Engineering Systems Reliability, Safety, and Maintenance: An Integrated Approach, 1st Edition (Hardback) book cover

Engineering Systems Reliability, Safety, and Maintenance

An Integrated Approach, 1st Edition

By B.S. Dhillon

CRC Press

278 pages | 42 B/W Illus.

Purchasing Options:$ = USD
Hardback: 9781498781633
pub: 2017-03-09
SAVE ~$31.00
eBook (VitalSource) : 9781315160535
pub: 2017-04-21
from $77.50

FREE Standard Shipping!


Today, engineering systems are an important element of the world economy and each year billions of dollars are spent to develop, manufacture, operate, and maintain various types of engineering systems around the globe. Many of these systems are highly sophisticated and contain millions of parts. For example, a Boeing jumbo 747 is made up of approximately 4.5 million parts including fasteners. Needless to say, reliability, safety, and maintenance of systems such as this have become more important than ever before.  Global competition and other factors are forcing manufacturers to produce highly reliable, safe, and maintainable engineering products. Therefore, there is a definite need for the reliability, safety, and maintenance professionals to work closely during design and other phases.

Engineering Systems Reliability, Safety, and Maintenance: An Integrated Approach eliminates the need to consult many different and diverse sources in the hunt for the information required to design better engineering systems.


"The unique strength of this book is an integrated approach covering the fields of Reliability, Safety and Maintenance with all the foundational materials, methods and detailed applications with step by step approach to leverage.

The author is an International Authority in the fields Reliability, Safety and Maintenance Engineering. The primary strength of this book is the integrated approach covering the fields of Reliability, Safety and Maintenance Engineering fields. The book covers some of the most relevant applications of 21st Century such as Internet, Robotics, Software, Mining, Medical, Aerospace, Navy and various real life Transportation Systems. The author has simplified the most difficult & complex concepts and methods into simple, easy to use, step-by-step approach. This is a major differentiation for the book.

This book will be extremely useful to not only senior Under Graduate Students but also useful to Graduate students, Researchers and various Engineering Professionals."

Subramanyam Naidu Rayapati, Agile CloudTech, LLC., USA

"Reliability, safety and maintenance are the key issues in contemporary systems as they become more and more complex. Following a general overview of the significance of these issues, this book presents a systematic survey of fundamental concepts assuring the above mentioned system features. This book is unique due to combining reliability, safety and maintenance issues in one volume, moreover the presented considerations refer to systems and practical problems from different domains; e.g. robot, transportation, aviation, medicine and other industries."

Janusz Sosnowski, Institute of Computer Science, Warsaw University of Technology, Poland

Table of Contents

CHAPTER 1: Introduction

1.1 Background

1.2 Engineering Systems Reliability, Safety, and Maintenance Facts, Figures, and Examples

1.3 Terms and Definitions

1.4 Useful Sources for Obtaining Information on Reliability, Safety, and Maintenance

1.4.1 Organizations

1.4.2 Journals and Magazines

1.4.3 Data Information Sources

1.4.4 Standards and Reports

1.4.5 Books

1.4.6 Conference Proceedings

1.5 Scope of the Book

1.6 Problems

1.7 References

CHAPTER 2: Reliability, Safety, and Maintenance Mathematics

2.1 Introduction

2.2 Median, Arithmetic Mean, and Mean Deviation

2.2.1 Median

2.2.2 Arithmetic Mean

2.2.3 Mean Deviation

2.3 Boolean Algebra Laws

2.4 Probability Definition and Properties

2.5 Useful Mathematical Definitions

2.5.1 Cumulative Distribution Function

2.5.2 Probability Density Function

2.5.3 Expected Value

2.5.4 Laplace Transform

2.6 Solving First Order Differential Equations with Laplace Transforms

2.7 Statistical Distributions

2.7.1 Binomial Distribution

2.7.2 Exponential Distribution

2.7.3 Rayleigh Distribution

2.7.4 Weibull Distribution

2.7.5 Bathtub Hazard Rate Curve Distribution

2.8 Problems

2.9 References

CHAPTER 3: Reliability, Safety, and Maintenance Basics

3.1 Introduction

3.2 Bathtub Hazard Rate Curve

3.3 General Reliability Formulas

3.3.1 Probability (or Failure) Density Function

3.3.2 Hazard Rate (or Time Dependent Failure Rate) Function

3.3.3 General Reliability Function

3.3.4 Mean Time to Failure (MTTF)

3.4 Reliability Configurations

3.4.1 Series Configuration

3.4.2 Parallel Configuration

3.4.3 k-out-of-n Configuration

3.4.4 Standby System

3.4.5 Bridge Configuration

3.5 Need for Safety and the Role of Engineers in Regard to Safety

3.6 Product Hazard Classifications

3.7 Safety Management Principles and Product Safety Organization Tasks

3.8 Accident Causation Theories

3.8.1 Human Factors Accident Causation Theory

3.8.2 Domino Accident Causation Theory

3.9 Facts and Figures Related to Engineering Maintenance

3.10 Maintenance Engineering Objectives

3.11 Preventive Maintenance

3.11.1 Preventive Maintenance Elements and Principle for Selecting Items for Preventive Maintenance

3.11.2 Steps for Developing Preventive Maintenance Program

3.11.3 Preventive Maintenance Measures

3.11.4 Preventive Maintenance Benefits and Drawbacks

3.12 Corrective Maintenance

3.12.1 Types of Corrective Maintenance

3.12.2 Corrective Maintenance Steps, Downtime Components, and Time- Reduction Strategies at System Level

3.12.3 Corrective Maintenance Measures

3.13 Problems

3.14 References

CHAPTER 4: Methods for Performing Reliability, Safety, and Maintenance

Analysis of Engineering Systems

4.1 Introduction

4.2 Fault Tree Analysis (FTA)

4.2.1 Probability Evaluation of Fault Trees

4.2.2 FTA Advantages and Disadvantages

4.3 Markov Method

4.4 Failure Modes and Effect Analysis

4.5 Probability Tree Analysis

4.6 Technique of Operations Review

4.7 Hazards and Operability Analysis

4.8 Interface Safety Analysis (ISA)

4.8.1 Classification I: Flow Relationships

4.8.2 Classification II: Physical Relationships

4.8.3 Classification III: Functional Relationships

4.9 Maintenance Program Effectiveness Evaluation Approach for Managers

4.10 Indices for Maintenance Management Analysis

4.10.1 Category I: Broad Indices

4.10.2 Category II: Specific Indices

4.11 Problems

4.12 References

CHAPTER 5: Computer, Internet, and Robot Systems Reliability

5.1 Introduction

5.2 Computer System Reliability Issues-Related Factors and Computer Failure Sources

5.3 Computer-Related Faults Classifications and Reliability Measures

5.4 Fault Masking

5.4.1 Triple Modular Redundancy

5.4.2 N-Modular Redundancy

5.5 Internet Failure Examples and Reliability-Related Observations

5.6 Internet Outages’ Classifications

5.7 A Method for Automating Fault Detection in Internet Services and Models for Conducting Internet Reliability and Availability Analysis

5.7.1 Mathematical Model I

5.7.2 Mathematical Model II

5.8 Robot Reliability-Related Surveys Results and Effectiveness Dictating Factors

5.9 Categories of Robot Failures and Their Causes and Corrective Measures

5.10 Robot Reliability Measures and Analysis Methods

5.10.1 Robot Reliability Measures

5.10.2 Robot Reliability Analysis Methods

5.11 Problems

5.12 References

CHAPTER 6: Transportation Systems Failures and Human Error in

Transportation Systems

6.1 Introduction

6.2 Defects in Vehicle Parts and Categories of Vehicle Failures

6.3 Rail Weld Failures and Defects

6.4 Classifications of Road and Rail Tanker Failure Modes and Causes of Failures and the Factors Influencing the Nature of Failure Consequences

6.5 Mechanical Failure-Related Aviation Accidents and Their Examples

6.6 Ship Failures and Their Common Causes

6.7 Railway System Human Error-Related Facts and Figures and Typical Human Error Occurrence Areas in Railway Operation

6.8 Aviation Systems Human Error-Related Facts and Figures and Types of Pilot- Controller Communication-Related Errors

6.9 Organizational-Related Factors in Commercial Aviation Accidents with Respect to Pilot Error and Recommendations for Reducing Pilot-Controller Communication Errors

6.10 Shipping Systems Human Error-Related Facts and Figures

6.11 Marine Industry-Related Human Factors Issues and Methods for Reducing the Manning Impact on Shipping System Reliability

6.12 Road Transportation Systems Human Error-Related Facts and Figures and Common Driver Errors

6.13 Classifications and Ranking of Driver Errors

6.14 Problems

6.15 References

CHAPTER 7: Software, Robot, and Transportation Systems Safety

7.1 Introduction

7.2 Software Potential Hazards and Software Risk and Safety Classifications

7.3 Software System Safety-Associated Tasks and the Role of Software Quality Assurance Organization with Respect to Software Safety

7.4 Software Safety Assurance Program

7.5 Software Hazard Analysis Methods

7.5.1 Software Sneak Circuit Analysis

7.5.2 Code Walk-Through

7.5.3 Proof of Correctness

7.6 Robot Hazards and Safety-Related Problems

7.7 Robot Safety-Related Problems Causing Weak Points in Planning, Design, and Operation

7.8 Common Robot Safety-Related Features and Their Functions

7.9 Robot Safeguard Methods

7.9.1 Flashing Lights

7.9.2 Intelligent Systems

7.9.3 Warning Signs

7.10 Truck Safety-Related Facts and Figures

7.11 Truck and Bus Safety-Related Issues

7.12 Recommendations for Improving Truck Safety

7.12.1 Recommendations on the Driver Training and Empowerment Issue

7.12.2 Recommendations on the Driver Fatigue Issue

7.12.3 Recommendations on the Vehicle Brakes and Maintenance Standards Issue

7.12.4 Recommendations on the Harmonization of Safety Standards Across All Jurisdictions Issue

7.12.5 Recommendations on the Data Needs Issue

7.13 Examples of Rail Accidents and Their Causes

7.14 Rail Accidents’ Classifications by Causes and Effects

7.15 Railroad Tank Car Safety

7.16 Analysis of World Airline Accidents

7.17 United States Airline-Related Fatalities and Causes of Airplane Crashes

7.18 Marine Accidents

7.18.1 The Estonia Accident

7.18.2 The Herald of Free Enterprise Accident

7.19 Ship Port-Associated Hazards

7.20 Problems

7.21 References

CHAPTER 8: Medical and Mining Systems Safety

8.1 Introduction

8.2 Medical System Safety-Related Facts and Figures

8.3 Safety-related Requirements for Medical Devices/Systems and Types of Medical Device/System Safety

8.4 Safety in Medical Device/System Life Cycle

8.5 Classifications of Medical Device/System Accident Causes and Methods for Conducting Medical Device/System Safety Analysis and Considerations for Their Selection

8.5.1 Operating Hazard Analysis

8.5.2 Fault Tree Analysis (FTA)

8.5.3 Human Error Analysis

8.5.4 Considerations for the Selection of Safety Analysis Methods for Conducting Medical Device/System Safety Analysis

8.6 Mining Equipment/Systems Safety-Related Facts and Figures and Injuries and Fatalities Due to Crane, Drill Rig, and Haul Truck Contact with High Tension Power Lines

8.7 Human Factors-Related Tips or Safer Mining Equipment/Systems

8.8 Causes for Mining Equipment-Related Accidents and Mining Equipment Maintenance-Related Accidents

8.9 Methods for Performing Mining Equipment/System Safety Analysis

8.9.1 Management Oversight and Risk Tree (MORT) Analysis

8.9.2 Binary Matrices

8.9.3 Consequence Analysis

8.10 Problems

8.11 References

CHAPTER 9: Software Maintenance and Reliability Centered Maintenance

9.1 Introduction

9.2 Software Maintenance-Related Facts and Figures

9.3 Software Maintenance Problems and Maintenance Types

9.4 Software Maintenance Methods

9.4.1 Impact Analysis

9.4.2 Maintenance Reduction

9.4.3 Software Configuration Management

9.5 Software Maintenance Costing

9.6 Reliability Centered Maintenance Goals and Principles

9.7 Reliability Centered Maintenance Process

9.8 Elements of Reliability Centered Maintenance

9.8.1 Reactive Maintenance

9.8.2 Preventive Maintenance

9.8.3 Predictive Testing and Inspection

9.8.4 Proactive Maintenance

9.9 Reliability Centered Maintenance Program Effectiveness Measurement Indicators

9.9.1 Indicator I: Emergency Percentage Index

9.9.2 Indicator II: Maintenance Overtime Percentage Index

9.9.3 Indicator III: Equipment Availability

9.9.4 Indicator IV: PM/PTI-Reactive Maintenance Index

9.9.5 Indicator V: Emergency-PM/PTI Work Index

9.9.6 Indicator VI: PTI Covered Equipment Index

9.10 Reasons for Reliability Centered Maintenance Failures and Benefits of Reliability Centered Maintenance

9.11 Problems

9.12 References

CHAPTER 10: Maintenance Safety and Human Error in Aviation and Power Plant Maintenance

10.1 Introduction

10.2 Maintenance Safety-Related Facts, Figures, and Examples

10.3 Factors Responsible for Dubious Safety Reputation in Performing Maintenance Tasks and Reasons for Safety-Related Problems in Maintenance

10.4 Maintenance Personnel Safety and Maintenance Safety-Related Questions for Manufacturers of Engineering Systems/Equipment

10.5 Guidelines for Equipment/System Designers for Improving Safety in Maintenance

10.6 Models for Performing Maintenance Safety Analysis

10.6.1 Model I

10.6.2 Model II

10.7 Aviation Maintenance Human Error-Related Facts, Figures, and Examples

10.8 Major Categories of Human Errors in Aviation Maintenance and Inspection Tasks, and Causes of Human Error in Aviation Maintenance

10.9 Common Human Errors in Aircraft Maintenance Tasks and Guidelines to Reduce Human Error in Aircraft Maintenance-Related Tasks

10.10 Methods for Performing Aircraft Maintenance Error Analysis

10.10.1 Error-Cause Removal Program

10.10.2 Cause-and-Effect Diagram

10.11 Power Plant Maintenance Human Error-Related Facts, Figures, and Examples

10.12 Human Error Causes in Power Plant Maintenance and Most Susceptible Maintenance Tasks to Human Error in Power Generation

10.13 Guidelines to Reduce and Prevent Human Error in Power Generation Maintenance

10.14 Power Plant Maintenance Error Analysis Methods

10.14.1 Maintenance Personnel Performance Simulation (MAPPS) Model

10.14.2 Fault Tree Analysis

10.15 Problems

10.16 References

CHAPTER 11: Mathematical Models for Performing Engineering Systems

Reliability, Safety, and Maintenance Analysis

11.1 Introduction

11.2 Model I

11.3 Model II

11.4 Model III

11.5 Model IV

11.6 Model V

11.7 Model VI

11.8 Problems

11.9 References

APPENDIX: Bibliography: Literature on Engineering Systems Reliability, Safety,

and Maintenance

A.1 Introduction

A.2 Publications

About the Author

Dr. B.S. Dhillon is a professor of Engineering Management in the Department of Mechanical Engineering at the University of Ottawa. He has served as a Chairman/Director of Mechanical Engineering Department/Engineering Management Program for over 10 years at the same institution. He is the founder of the probability distribution named Dhillon Distribution/Law/Model by statistical researchers in their publications around the world. He has published over 376 {(i.e., 226( 70 single authored + 156 co-authored) journal and 150 conference proceedings} articles on reliability engineering, maintainability, safety, engineering management, etc. He is currently or has been on the editorial boards of 12 international scientific journals. In addition, Dr. Dhillon has written 42 books on various aspects of health care, engineering management, design, reliability, safety, and quality published by Wiley (1981), Van Nostrand (1982), Butterworth (1983), Marcel Dekker (1984), Pergamon (1986), etc. His books are being used in over 100 countries, and many of them are translated into languages such as German, Russian, Chinese, and Persian (Iranian).

He has served as General Chairman of two international conferences on reliability and quality control held in Los Angeles and Paris in 1987. Prof. Dhillon has also served as a consultant to various organizations and bodies and has many years of experience in the industrial sector. At the University of Ottawa, he has been teaching reliability, quality, engineering management, design, and related areas for over 34 years. Dr. Dhillon has also lectured in over 50 countries, including keynote addresses at various international scientific conferences held in North America, Europe, Asia, and Africa. In March 2004, he was a distinguished speaker at the Conf./Workshop on Surgical Errors (sponsored by White House Health and Safety Committee and Pentagon), held at Capitol Hill (One Constitution Avenue, Washington, D.C.).

Professor Dhillon attended the University of Wales where he received a BS in electrical and electronic engineering and an MS in mechanical engineering. He received a Ph.D. in industrial engineering from the University of Windsor.

Subject Categories

BISAC Subject Codes/Headings:
TECHNOLOGY & ENGINEERING / Engineering (General)
TECHNOLOGY & ENGINEERING / Industrial Health & Safety