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Tables of Contents for Reliability Simplified
Chapter/Section Title
Page #
Page Count
About the Series
xi
2
About the Authors
xiii
2
Dedication
xv
2
Preface
xvii
6
Acknowledgments
xxiii
1 Shared Product Reliability Experience
1
28
Introduction
1
1
Quality-Reliability, Is There a Difference?
2
1
Reliability, Not Quality, Is the Problem
3
2
The Many Views of Product Reliability
5
7
Reliability Program Implementation Perplexity
12
7
Product Reliability's Dark Side
19
3
Good Customer/Consumer Product Reliability Business
22
3
Summary
25
4
2 The Reliability Cycle
29
20
Introduction
29
1
Phase I: Defining Reliability Requirements
29
4
Phase II: Designing Reliability into the Item
33
1
Phase III: Defining Component Reliability
34
3
Phase IV: Calculating the Item's Reliability
37
1
Phase V: Minimizing Manufacturing Degradation
38
2
Phase VI: Qualifying the Item
40
3
Phase VII: Measuring Customer/Consumer Reliability
43
1
Phase VIII: Corrective Action and Database Updating
44
3
Summary
47
2
3 Product Reliability Economics
49
32
Introduction
49
1
Reliability Economic Models
50
6
Developing Your Product Reliability Economic Strategy
56
23
Step 1--The Tentative Evaluation of Your Product's Reliability Cost
58
4
Step 2--Reliability Prices Based upon Customer/Consumer Demand
62
9
Step 3--Competitive Reliability Analysis
71
3
Step 4--Product Reliability Strategy
74
5
Summary
79
2
4 Interpreting Product Failure Data
81
22
Introduction
81
1
Product Failure Concepts
82
9
Failure Rates during Product Use Time
82
6
Reliability Growth
88
3
Interpretation of Mean Time before Failure (MTBF)
91
5
Information Your Organization Should Know
96
4
Summary
100
3
5 Product Reliability Mathematics
103
22
Introduction
103
1
Distributions
104
1
The Bernoulli Distribution
104
7
The Binomial Distribution
106
2
The Poisson Distribution
108
2
The Gaussian or Normal Distribution
110
1
The Exponential Reliability Distribution
111
7
Introduction
111
1
Conditions for an Exponential Distribution of Reliability
112
1
Exponential Distribution Mathematics
113
2
Your Product's Exponential Distribution
115
1
Examples Using the Exponential Reliability Distribution
116
2
Exponential Distribution Conclusions
118
1
The Pseudo-MTBF Calculations
118
4
Summary
122
3
6 Reliability Design Development
125
30
Introduction
125
2
Reliability Specification and Prediction
127
9
Introduction
127
1
How Did You Arrive at Your Product Reliability Specification?
128
3
Data Sources for Product Reliability Specification and Prediction
131
2
Product Reliability Prediction Procedure
133
3
Reliable Design
136
10
Electrical Reliability Design
137
2
Mechanical Reliability Design
139
7
Redundant System Reliability
146
7
Introduction
146
1
Redundant Design Fundamentals
147
3
An Elementary Redundant Design Example
150
2
Redundancy Design Applications
152
1
Summary
153
2
7 Manufacturing a Reliable Product
155
50
Introduction
155
3
Control of Incoming Material and Components
158
20
Introduction
158
3
Incoming Inspection Fundamentals
161
3
Sampling Inspection Background
164
1
Generating the OC Curve
165
2
The Random Sample
167
1
The OC Curve
168
4
Choosing an OC Curve
172
4
Formalized Incoming Inspection Procedure
176
2
Controlling the Manufacturing Process
178
24
Introduction
178
1
The Distribution of Measured Values
179
2
The Mathematical Description of a Distribution
181
6
Manufacturing Process and Product Specification
187
4
How Good Is Good?
191
1
The SPC Cookbook Approach
192
3
Now Wait Just a Minute
195
2
Other SPC Applications
197
1
Unnatural Patterns of Data
198
4
Summary
202
3
8 New Product Reliability Qualification
205
28
Introduction
205
2
The Reliability Qualification Concept
207
5
Accelerating Product Life
207
2
A Little Mathematics
209
3
A Qualification Test Example
212
6
The Product Qualification Equation
216
2
Acceleration Factors
218
8
Temperature
219
1
Temperature-Induced Mechanical Stress
220
2
Vibration
222
1
Mechanical Stress
223
1
Mechanical Shock Tests
224
1
Electrical Stress
224
1
Reactive Chemical Exposure
225
1
Humidity Exposure
225
1
Particulate Contamination
225
1
Planning a Product Reliability Qualification Test
226
4
The Qualification Test Request
226
4
The Major Weaknesses of Product Reliability Qualification
230
1
Summary
231
2
9 Environmental Stress Screening (ESS) to Improve Product Reliability
233
24
Introduction
233
1
The Weibull Distribution
234
4
An ESS Example
238
5
The ESS Economic Dilemma
243
1
ESS Implementation and Discontinuation
244
11
The Financial Analysis to Discontinue
246
2
ESS Disillusionment
248
1
The Secondary ESS Program
249
6
Summary
255
2
10 Product Failure Database and Field Failure Analysis
257
24
Introduction
257
3
The Scope of Product Failure Identification
260
2
Constructing a New Product Reliability Failure Database
262
12
Step 1--Indentify Your Reliability Failure Data Requirements
263
2
Step 2--Select a Universal Level of Detail and Communications Format
265
2
Step 3--Develop an Optimum Global System
267
4
Step 4--Obtain Universal Approval of the Global Optimum Product Failure Database
271
2
Conclusions Regarding Constructing a Product Failure Database
273
1
Product Field Failure Analysis
274
3
An Example of a Reliability FFA
277
3
Summary
280
1
11 The Customer/Consumer
281
18
Introduction
281
2
Overview
283
2
Defining a Customer/Consumer Set
285
3
Why We Want to Identify the Customer/Consumer
285
3
Defining Customer/Consumer Needs and Expectations
288
1
Measuring Customer/Consumer Reliability Satisfaction
289
5
Product Performance Reliability Measurement System
290
2
Customer/Consumer Reliability Performance Expectation Measurement System
292
2
Reliability Education for Customers/Consumers
294
2
Responsiveness to Customer/Consumer Problems
296
1
Product Recall
296
2
Summary
298
1
12 Product Reliability Management Structure
299
38
Introduction
299
1
Upper Management Support and Direction of the Reliability System
300
1
Organizational Reliability Policy Statement
300
13
Customer/Consumer Expectations
301
2
Competitive Evaluation
303
2
Replacement Products
305
3
Life-Cycle Cost
308
1
Maintainability
309
3
Controllability
312
1
Confidence
312
1
The Reliability System
313
4
Reliability Management Function's Personnel
317
5
Reliability Engineering's Body of Knowledge
318
4
The Reliability Management Function's External Relationships
322
4
Reliability Management Function's Internal Operation
326
2
Diffused Reliability Management Function
328
5
Expert and Experienced in Product Reliability
331
1
Works Well with Reliability Tools
331
1
Understands the Product Reliability Specification
331
1
Prime Authority on Reliability Information
331
1
Provides Reliability Training
332
1
Communicates with the Customer Regarding Product Reliability
332
1
Reliability Authority for Executive Management
332
1
Organization Center of Reliability Competence
332
1
Generates Product Reliability Cost-Benefit Analysis
332
1
Understands Competitive Product Reliability
333
1
Plans an Optimized Reliability Management Function
333
1
Internal Considerations For Reliability Management Function
333
1
Summary
334
3
13 If It Can Go Wrong, It Will Go Wrong
337
8
Introduction
337
1
Problems and Solutions
338
5
Summary
343
2
Appendix A--Glossary
345
6
Appendix B--Weibull Distribution
351
4
Appendix C--References
355
2
Appendix D--Sampling Plans
357
4
Appendix E--Critical Values of t
361
2
Appendix F--Reverse Engineering
363
14
Index
377
10
CD-ROM Guided Tour
387