The Certified Reliability Engineer Handbook

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1 The Certified Reliability Engineer Handbook Second Edition Donald W. Benbow and Hugh W. Broome ASQ Quality Press Milwaukee, Wisconsin

2 Table of Contents CD-ROM Contents List of Figures and Tables x Preface Acknowledgments ix xiii xiv Part I Reliability Management Chapter 1 A. Strategic Management 2 1. Benefits of Reliability Engineering 2 2. Interrelationship of Quality and Reliability 3 3. Role of the Reliability Function in the Organization 5 4. Reliability in Product and Process Development 6 5. Failure Consequence and Liability Management 9 6. Warranty Management Customer Needs Assessment Supplier Reliability 16 Chapter 2 B. Reliability Program Management Terminology Elements of a Reliability Program Types of Risk Product Lifecycle Engineering Design Evaluation Systems Engineering and Integration 32 Chapter 3 C. Ethics, Safety, and Liability Ethical Issues Roles and Responsibilities System Safety 37 Part II Probability and Statistics for Reliability Chapter 4 A. Basic Concepts Statistical Terms Basic Probability Concepts Discrete and Continuous Probability Distributions Poisson Process Models Non-parametric Statistical Methods 63 v

3 vi Table of Contents 6. Sample Size Determination Statistical Process Control (SPC) and Process Capability 70 Chapter 5 B. Statistical Inference Point Estimates of Parameters Statistical Interval Estimates Hypothesis Testing (Parametric and Non-Parametric) 98 Part III Reliability in Design and Development Chapter 6 A. Reliability Design Techniques Environmental and Use Factors Stress-Strength Analysis FMEA and FMECA Common Mode Failure Analysis Fault Tree Analysis (FTA) and Success Tree Analysis (STA) Tolerance and Worst-Case Analyses Design of Experiments Fault Tolerance Reliability Optimization Human Factors Design for X (DFX) Reliability Apportionment (Allocation) Techniques 156 Chapter 7 B. Parts and Materials Management Selection, Standardization, and Reuse Derating Methods and Principles Parts Obsolescence Management Establishing Specifications 163 Part IV Reliability Modeling and Predictions Chapter 8 A. Reliability Modeling Sources and Uses of Reliability Data Reliability Block Diagrams and Models Physics of Failure Models Simulation Techniques Dynamic Reliability 187 Chapter 9 B. Reliability Predictions Part Count Predictions and Part Stress Analysis Reliability Prediction Methods 191 Part V Reliability Testing Chapter 10 A. Reliability Test Planning Reliability Test Strategies Test Environment 200

4 Table of Contents vii Chapter 11 B. Testing During Development Accelerated Life Tests (e.g., Single-Stress, Multiple-Stress, Sequential Stress, Step-Stress) Discovery Testing (e.g., HALT, Margin Tests, Sample Size of 1) Reliability Growth Testing (e.g., Test, Analyze, and Fix (TAAF), Duane) Software Testing (e.g., White-Box, Black-Box, Operational Profile, and Fault Injection) 209 Chapter 12 C. Product Testing Qualification/Demonstration Testing (e.g., Sequential Tests, Fixed- Length Tests) Product Reliability Acceptance Testing (PRAT) Ongoing Reliability Testing (e.g., Sequential Probability Ratio Test [SPRT]) Stress Screening (e.g., ESS, HASS, Burn-In Tests) Attribute Testing (e.g., Binomial, Hypergeometric) Degradation (Wear-to-Failure) Testing 224 Part VI Maintainability and Availability Chapter 13 A. Management Strategies Planning Maintenance Strategies Availability Tradeoffs 230 Chapter 14 B. Maintenance and Testing Analysis Preventive Maintenance (PM) Analysis Corrective Maintenance Analysis Non-destructive Evaluation Testability Spare Parts Analysis 237 Part VII Data Collection and Use Chapter 15 A. Data Collection Types of Data Collection Methods Data Management 246 Chapter 16 B. Data Use Data Summary and Reporting Preventive and Corrective Action Measures of Effectiveness 260 Chapter 17 C. Failure Analysis and Correction Failure Analysis Methods Failure Reporting, Analysis, and Corrective Action System (FRACAS)

5 viii Table of Contents Part VIII Appendices Appendix A ASQ Certified Reliability Engineer Body of Knowledge 270 Appendix B ASQ Code of Ethics 279 Appendix C Control Limit Formulas 281 Appendix D Constants for Control Charts 282 Appendix E Areas under Standard Normal Curve 283 Appendix F F Distribution F0.i 285 Appendix G F Distribution F Appendix H F Distribution F Appendix I Chi Square Distribution 297 Appendix J Values of the t-distribution 299 Appendix K Statistical Tolerance Factors for at Least 99 Percent of the Population 301 Appendix L Critical Values for the Mann-Whitney Test 302 Appendix M Critical Values for Wilcoxon Signed Rank Test 303 Appendix N Poisson Distribution 304 Appendix O Binomial Distribution 306 Appendix P Exponential Distribution 308 Appendix Q Median Ranks 310 Appendix R 312 Glossary 323 References 335 Index 337

CERTIFIED RELIABILITY ENGINEER (CRE) BODY OF KNOWLEDGE MAP 2018

CERTIFIED RELIABILITY ENGINEER (CRE) BODY OF KNOWLEDGE MAP 2018 The Certified Reliability Engineer (CRE) Body of Knowledge () has been updated to ensure that the most current state of reliability practice