Reliability Engineering: A Life Cycle Approach

Cover
Half Title
Title
Copyright
Contents
Foreword to the First Edition
Preface
Author
Introduction
Chapter 1 Reliability Fundamentals I: Component Reliability
Introduction
The Importance of Reliability
History
Definitions
Reliability
Maintainability
Availability
Unreliability
Unavailability
Component
Correlation Coefficient
System
Failure
Failure Rate
Failure Probability Density Function
Sample
Population
Acronyms
Basic Statistics
Probability
Assignment
The Failure Probability Density Function
Three Common Failure Patterns
The Negative Exponential Distribution
The Mathematics of Randomness
The Normal Distribution
The Weibull Distribution
The Bathtub Curve
Weibull Analysis
Problems with Weibull
Weibull Cautions
Using Weibull When Very Little Data Are Available
Assignments
Assignment 1.1: Weibull Familiarisation
Assignment 1.2: Weibull Problem
Assignment 1.3: Another Weibull Problem
Assignment 1.4: Spring Design
Assignment 1.5: Weibull Analysis of Rolling Element Bearings
Assignment 1.6: New Era Fertilizer Plant
Assignment 1.7: The Life History of a Hillman Vogue Sedan
Note
Chapter 2 Reliability Fundamentals II: System Reliability
A Note of Caution
System Configurations
Redundancy
M-Out-of-N Redundancy
System Reliability Prediction
Availability and Maintainability
The Maintainability Equation
The Equations for System Availability
Storage Capacity (Figure 2.10)
Reduced-Capacity States
Other Forms of System Reliability Analysis
Method 1: Deconstruction Method
Method 2: Cut Sets
Monte Carlo Simulation
Markov Simulation
Interconnections
Laplace Analysis
Failure Modes and Effects Analysis (FMEA) and Failure Modes and Effects Criticality Analysis (FMECA)
History
Flavours of FMEA/FMECA
Process vs Design or Product FMEA/FMECA
Design FMECA
Which Templates to Use?
Basic Analysis Procedure for an FMEA or FMECA
Advantages of the FMEA/FMECA Process
Limitations of the FMEA/FMECA Process
FMEA of a Scraper Winch
Operation
Common Failures and Recent Improvements
Assignment
Fault Tree Analysis
Assignment
Additional Assignments
Assignment 2.1
The V1
Assignment 2.2
The Parallel System of Conveyors
Assignment 2.3
Availability Upgrade
Assignment 2.4
Laplace Calculation
Assignment 2.5
A System Availability Prediction
Abbreviations
Notes
Chapter 3 Maintenance Optimisation
Maintenance—Raison D’être
Know Your Plant, Keep It Good as New
Data Collection
The Big Five
Maintenance Optimisation
RCM
The RCM Process
The RCM Decision Diagram
On-Condition Inspection Task
Scheduled Rework
Scheduled Discard
Acronyms
The RCM Failure Modes and Effects Analysis
Alternative and Modified Forms of RCM
Summary of the RCM Output
An RCM Example
Economic Evaluation
Total Productive Maintenance, TPM
The Five Pillars Definition of TPM
The Six Major Losses (Manufacturing Industry)
The Eight Major Losses (Process Industry)
The Primary TPM Metric: OEE
The Goals of TPM
Zero Breakdowns
Zero Adjustments
Zero Idling and Zero Minor Stoppages
Speed Loss
Quality Problems
Semantics in Maintenance Management: Explanation and Qualification
ISO 55000
Wrench Time
Takeout: Panel—Work Sampling
Takeout: End of Panel
Estimating Job Times
Note
Chapter 4 Condition Monitoring
The Four Kinds of Maintenance
The Major Types of Condition Monitoring
Vibration Monitoring
The Time Domain
The Frequency Domain
The Measurement of Vibration
Positioning of Transducers
Detection of Various Vibration Problems
Resonance
Unbalance
Misalignment
Rolling Element Bearings
Ultrasonics
Plain Bearings
Gearboxes
Sidebands
Compressors
Fans
Oil Analysis
History
Requirements for Oil Analysis
A Basic Test Programme
Viscosity
Water Content
Acid Number
Oxidation
Element Analysis
Additional Oil Analysis Tests
Particle Count
Ferrography
Flash Point
Thermography
Chapter 5 Incident Investigation or Root Cause Analysis
Introduction
Scope of Any Investigation
Definitions and Abbreviations
Definitions
Root Cause Analysis
Abbreviations and Acronyms
Root Cause Analysis
Incident Investigation Techniques
The Five Whys
Kepner-Tregoe and Its Derivatives
Step 1: Problem Definition
Step 2: The Problem Described in Detail: Identity, Location, Timing, Magnitude
Step 3: Where Does the Malfunction NOT Occur?
Step 4: What Differences Could Have Caused the Malfunction?
Step 5: Analyse the Differences
Step 6: Verify Proposed Solution
The ASSET Methodology
Background to the Process
The Sequence of Actions in the ASSET Process
Personnel Errors
Reliability at Work
External Factors
Physical Environment
Safety Culture
Qualification to Perform the Task
Training
Educational Background
Contributors to the Identified Errors
Procedural Errors
Reliability of the Procedures
Assurance of Currency
Scope Limitations
Adaptation to Working Conditions
Ergonomics
Environmental Adaptation
Task Qualification
Adequacy of Content
Background Support
Contributors
Deficiencies in Plant
Plant Reliability
Endurance
Performance Limitations
External Influences
Physical Environment
Operating Practices
Qualification of Function
Manufacture, Storage, and Installation
Specification and Design
Contributory Factors
Proposal of Solutions
Tables
Management of the Incident Investigation Process
Fault Trees
Introduction
Construction of the Fault Tree
Ishikawa Diagrams
Causes
Questions to Be Asked While Building a Fishbone Diagram
Criticism of the Ishikawa Technique
Kipling’s Serving-Men
Apollo Root Cause Analysis—Dean L Gano
Causal Relationship Methods
The Nature of Failure
Notes
Chapter 6 Other Techniques Essential for Modern Reliability Management I
Introduction
Configuration Management
Flavours of CM: CMI versus CMII
Preventive Maintenance
Predictive Maintenance
Information
The Human Factor
A Case Study of Poor CM
Software for CM
A Final Note
Codification and Coding Systems
The History of Coding
Coding Systems
Linnaeus
Dewey Decimal Classification System
UNSPSC
Engineering Codification
The History of the NATO Coding System
Nations Using the Code
Standardised Long Description
Standardised Short Description
Technical Dictionaries
Advantages of the NATO System
Master Data
ISO 22745: Standard-Based Exchange of Product Data
Non-Military Applications of Master Data
Coding by Colour or Stamping
Modern Trends in Codification
Lubrication
Manufacture of Lubricants
Tribology
The Requisite Qualities of a Lubricant
Friction
Wear
Lubrication
Hydrodynamic Lubrication
Thin-Film or Mixed Lubrication
Boundary Lubrication
Elasto-Hydrodynamic Lubrication
Lubricant Selection
Lubricant Properties
Viscosity Measurement
Absolute Viscosity
Kinematic Viscosity
The Role of Additives
Different Lubricants for Different Applications
Hydraulic Oils
Turbine Oils
Gear Oils
Compressor Oils
Wire Rope Lubricants
Biodegradable Lubricants
Greases
Grease Tests
Other Tests for Greases
Compatibility
A Case Study in Lubricant Application
Reverse Engineering
Regression Analysis
Using the Regression Equation
Correlation
Confidence Limits
Analysis of Variance
Analysis of Variance Report
Note
Chapter 7 Other Techniques Essential for Modern Reliability Management II
Systems Engineering
Optimisation
Interface Management
The Systems Engineering Approach
Systems Engineering Design
Systems Engineers
Systems Engineering Organisation
Financial Optimisation
Features of Investment Projects
Payback
Discounted Cash Flow
Internal Rate of Return
Profitability Index
Calculations
Class Assignment
Determination of the Discount Rate
Handling Inflation
Handling Tax
System Modelling
Simulation
Simulation Example: Stock Control
Class Assignment
Monte Carlo Simulation Using Random Number Generation
Assignment
Linear Programming
History of Linear Programming
Two-Dimensional Linear Programming
Assignment
Model Assumptions
Parameters Required
Assignment
Other System Engineering Concerns
Design for Operability
An Example of Poor Operability
Operability Concerns: Human Physical Dimensions
Strength Requirements
Job Design
Human Sensory Factors: Vision
Other Factors to Be Considered
Design for Supportability: The Concept of Integrated Logistic Support
Queuing Theory
Single-Line Queuing with Single-Service Channel
Single-Line Queuing with Two Service Bays
Project Management
The Work Breakdown Structure
The Critical Path Network
Activity on Arrow
Project Budgeting and the S Curve
Resource Allocation
Chapter 8 Reliability Management
Introduction
The Management Process
What It Takes to Be a Manager
A History of Management Thought
Writers on Management
Mary Parker Follett
Henri Fayol
Frederick Winslow Taylor
Elton Mayo
Douglas MacGregor
Frederick Herzberg
Peter Drucker
J. Edwards Deming
The Characteristics of a Successful Manager
The Management Triangle
The Management Process
The Characteristics of a Successful Reliability Engineer
The Characteristics of a Successful Reliability Engineering Manager
Stress in Management
Communication
Readings in Reliability Management
Introduction
Reading #1: Human Error in Maintenance and Reliability and What to Do about It (Also Known as Rules, Tools, and Schools)
Jack Nicholas Jr
Assignment
Introduction
Concept #1: Exercise and Practice Leadership as Well as Management
Concept #2: Look First at “Programmatic” Rather Than “Technical” Solutions to Reliability Problems
Concept #3: Look for Indicators of Small, Seemingly Insignificant, but Repetitious Reliability Problems and Act on the Findings
Concept #4: Don’t Be Afraid of Mistakes; Learn from Them
Adopt a No-Fault Policy
Adopt a Compliance Policy
Practise Peer Review
Practise Focusing on the Incident at Hand while It Is Being Investigated
Concept #5: Become a Procedure-Based Organisation, but Don’t Overdo It
Concept #6: Eliminate as Much Maintenance as Possible and Increase Emphasis on Reliability
Concept #7: Don’t Forget the Roots of Your M&R Programme Initiatives for Improvement
Conclusions
Reading #2: Why Managers Don’t Endorse Reliability Initiatives
Winston Ledet
Notes
Chapter 9 Design Issues in Reliability Engineering and Maintenance
Introduction
Factors of Safety and Probabilistic Design
Two Cases with the Same Safety Margin
This Concept Is Shown in Figure 9.5
Computers in Reliability Engineering and Maintenance
Computer Programs Used in Hardware Design
Computer Programs Used in the Testing Phase
Computer Programs Used in the Systems Engineering Phase of a System Design
Computer Programs Used in the Middle of the Life Cycle
Assignment 9.1
Assignment 9.2
Chapter 10 Maintenance Planning and Scheduling
Maintenance Planning and Scheduling
The History of Maintenance
No Easy Task
Preparation for Maintenance Planning and Scheduling
10.1 Maintenance Key Performance Indicators
10.2 Maintenance Costing System
10.3 Wrench Time
Maintenance Policy Document
CMMS
Maintenance Plan
Maintenance Budget
The Importance of the Planners and Schedulers
The Maintenance Planning Process (As Undertaken by the Planning Department)
Maintenance Scheduling (As Undertaken by the Maintenance Planner and Scheduler)
Case Studies in Maintenance Planning and Scheduling
Outage Management
Requirements Planning
Man-Hours Required
The Master Schedule
Plannable Work Hours
Equipment Utilisation
The Draft Master Schedule
Delay Report
The Review Meeting
The Official Master Schedule
Job Cards
Chapter 11 ISO 55000
Prelude: Standardisation
Standardisation: A Short History
The Organisation
Leadership
Planning
Support
Operations
Performance Evaluation
Improvement
Case 11.1
ISO 55000 Pre-Audit
Model Audit Book
Possible Grand Total (Sections 1–14)
Appendix 1: The Standard Normal Distribution
Appendix 2: A Perspective on Robert Lusser
References
Index