Product Reliability, Maintainability, and Supportability Handbook

This unique publication addresses the role of reliability, maintainability, and supportability in the life-cycle of a product, in the context of product effectiveness and worth. It emphasizes all aspects of producing an effective electrical or mechanical system. This is the only handbook available on this subject and the only book that is this comprehensive and informative. The Product Reliability, Maintainability, and Supportability Handbook examines the logistics, cost, and the physics of failure-topics never before found in a single volume on reliability. It describes the factors that affect product effectiveness and worth: performance, reliability, design effectiveness and margin for error, availability, affordability, use effectiveness, and logistic effectiveness. The handbook contains 13 in-depth chapters, opening with an introduction on product effectiveness and worth and concluding with reliability and maintainability data that can be combined with performance data to assess overall effectiveness of the product. The pages are filled with valuable information that can be easily and quickly put to practical use. Basic principles of the mathematical theory of probability and necessary background are provided. Concepts and basic theory of reliability in terms of probability and statistical inference are also given. Techniques for deriving probabilistic models from observational data as well as reliability models and associated validation techniques are detailed. Software and software reliability, quality, and safety are all covered, including the development life-cycle process and mechanisms by which software errors are introduced. The book presents design guidelines and techniques and the requirements for materials, manufacturing, and assembly. Learn how to analyze the reliability of redundant and fault-tolerant products. Use the methods for modeling and analyzing failures of repairable products that normally exhibit wearout characteristics. The Product Reliability, Maintainability, and Supportability Handbook also provides reliability improvement techniques to improve the competitiveness of existing products. The book includes helpful summaries and numerous problem sections to reinforce and test learned information. This reference source is the guide that professionals and technical managers should turn to when they need a comprehensive and detailed overview of everything that goes into producing systems and products that meet customer needs in an effective and timely manner.

Table of Contents:
PRODUCT EFFECTIVENESS AND WORTH Product Attributes Programmatic Factors Product Effectiveness Factors Operational Availability Design, Use, and Logistic Effectiveness Design Effectiveness.. Use Effectiveness. Logistic Effectiveness Reliability Mission Reliability. Logistic Reliability Restoration Maintainability Time Elements and Product Effectiveness Relationships among Time Intervals Assigning Responsibility Integrated Product and Process Development Managing Product Effectiveness Summary PROBABILITY CONCEPTS Random Events Definitions of Probability Basic Theorems of Probability Conditional Probability and Multiplication Rule. Statistical Independence. Total Probability Theorem. Bayes' Theorem Random Variables and Their Distributions Random Variables Probability Distribution Main Descriptors of a Random Variable Mean. Variance and Standard Deviation. Markov Inequality. Chebyshev Inequality. Skewness. Quantiles and Percentiles Brief Review of Distributions Discrete Distributions. Continuous Distributions Multiple Random Variables Joint Probability. Conditional Probability Distributions Covariance and Correlation Functions of Random Variables Probability Distributions Main Descriptors of Random Functions Random Processes Definition of a Random Process Main Descriptors of Random Process Mean Value. Variance Stationary Random Processes Ergodicity of Random Processes Counting Processes Recurrent Point Processes Markov Process Some Limit Results in Probability and Stochastic Processes Limit Theorems in Probability Theory The Central Limit Theorem. The Poisson Theorem. A Random Number of Random Variables in a Sum Stochastic Processes Crossing a "High Level" by Continuous Process. Thinning a Point Process The Superposition of Point Processes STATISTICAL INFERENCE CONCEPTS Statistical Estimation Point Estimation Method of Moments. Method of Maximum Likelihood Interval Estimation Hypothesis Testing Frequency Histogram Goodness-of-Fit Tests The Chi-Square Test. The Kolmogorov-Smirnov Test. Sample Comparison Reliability Regression Model Fitting Gauss-Markov Theorem and Linear Regression Regression Analysis. The Gauss-Markov Theorem. Multiple Linear Regression Proportional Hazard (PH) and Accelerated Life (AL) Models Accelerated Life (AL) Model. Proportional Hazard (PH) Model Accelerated Life Regression for Constant Stress Accelerated Life Regression for Time-Dependent Stress PRACTICAL RELIABILITY CONCEPTS Reliability Measures Time-to-Failure Distribution and Reliability Function Mean Time to Failure and Percentile Life Failure Rate and Cumulative Hazard Function Life Distributions as Reliability Models Geometric Distribution The Binomial Distribution Exponential Distribution Classes of Distribution Functions Based on Aging Failure Rate and the Notion of Aging. Bounds on Reliability for Aging Distributions. Inequality for Coefficient of Variation. Cumulative Damage Model The Weibull-Gnedenko Distribution The Normal Distribution The Logarithmic Normal Distribution Parametric and Nonparametric Distribution Estimation Statistical Data in Reliability Parametric Estimation The Exponential Distribution. The Weibull-Gnedenko Distribution Nonparametric Distribution Estimation Distribution Function Estimation. Percentile Life Estimation for Continuous Distributions. Percentile Life Estimation for Aging Distributions HARDWARE RELIABILITY Failure Mechanisms and Damage Models Mechanical Design Failures Thermal Design Failures Electrical Design Failures Electromagnetic Interference. Particle Radiation Yield Buckling Fracture Interfacial De-Adhesion Fatigue Creep Wear Aging due to Interdifussion Aging due to Particle Radiation Other Forms of Aging Corrosion Metal Migration Loadings, Stresses, and Material Behavior Variabilities and Reliability Reliability Prediction Techniques Case Study: Wire Bond Assembly in Microelectronic Packages Failure Mechanisms and Stress Analysis Wire Flexure. Shear of Bond Pad. Shear of Wire and Substrate. Axial Tension of Wire Stochastic Modeling of Variabilities and Reliability Fatigue Lifetime and Reliability Prediction Qualification and Accelerated Testing Derating and Logistic Implication Manufacturing Issues Process Qualification Manufacturability, Process Variabilities, Defects, and Yields Screening and Statistical Process Control Summary Software Reliability Definitions Software Development: The Classic Waterfall Life-Cycle Full Description Software Requirements Analysis Phase. Preliminary and Detailed Design Phases. Code and Unit Test Phase. Integration and Product Testing. Acceptance Testing. Maintenance and Operations. Retirement Distribution of Errors over the Development Life-Cycle and Related Costs Techniques to Improve Software Reliability Designing Reliable Software Structured Programming. Design Techniques. Design Issues Designing Fault-Tolerant Software Recovery-Block Design. N-Version Programming. Consensus Recovery Block Testing Black Box and White Box Testing. Module Testing: White-Box and Black-Box Testing Strategies. Integration Testing Formal Methods [Neuhold and Paul, 1991] Formal Specification Methods. Formal Verification Developing of a Process Infrastructure for Effective Software Development Techniques to Assess Software Reliability Software Analysis Methods Failure Mode and Effect Analysis (FMEA). Fault-Tree Analysis Software Metrics Requirements Measures: The Specification Completeness Measure. Design Phase Measures. Code and Unit Test Phase Measure: Defect Density [IEEE, 1989a] Software Reliability Models A Classification of Software Reliability Models. Jelinski and Moranda's Model [1972]. Musa Basic Execution Time Model (BETM) [1975]. Musa-Okumoto Logarithmic Poisson Execution Time Model. Mills Fault Seeding Model [IEEE, 1989b]. Nelson's Input-Based Domain Model. Derived Software Reliability Models. A Critique of Existing Software Reliability Models Conclusions MAINTAINABILITY CONCEPTS AND ANALYSES Measures of Maintainability Establishing Maintainability Requirements Elements of the Maintainability Program The Maintainability Program Plan Modeling the Maintainability Design Designing for Serviceability Designing for Supportability Designing for Maintainability Testability Testability Measures. Testability Analysis Hardware and Construction Accessibility and Fasteners. Packaging and Connectors Maintainability Verification Testing Objective General Procedure Test Planning Test Index Test of the Mean, Lognormal Assumption Preventive Maintenance Scheduling Testability Problem DESIGNING FOR RELIABILITY Requirements The Life Cycle Usage Environment Characterization of Materials, Parts, and the Manufacturing Processes Design Guidelines and Techniques Preferred Parts Redundancy Protective Architectures Stress Margins Derating Size and Weight Control Potential Failure Sites and Failure Mechanisms Catastrophic Failure. Intermittent Failures. Out-of-Tolerance Failures. Maladjustment Failures Designing for Operability Designing for the Environment Temperature Control Shock and Vibration Control Chemical Actions Control Biological Growths Control Moisture Control Sand and Dust Protection Explosion Control Electromagnetic Radiation Control Nuclear Radiation Control High Vacuum Control Human Factors Designing for Maintainability Design Reviews and Reliability Controls Preliminary Design Review Detailed Analysis Review Final Design Review Test Correlation Review Summary RELIABILITY ANALYSIS OF REDUNDANT AND FAULT-TOLERANT PRODUCTS Static Redundancy-Combinatorial Modeling Simple Redundancy Series Connections. Parallel Connections Series-Parallel Connections. Non-Series-Parallel Connections Masking Redundancy Triple Modular Redundancy. N-Modular Redundancy Fault Trees Cutset Generation. Inclusion/Exclusion Method Time Dependence Mean Time to Failure Hazard Rate Dynamic Redundancy-Markov Modeling Standby Sparing TMR/Simplex Product Repairable Products Independent Repair. Dependent Repair Dependent Failures Common-Mode Failures Dependent Failure Rate Multi-Mode Failures Coverage Modeling for Fault-Tolerant Computer Product Terminology The Impact of Imperfect Coverage Some Coverage Models General Structure of a Coverage Model Near-Coincident Faults Including the Coverage Model in the Product Model Bounded Approximate Models Truncated Exhaustive State Enumeration Truncated Sum of Disjoint Products Truncating a Markov Chain Advanced Topics Combining Performance with Reliability Phased Applications Advanced Fault-Tree Modeling Summary and Conclusions RELIABILITY MODELS AND DATA ANALYSIS FOR REPAIRABLE PRODUCTS Analytical Background Age-Independent F-R Processes Age-Persistent F-R Processes Defining Characteristics of AI and AP Processes Failure Repair as Renewal and Poisson Processes Renewal Processes. Homogeneous Poisson Processes. Non-Homogeneous Poisson Processes. Failure-Repair Process Relationships Data Analysis Techniques Graphical Trend Tests Test for a Renewal Process Test for a Homogeneous Poisson Process Comparison of Two Samples Fitting the Weibull Non-Homogeneous Poisson Process Weibull Process Characteristics. Estimation of l and b. Goodness-of-Fit Tests. Confidence Interval Estimates CONTINUOUS RELIABILITY IMPROVEMENT Reliability Growth Process Reliability Improvement Program Failure Classification Test Optimatization Test Cycles and Environmental Considerations Stress Margin Testing Stressed Life Test (STRIFE) Highly Accelerated Life Test (HALT) Inverse Power Law Model and Miner's Rule Continuous Growth Monitoring Continuous Growth Models Duane Model. AMSAA Model Discrete Models Lloyd and Lipow Model. Wolman Model Reliability Improvement Effectiveness and Uncertainty Reliability Improvement Effectiveness Reliability Improvement Uncertainty LOGISTICS SUPPORT Logistics Elements Influence of Reliability on Logistics Resources Reliability, Maintenance Rates, and the Expected Demand for Logistics Resources False Alarm Rate (FAR). Cannot Duplicate Rate (CND). Probability of Fault Detection. Probability of Fault Isolation. Maintenance Action Rate. Demand Rate. Mean Downtime Supply Support-Provisioning of Repair Parts and Consumables Optimal Reorder Quantity. Spares Availability and Provisioning. Provisioning a Product Composed of Replaceable Parts. Spares Optimization Manpower and Personnel-Manning Levels Support Product-Utilization and Productivity Repair Level Analysis Summary PRODUCT EFFECTIVENESS AND COST ANALYSIS A Framework for Product Effectiveness Quantification using Markov Processes A Generalization of the Model for Multifunction Operations Effectiveness Evaluation Example-Continuous Performance Model Applicability Factors to Consider in Analyzing Product Effectiveness Phase I: Define Application, Product, and Logistics Support Phase II: Select Measures of Effectiveness A Model Concept for Capability Phase III: Develop the Mathematical Model Phase IV: Obtain Data Inputs Phase V: Exercise, Interpret, and Refine Model Cost Effectiveness Analysis Cost Categorization Cost Estimation Cost Adjustments Cost Uncertainty and Cost Sensitivity Combining Effectiveness and Cost