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Maintainability, Maintenance, and Reliability for Engineers © 2006 by Taylor & Francis Group, LLC Maintainability, Maintenance, and Reliability for Engineers B.S. Dhillon Boca Raton London New York CRC is an imprint of the Taylor & Francis Group, an informa business © 2006 by Taylor & Fr...

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Maintainability, Maintenance, and Reliability for Engineers

© 2006 by Taylor & Francis Group, LLC

Maintainability, Maintenance, and Reliability for Engineers

B.S. Dhillon

Boca Raton London New York

CRC is an imprint of the Taylor & Francis Group, an informa business

© 2006 by Taylor & Francis Group, LLC

Published in 2006 by CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2006 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group No claim to original U.S. Government works Printed in the United States of America on acid-free paper 10 9 8 7 6 5 4 3 2 1 International Standard Book Number-10: 0-8493-7243-7 (Hardcover) International Standard Book Number-13: 978-0-8493-7243-8 (Hardcover) Library of Congress Card Number 2005056882 This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. A wide variety of references are listed. Reasonable efforts have been made to publish reliable data and information, but the author and the publisher cannot assume responsibility for the validity of all materials or for the consequences of their use. No part of this book may be reprinted, reproduced, transmitted, or utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including photocopying, microfilming, and recording, or in any information storage or retrieval system, without written permission from the publishers. For permission to photocopy or use material electronically from this work, please access www.copyright.com (http://www.copyright.com/) or contact the Copyright Clearance Center, Inc. (CCC) 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. CCC is a not-for-profit organization that provides licenses and registration for a variety of users. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation without intent to infringe.

Library of Congress Cataloging-in-Publication Data Dhillon, B. S. (Balbir S.), 1947Maintainability, maintenance, and reliability for engineers / B.S. Dhillon. p. cm. Includes bibliographical references and index. ISBN 0-8493-7243-7 (alk. paper) 1. Systems engineering--Management. I. Title. TA168.D53 2006 620.001’171--dc22

2005056882

Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com Taylor & Francis Group is the Academic Division of Informa plc.

© 2006 by Taylor & Francis Group, LLC

and the CRC Press Web site at http://www.crcpress.com

This book is affectionately dedicated to Professor Alexander S. Krausz for hiring me at the University of Ottawa and inspiring me to write journal articles and books.

© 2006 by Taylor & Francis Group, LLC

Preface In today’s competitive global economy, it is becoming clear that only those nations that lead in technology will lead the world. Within the framework of technology, we include research, development, and manufacturing, as well as maintainability, maintenance, and reliability. Various studies indicate that for many large and sophisticated products and systems, maintenance and support costs account for as much as 60 to 75% of their life cycle costs. Needless to say, maintainability, maintenance, and reliability of such systems and products have become more important than ever. Global competition and other associated factors are forcing manufacturers to produce highly reliable and easily maintainable engineering products. This means there is a definite need for the maintainability, maintenance, and reliability professionals and associated personnel to work together during the product and system design, and other phases. To achieve this goal effectively it is absolutely essential that they have, to a certain degree, an understanding of each other’s disciplines. To the best of the author’s knowledge, no book covers the topics of maintainability, maintenance, and reliability within its framework. Thus, to gain knowledge of each other’s specialties, these specialists and other associated personnel must study a variety of books, articles, and reports on each of the topics in question. This process is time-consuming and rather difficult to follow because of the specialized nature of the material involved. This book is an attempt to satisfy the pressing need for a single volume that considers maintainability, maintenance, and reliability topics. The material covered is treated in such a manner that the reader needs no previous related knowledge to understand it. The sources of most of the material presented are given in the reference section at the end of each chapter. At appropriate places, the book contains examples along with their solutions, and at the end of each chapter are numerous problems for testing reader comprehension. The book is composed of 16 chapters. Chapter 1 presents the need for maintainability, maintenance, and reliability; the historical aspects of maintainability, maintenance, and reliability; important terms and definitions; and useful sources for obtaining information on maintainability, maintenance, and reliability. Chapter 2 reviews mathematical concepts considered useful to understand subsequent chapters. It covers topics such as Boolean algebra laws, probability properties, useful mathematical definitions, and probability distributions. Chapter 3 presents various introductory aspects of reliability. Chapter 4 presents a number of reliability evaluation methods including fault tree analysis, the network reduction method, the delta–star method, the Markov method, and the supplementary variables method. Useful aspects of reliability management are

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presented in Chapter 5. Chapter 6 is devoted to mechanical and human reliability. It covers topics such as general mechanical failure causes and modes, safety factors, stress–strength interference theory modeling, human-error causes and classifications, human stress–performance effectiveness and stress factors, and methods for performing human-reliability analysis. Chapter 7 presents introductory aspects of maintainability, including the need for maintainability, maintainability versus reliability and maintenance, and maintainability functions. Chapter 8 presents two important topics of maintainability: maintainability tools and specific maintainability design considerations. Chapter 9 is devoted to maintainability management and costing. It covers topics such as maintainability management tasks during the product life cycle, maintainability program plans, maintainability organization functions, maintainability design reviews, life cycle costing, maintainability investment cost elements, and life cycle cost estimation models. Important aspects of human factors in maintainability are covered in Chapter 10. Chapter 11 covers topics such as the need for maintenance, maintenance engineering objectives, maintenance measures, safety in maintenance, and quality in maintenance. Chapter 12 is devoted to corrective and preventive maintenance. It covers many useful aspects of both corrective and preventive maintenance. Chapter 13 presents reliability-centered maintenance (RCM) topics, such as RCM goals and principles, RCM process, key RCM program elements, and RCM program measures. Chapter 14 is devoted to maintenance management and costing, and Chapter 15 presents important aspects of human error in engineering maintenance. Chapter 16 covers three important topics of engineering maintenance: software maintenance, robotic maintenance, and medical equipment maintenance. This book will be useful to many people including maintainability engineers; maintenance engineers; reliability specialists; design engineers; system engineers; engineering managers; graduate and senior undergraduate students of engineering; instructors and researchers of maintainability, maintenance, and reliability; and engineers-at-large. I am deeply indebted to many people including students, friends, and colleagues for their input and encouragement at the moment of need. I thank my children Jasmine and Mark for their patience and intermittent disturbances that resulted in many desirable breaks. Last, but not least, I thank my other half, friend, and wife, Rosy, for her patience and for her help in proofreading. B.S. Dhillon Ottawa, Ontario

© 2006 by Taylor & Francis Group, LLC

Author B.S. Dhillon is a professor of mechanical engineering at the University of Ottawa. He has served as a chairman and director of the Mechanical Engineering Department/Engineering Management Program for over 10 years at the same institution. He has published over 320 articles and 29 books with publishers, including John Wiley & Sons (1981), Van Nostrand (1983), Marcel Dekker (1984), and Pergamon (1986). His books are used in over 70 countries and many of them have been translated into languages such as German, Russian, and Chinese. He is or has been on the editorial boards of nine international scientific journals. He has served as general chairman of two international conferences on reliability and quality control held in Los Angeles and Paris in 1987. Professor Dhillon has served as a consultant to various organizations and has many years of experience in the industrial sector. At the University of Ottawa, he has taught engineering management, reliability, maintainability, safety, and related areas for over 25 years and he has also lectured in over 50 countries, including keynote addresses in North America, Europe, Asia, and Africa. In March 2004, he was a distinguished speaker at the conference and workshop on surgical errors sponsored by the White House Health and Safety Committee and the Pentagon, held at the Capitol Hill. Professor Dhillon attended the University of Wales, where he earned a B.S. in electrical and electronic engineering and an M.S. in mechanical engineering. He was granted a Ph.D. in industrial engineering from the University of Windsor.

© 2006 by Taylor & Francis Group, LLC

Contents Chapter 1

Introduction ..........................................................................................1

1.1 1.2

Need for Maintainability, Maintenance, and Reliability.................................1 History ..............................................................................................................2 1.2.1 Maintainability .....................................................................................2 1.2.2 Maintenance .........................................................................................2 1.2.3 Reliability .............................................................................................2 1.3 Maintainability, Maintenance, and Reliability Terms and Definitions .................................................................................................3 1.4 Useful Information on Maintainability, Maintenance, and Reliability ..................................................................................................4 1.4.1 Journals and Magazines .......................................................................4 1.4.2 Books....................................................................................................5 1.4.3 Data Information Sources ....................................................................5 1.4.4 Organizations........................................................................................6 1.5 Problems...........................................................................................................6 References..................................................................................................................7 Chapter 2 2.1 2.2 2.3

2.4

Maintainability, Maintenance, and Reliability Mathematics...............9

Introduction ......................................................................................................9 Boolean Algebra Laws and Probability Properties .........................................9 Useful Definitions and Probability Distributions ..........................................12 2.3.1 Probability ........................................................................................12 2.3.2 Cumulative Distribution Function....................................................12 2.3.3 Probability Density Function ...........................................................13 2.3.4 Reliability Function..........................................................................13 2.3.5 Continuous Random Variable Expected Value ................................13 2.3.6 Discrete Random Variable Expected Value .....................................13 2.3.7 Exponential Distribution ..................................................................13 2.3.8 Rayleigh Distribution .......................................................................14 2.3.9 Weibull Distribution .........................................................................15 2.3.10 Gamma Distribution .........................................................................15 2.3.11 Normal Distribution .........................................................................16 2.3.12 Lognormal Distribution....................................................................16 2.3.13 Binomial Distribution.......................................................................17 Laplace Transforms and Their Applications to Differential Equations ........................................................................................................17 2.4.1 Laplace Transforms: Initial and Final Value Theorems ....................18 2.4.2 Laplace Transform Application to Differential Equations ................19

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2.5 Problems.........................................................................................................20 References................................................................................................................21 Chapter 3

Introduction to Engineering Reliability.............................................23

3.1 3.2 3.3

Need for Reliability .......................................................................................23 Bathtub Hazard Rate Concept .......................................................................23 General Reliability Analysis Formulas..........................................................25 3.3.1 Failure Density Function ...................................................................25 3.3.2 Hazard Rate Function ........................................................................25 3.3.3 General Reliability Function..............................................................26 3.3.4 Mean Time to Failure ........................................................................27 3.4 Reliability Networks ......................................................................................28 3.4.1 Series Network ...................................................................................29 3.4.2 Parallel Network.................................................................................30 3.4.3 M-Out-of-N Network .........................................................................32 3.4.4 Standby System..................................................................................33 3.4.5 Bridge Network..................................................................................35 3.5 Reliability Allocation .....................................................................................36 3.5.1 Hybrid Method...................................................................................37 3.6 Problems.........................................................................................................38 References................................................................................................................38 Chapter 4

Reliability Evaluation Tools...............................................................41

4.1 Introduction ....................................................................................................41 4.2 Failure Modes and Effect Analysis (FMEA).................................................41 4.3 Network Reduction Method...........................................................................42 4.4 Decomposition Method..................................................................................44 4.5 Delta–Star Method .........................................................................................46 4.6 Markov Method..............................................................................................49 4.7 Supplementary Variables Method ..................................................................51 4.8 Problems.........................................................................................................53 References................................................................................................................54 Chapter 5 5.1 5.2 5.3 5.4

Reliability Management.....................................................................55

Introduction ....................................................................................................55 General Management Reliability Program Responsibilities .........................55 A Method for Establishing Reliability Goals and Guidelines for Developing Reliability Programs.............................................................55 Reliability and Maintainability Management Tasks in System Life Cycle.......................................................................................................57 5.4.1 Concept and Definition Phase ...........................................................57 5.4.2 Acquisition Phase...............................................................................58 5.4.3 Operation and Maintenance Phase ....................................................59 5.4.4 Disposal Phase ...................................................................................59

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5.5

Reliability Management Tools and Documents ............................................59 5.5.1 Configuration Management................................................................60 5.5.2 Value Engineering ..............................................................................60 5.5.3 Critical Path Method ..........................................................................60 5.5.4 Reliability Manual..............................................................................61 5.6 Reliability Department Functions and Tasks of Reliability Engineer .......................................................................................61 5.7 Pitfalls in Reliability Program Management .................................................62 5.8 Problems.........................................................................................................63 References................................................................................................................63 Chapter 6

Mechanical and Human Reliability ...