in order to understand the contents.

The author includes numerous examples, problems, and solutions to test the reader's comprehension. He also lists important journals, organizations, standards, and books for further study, creating a comprehensive resource for design, system, safety and manufacturing engineers as well as reliability specialists and quality assurance professionals.

Table of Contents:
INTRODUCTION
Need for Reliability, Quality, and Safety
History
Terms and Definitions
Useful Information on Reliability, Quality, and Safety
Problems

RELIABILITY, QUALITY, AND SAFETY MATHEMATICS
Introduction
Mode, Median, Range, Arithmetic Mean, Root Mean Square, Mean Deviation, and Standard Deviation
Boolean Algebra Laws
Probability Definition and Properties
Useful Mathematical Definitions
Solving First Order Differential Equations with Laplace Transforms
Statistical Distributions
Problems

INTRODUCTION TO RELIABILITY
Need for Reliability
Bathtub Hazard Rate Curve
General and Specific Hazard Rate Functions
General and Specific Reliability Functions
Mean Time to Failure
Failure Rate Estimation
Failure Data Collection, Sources, and Failure Rates for Selected Items
Problems

STATIC RELIABILITY EVALUATION MODELS
Introduction
Series Network
Parallel Network
k-Out-of-m Network
Series-Parallel Network
Parallel-Series Network
Bridge Network
Problems

DYNAMIC RELIABILITY EVALUATION MODELS
Introduction
Series Network
Parallel Network
k-Out-of-m Network
Series-Parallel Network
Parallel-Series Network
Standby System
Bridge Network
Problems

RELIABILITY EVALUATION METHODS
Introduction
Network Reduction Method
Fault Tree Analysis (FTA) Method
Markov Method
Decomposition Method
Failure Modes and Effect Analysis (FMEA) Method
Common Cause Failure Analysis Method
Problems

RELIABILITY TESTING
Introduction
Types of Reliability Testing
Tests for Determining the Validity of an Item's Exponentially Distributed Times to Failure
Confidence Limit Estimation on Mean Item Life
Economics of Testing
Problems

RELIABLITY MANAGEMENT AND COSTING
Introduction
General Management Reliability Program-Related Responsibilities and Guiding Force Associated Facts for an Effective Reliability Program
An Approach for Developing Reliability Goals and Useful Guidelines for Developing Reliability Programs
Reliability Engineering Department Responsibilities and Tasks of a Reliability Engineer
Reliability Cost
Reliability Activity Cost Estimation Models
Problems

INTRODUCTION TO QUALITY
Introduction
Comparisons of Modern and Traditional Products, Direct Factors Influencing the Quality of Product and Services, and Quality Design Characteristics
Quality Goals
Quality Assurance System Elements
Design for Quality
Total Quality Management (TQM)
Problems

QUALITY ANALYSIS METHODS
Introduction
Quality Control Charts
Pareto Diagram
Quality Function Deployment (QFD)
Scatter Diagram
Cause-and-Effect Diagram
Hoshin Kanri
Design of Experiments (DOE)
Fault Tree Analysis (FTA)
Failure Modes and Effect Analysis (FMEA)
Problems

QUALITY MANAGEMENT AND COSTING
Introduction
Upper and Middle Management Quality-Related Roles
Quality Control Engineering Functions and Quality-Related Responsibilities Among Various Organizational Groups
Steps for Planning the Quality Control Organizational Structure and Quality Control Organizational Methods
Quality Manager Attributes, Functions, and Reasons for Failure
Quality Control Manual and Quality Auditing
Procurement Quality Control
Quality Costs
Quality Cost Indexes
Problems

INTRODUCTION TO SAFETY
Need for Safety
Safety-Related Facts and Figures
Engineers and Safety
Product Hazard Classifications and Common Mechanical Injuries
Statute, Common, Administrative, and Liability Laws and Product Liability
Workers' Compensation
Problems

SAFETY ANALYSIS METHODS
Introduction
Cause and Effect Diagram (CAED)
Fault Tree Analysis (FTA)
Control Charts
Markov Method
Failure Modes and Effect Analysis (FMEA)
Hazards and Operability Analysis (HAZOP)
Technic of Operations Review (TOR)
Interface Safety Analysis (ISA)
Job Safety Analysis (JSA)
Safety Indexes
Problems

SAFETY MANAGEMENT AND COSTING
Introduction
Safety Management Principles and Developing a Safety Program Plan
Safety Department Functions
Functions and Qualifications of Safety Professionals
Safety Committees and Motivating Employees to Work Safely
A Manufacturer's Losses or Cost due to an Accident Involving its Product
Safety Cost Estimation Methods and Models
Safety Cost Indexes
Problems

ROBOT, SOFTWARE, AND MEDICAL DEVICE SAFETY
Introduction
Robot Safety
Software Safety
Medical Device Safety
Problems