Affordable Reliability Engineering: Life-Cycle Cost Analysis for Sustainability & Logistical Support, 1st Edition (Paperback) book cover

Affordable Reliability Engineering

Life-Cycle Cost Analysis for Sustainability & Logistical Support, 1st Edition

By William R. Wessels, Daniel Sillivant

CRC Press

372 pages | 95 B/W Illus.

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Description

How Can Reliability Analysis Impact Your Company’s Bottom Line?

While reliability investigations can be expensive, they can also add value to a product that far exceeds its cost. Affordable Reliability Engineering: Life-Cycle Cost Analysis for Sustainability & Logistical Support shows readers how to achieve the best cost for design development testing and evaluation and compare options for minimizing costs while keeping reliability above specifications. The text is based on the premise that all system sustainment costs result from part failure. It examines part failure in the design and sustainment of fielded parts and outlines a design criticality analysis procedure that reflects system design and sustainment.

Achieve the Best Cost for Life-Cycle Sustainment

Providing a framework for managers and engineers to develop and implement a reliability program for their organizations, the authors present the practicing professional with the tools needed to manage a system at a high reliability at the best cost. They introduce analytical methods that provide the methodology for integrating part reliability, failure, maintainability, and logistic math models. In addition, they include examples on how to run reliability simulations, highlight tools that are commercially available for such analysis, and explain the process required to ensure a design will meet specifications and minimize costs in the process.

This text:

  • Demonstrates how to use information gathered from reliability investigations
  • Provides engineers and managers with an understanding of a reliability engineering program so that they can perform reliability analyses
  • Seeks to resolve uncertainty and establish the value of reliability engineering

Affordable Reliability Engineering: Life-Cycle Cost Analysis for Sustainability & Logistical Support focuses on reliability-centered maintenance and is an ideal resource for reliability engineers and managers. This text enables reliability professionals to determine the lowest life-cycle costs for part selection, design configuration options, and the implementation of maintenance practices, as well as spare parts strategies, and logistical resources.

Reviews

"… an excellent reference book … written in an interesting and different way than traditional reliability books. The focus on economics of reliability will be welcome by both engineers and managers. … The book is based on many years’ experience of the authors and the coverage reflects the importance and priority and needs of industry. I will share more of these thoughts with my students in class."

—Min Xie, City University of Hong Kong

"… provides technical information and facts that will help improve the communication and understanding of important reliability life cycle concepts and principles among fellow technical and managerial professionals. … will attract the well-deserved attention of the expert and novice alike. The focus on life-cycle cost analysis brings to the engineering community something new and significant that helps to better underscore important role of reliability analysis in the in the total life cycle process."

—Dr. Russell A. Vacante, RMS Partnership Inc.

Table of Contents

Scope of Reliability-Based Life-Cycle Economical Analysis

Background

Reliability Engineering Approaches

Reliability Engineering Economics

Reliability Engineering Analysis Impacts on Life-Cycle Costs

Reliability Analysis for Part Design

Failure

Criticality Items List and Database

Proposed Criticality Analysis Procedure

Reliability Block Diagram

Qualitative Part Failure Analysis

Quantitative Failure Analysis

Assembly Reliability Functions

Fitting Reliability Data to Reliability Math Models

Exponential Reliability Math Models

Weibull Reliability Math Models

Qualitative Maintainability Analysis

Quantitative Maintainability Analysis

System Logistics Downtime Math Model

Summary of Reliability Math Models

Availability

Application of Reliability Math Models

Reliability Analysis for System Sustainment

Baseline Reliability Analysis

Failure Report, Analysis, Corrective Action System—FRACAS

Prerepair Logistics Downtime

Postrepair Logistics Downtime

Quantitative Reliability Analysis

Exponential Reliability Math Models

Weibull Reliability Math Models

Quantitative Maintainability Analysis

Mean Maintenance Time

Mean Downtime

System Logistics Downtime Math Model

Summary of Reliability Math Models

Availability

Application of Reliability Math Models

Engineering Economic Analysis

Engineering Economic Analysis Information

Fundamental Economic Concepts

Amounts versus Equivalent Value

Cost Estimation

Classifications of Sources and Uses of Estimated Cash

Cash Flow Timeline

Equivalent Values

Example 1: Project Cash Flow Timeline: m =

Example 2: Project Cash Flow Timeline: m =

Example 3: Project Cash Flow Timelines for Three Projects: m =

Example 4: Project Cash Flow Timelines for Three Projects: m =

Application to Reliability Based Life-Cycle Economic Analysis

Reliability-Based Logistical Economic Analysis

Failure Math Model

Repair Math Model

Logistics Downtime Math Model

Impact of Preventive Maintenance on Logistics Downtime

Special Cause Variability in Logistics Downtime

Cost Objective Function

Spare Parts Acquisition Strategies

Specialty Tools

Cash Flow Timeline

Life-Cycle Economic Analysis

Selection

Cautionary Note

Preventive Maintenance

Life-Cycle Simulation Approach

System Reliability Analysis

Spare Parts Strategy

Standby Design Configuration

Reliability-Centered Maintenance

Choosing the Correct Maintenance Plan

RCM Challenges

RCM Benefits

Reliability Database

Segment 1: Criticality Analysis

Segment 2: Qualitative Failure Analysis

Segment 3: Quantitative Failure Analysis

Segment 4: Quantitative Repair Analysis

Segment 5: Pre-Repair Logistics Downtime Quantitative Analysis

Segment 6: Post-Repair Logistics Downtime Quantitative Analysis

Segment 7: Spare Part Strategy

Reliability Simulation and Analysis

Reliability Simulations

Assembly and System Simulations

Summary

A: Reliability Failure Math Models and Reliability Functions

Exponential Reliability Math Modeling Approach

Weibull Reliability Math Modeling Approach

B: Maintainability Math Models and Maintainability Functions

Time-to-Repair Math Model, Log-Normal Distribution Approach

Time-to-Repair Math Model, Weibull Distribution Approach

Comparison between the Log-Normal and Weibull Approach

Logistics Downtime Functions

Engineering Economics Functions

Cost Estimation: Present Amount

Cost Estimation: Future Amount

Equivalent Present Value: Future Amount

Cost Estimation: Uniform Recurring Amounts

Recurring Amounts with Linear Gradient

Recurring Amounts with Geometric Gradient

Capital Recovery

Sinking Fund

Net Present Value and Equivalent Uniform Recurring Amount

Less Common Engineering Economics Functions

References

About the Authors

Bill Wessels has over 45 years of experience in system design and sustainability. He currently works at the University of Alabama in Huntsville, where he cofounded the Reliability and Failure Analysis Laboratory and performs basic and applied research in design-for-reliability, reliability-based maintainability, and reliability-based life-cycle economic analysis. Wessels has a BS in engineering from the United States Military Academy at West Point, an MBA in decision sciences from the University of Alabama in Tuscaloosa, and a PhD in systems engineering from the University of Alabama in Huntsville. He is a registered professional mechanical engineer and a certified reliability engineer.

Daniel S. Sillivant is a researcher at the University of Alabama in Huntsville performing basic and applied research and investigations in reliability life-cycle modeling for aviation and sensors systems. He is published in peer-reviewed proceedings for the International Mechanical Engineering Congress and Exposition; Reliability, Availability, Maintainability Workshop; and Industry, Engineering, and Management Systems. Sillivant has a bachelor’s degree in chemical engineering and a master’s degree in industrial/reliability engineering from UAH. He has begun his dissertation research in reliability based life-cycle economic modeling for implementation of reliability-centered maintenance. In addition, he holds certificates in Lean Concepts Training and Six Sigma Green Belt.

Subject Categories

BISAC Subject Codes/Headings:
TEC009070
TECHNOLOGY & ENGINEERING / Mechanical
TEC016000
TECHNOLOGY & ENGINEERING / Industrial Design / General
TEC032000
TECHNOLOGY & ENGINEERING / Quality Control