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EbookNice Team
Status:
Available4.4
38 reviewsISBN 10: 0470854499
ISBN 13: 978-0470854495
Author: Mark Levin, Ted Kalal
The design and manufacture of reliable products is a major challenge for engineers and managers. This book arms technical managers and engineers with the tools to compete effectively through the design and production of reliable technology products.
PART I Reliability – It's a Matter of Survival
1 Competing in the Twenty-first Century
1.1 Gaining competitive advantage
1.2 Competing in the next decade - winners will compete on reliability
1.3 Concurrent engineering
1.4 Reducing the number of Engineering Change Orders (ECOs) at product release
1.5 Time-to-market advantage
1.6 Accelerating product development
1.7 Identifying and managing risks
1.8 ICM, a process to mitigate risk
Reference
2 Barriers to Implementing Reliability
2.1 Lack of understanding
2.2 Internal barriers
2.3 Implementing change and change agents
2.4 Building credibility
2.5 Perceived external barriers
2.6 It takes time to gain acceptance
2.7 External barrier
3 Understanding Why Products Fail
3.1 Why things fail
3.2 Parts have improved, everyone can build quality products
3.3 Reliability - a twenty-first century paradigm shift
References
4 Alternative Approaches to Implementing Reliability
4.1 Hiring consultants
4.2
Outsourcing reliability
PART II Unraveling the Mystery
5 The Product Life Cycle
5.1 Six phases of the product life cycle
5.1.1 Mitigate risk
The ICM process for a small company
5.2.1
DFx - Design for Manufacturability (DFM), Design for Test (DFT), Design for Serviceability (DFS) and Maintainability, and Design for Reliability (DFR)
5.2.2 Warranty
References
6 Reliability Concepts
6.1 The bathtub curve
6.2 Mean Time Between Failure
6.2.1
Mean time between repair
6.2.2
Mean Time Between Maintenances (MTBM)
6.2.3
Mean Time To Failure (MTTF)
6.2.4
Mean Time To Repair (MTTR)
6.2.5 Mean Time To Restore System (MTTRS)
6.3 Warranty costs
6.4
Availability
6.4.1
On-site manufacturer service personnel
6.4.2
Customer trained service personnel
5.2
6.4.3 Manufacturer training for customer service personnel
6.4.4 Easy-to-Use service manuals
6.4.5 Rapid diagnosis capability
6.4.6 Repair and spare parts availability
6.4.7 Rapid response to customer requests for service
6.4.8 Failure data tracking
6.5 Reliability growth
6.6
Reliability demonstration testing
Reference
7 The Reliability Toolbox
7.1 The FMEA process
7.1.1 The functional block diagram
7.1.2 The fault tree analysis
7.1.3 Failure modes and effects analysis spreadsheet
7.1.4
Preparing for the FMEA
7.1.5 Barriers to the FMEA process
7.1.6 FMEA ground rules
7.2 The HALT process
7.2.1 Types of stresses applied in HALT
7.2.2 The theory behind the HALT process
7.2.3 HALT testing
7.3 Highly Accelerated Stress Screening (HASS)
7.3.1 Proof Of Screen (POS)
7.3.2 Burn-in
7.3.3 Environmental Stress Screening (ESS)
7.3.4 Economic impact of HASS
7.3.5 The HASA process
7.4 Summary of HALT, HASS, HASA and POF benefits
7.5 HALT and HASS test chambers
7.6 SPC tool
7.7 FIFO tool
7.8 Component derating - a first line of defense in product reliability
References
8 Why Reliability Efforts Fail
8.1 Lack of commitment to the reliability process
8.2 Inability to embrace and mitigate technologies risk issues
8.3 Choosing the wrong people for the job
8.4 Inadequate funding
8.5 Mil-Std 217/Telcordia - What they really do and why they don't work
8.6 Finding but not fixing problems
8.7 Nondynamic testing
8.8 Vibration testing too difficult to implement
8.9 Late software
8.10 Supplier reliability
Reference
9 Supplier Management
9.1 Purchasing interface
9.2 Identifying your critical suppliers
9.3 Develop a thorough supplier audit process
9.4 Develop rapid nonconformance feedback
9.5 Develop a Materials Review Board (MRB)
PART III Three Steps to Successful Implementation
10 Establishing a Reliability Lab
10.1 Staffing for reliability
10.2 The reliability lab
10.3 Facility requirements
10.4 Liquid nitrogen requirements
10.5 Air compressors requirements
10.6 Selecting a reliability lab location
10.7 Selecting a HALT test chamber
10.7.1 Chamber size
10.7.2 Machine overall height
10.7.3 Power required and consumption
10.7.4 Acceptable operational noise levels
10.7.5 Door swing
10.7.6 Ease of operation
10.7.7 Profile creation, editing, and storage
10.7.8 Temperature rates of change
10.7.9 Built-in test instrumentation
10.7.10 Safety
10.7.11 Time from order to delivery
10.7.12 Warranty
10.7.13 Technical/Service support
10.7.14 Compressed air requirements
10.7.15 Lighting
10.7.16 Customization
11 Hiring and Staffing the Right People
11.1 Staffing for reliability
11.2 Choosing the wrong people for the job
12 Implementing the Reliability Process
12.1 Reliability is everyone's job
12.2 Formalizing the reliability process
12.3 Implementing the reliability process
12.4 Rolling out the reliability process
12.5 Developing a reliability culture
12.6 Setting reliability goals
12.7 Training
12.8 Product life cycle defined
12.9 Concept phase
12.10 Design phase
12.11 Production phase
12.12 End-of-life phase
12.13 Proactive and reactive reliability activities
References
PART IV Reliability Process for Product Development
13 Product Concept Phase
13.1 Establish the reliability organization
13.2 Define the reliability process
13.3 Define the system reliability requirement
13.4 Capture and apply lessons learned
13.5 Risk mitigation
13.5.1 Filling out the risk mitigation form
13.5.2 Risk mitigation meeting
14 Design Concept Phase
14.1 Setting reliability requirements and budgets
14.2 Define reliability design guidelines
14.3 Risk mitigation in the design concept phase
14.3.1 Identifying risk issues
14.3.2 Reflecting back (capturing internal lessons learned)
14.3.3 Looking forward (capturing new risk issues)
14.4 Reliability capital budget and activity scheduling
14.5 Risk mitigation meeting
14.6 Reflection
15 Product Design Phase
15.1 Product design phase
15.2 Reliability estimates
15.3 Implementing risk mitigation plans
15.3.1 Mitigating risk issues captured reflecting back
15.3.2 Mitigating risk issues captured looking forward
15.4 Design For Reliability Guidelines (DFR)
15.4.1 Derating guidelines
15.5 Design FMEA
15.6 Installing a failure reporting analysis and corrective action system
15.7 HALT planning
15.8 HALT test development
15.9 Risk mitigation meeting
References
16 Design Validation Phase
16.1 Design validation
16.2 Using HALT to precipitate failures
16.2.1 Starting the HALT Test
16.2.2 Room ambient test
16.2.3 Tickle vibration test
16.2.4 Temperature step stress test
16.2.5 Rapid thermal cycling stress test
16.2.6 Vibration step stress test
16.2.7 Combinational temperature and vibration test
16.2.8 Combinational search pattern test
16.2.9 Additional stress tests
16.2.10 HALT validation test
16.3 Proof Of Screen (POS)
16.4 Operate FRACAS
16.5 Design FMEA
16.6 Closure of risk issues
References
17 Production Phase
17.1 Accelerating design maturity
17.1.1 Product improvement tools
17.2 Reliability growth
17.3 Design and process FMEA
17.3.1 Quality control tools
References
18 End of Life Phase
18.1 Product termination
18.2 Project assessment
Reference
19 Field Service
19.1 Design for ease of access
19.2 Identify high replacement assemblies (FRUS)
19.3 Wearout replacement
19.4 Preemptive servicing
19.5 Servicing tools
19.6 Service loops
19.7 Availability or repair time turnaround
19.8 Avoid system failure through redundancy
19.9 Random versus wearout failures
Reference
how can reliability be improved
how to improve reliability
how to improve reliability of a product
improved reliability means
improving equipment reliability
Tags: Mark Levin, Ted Kalal, Improving Product Reliability, Strategies and Implementation, Quality and Reliability
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