Reliability Engineering : A Life Cycle Approach book cover
1st Edition

Reliability Engineering
A Life Cycle Approach

ISBN 9781032097473
Published June 30, 2021 by CRC Press
390 Pages 116 B/W Illustrations

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Book Description

Reliability Engineering – A Life Cycle Approach is based on the author’s knowledge of systems and their problems from multiple industries, from sophisticated, first class installations to less sophisticated plants often operating under severe budget constraints and yet having to deliver first class availability. Taking a practical approach and drawing from the author’s global academic and work experience, the text covers the basics of reliability engineering, from design through to operation and maintenance. Examples and problems are used to embed the theory, and case studies are integrated to convey real engineering experience and to increase the student’s analytical skills. Additional subjects such as failure analysis, the management of the reliability function, systems engineering skills, project management requirements and basic financial management requirements are covered. Linear programming and financial analysis are presented in the context of justifying maintenance budgets and retrofits. The book presents a stand-alone picture of the reliability engineer’s work over all stages of the system life-cycle, and enables readers to:

  • Understand the life-cycle approach to engineering reliability

  • Explore failure analysis techniques and their importance in reliability engineering

  • Learn the skills of linear programming, financial analysis, and budgeting for maintenance

  • Analyze the application of key concepts through realistic Case Studies

This text will equip engineering students, engineers and technical managers with the knowledge and skills they need, and the numerous examples and case studies include provide insight to their real-world application. An Instructor’s Manual and Figure Slides are available for instructors.

Table of Contents

Reliability Fundamentals

The Importance of Reliability




Basic Statistics


Regression Analysis

Analysis of Variance (ANOVA)

Design for Reliability

Examples from Civil Engineering – Bridges and Structures

Examples from Mechanical Engineering – Pressure Vessels

Design for Maintainability

Factors of Safety and Probabilistic Design


Case Study: Weibull Analysis at the New Era Fertilizer Plant

Case Study: The Life History of a Hillman Vogue Saloon

Case Study: The Woodruff Key Problem

System Reliability

A Note of Caution

System Configurations

System Reliability Prediction

Availability and Maintainability

The Maintainability Equation

The Equations for System Availability

Storage Capacity

Reduced Capacity States

Other Forms of System Reliability Analysis


Laplace Analysis

Failure Modes and Effects Analysis (FMEA)

Assignment: FMEA of a Scraper Winch

Fault Tree Analysis


Maintenance Optimisation

Why Maintenance?

Know your Plant and Keep it Good as New

How Maintenance Actions Affect Failure

Data Collection

Maintenance Optimisation

Total Productive Maintenance, TPM

Semantics in Maintenance Management

ISO 55 000

Wrench Time

Estimating Job Times

Case Study: Maintenance at Automotive Pressings

Case Study: RCM at Dragon Peak

Case Study: RCM at Tiger Substation

Case Study: Crowning a Hangar Queen

Case Study: A Strange Case of TPM

Case Study: Challenger

Case Study: Electric Motor Maintenance Regimes

Condition Monitoring

The Four Kinds of Maintenance

The Major Types of Condition Monitoring

Vibration Monitoring

Oil Analysis


Incident Investigation or Root Cause Analysis (RCA)






Abbreviations and Acronyms

Root Cause Analysis

Incident Investigation Techniques

The Nature of Failure

The Black Decades (the 1970’s and the 1980’s)

Human Causes of Failure

Case Study: Chernobyl

Case Study: Piper Alpha

Case Study: Flixborough

Case Study: The Hyatt Regency Hotel, Kansas City

Case Study: The Embraer 120 Aircraft Crash

Case Study: Three Mile Island

Other Techniques Essential for Modern Reliability Management - I

Configuration Management (CM)

Case Study: Poor CM

Codification and Coding Systems

Short Description

Long Description

Technical Dictionaries

Advantages of the NATO system

Master Data

ISO 22745

Non-military Applications of Master Data

Coding by Colour or Stamping

Modern Trends in Codification


Reverse Engineering: The Importance of Reverse Engineering

Case Studies

Other Techniques Essential for Modern Reliability Management - II

Financial Optimisation: I

Use in maintenance budget optimisation and retrofit justification

Case Study: The Pulveriser Tender

Financial Optimisation – II

System Simulation

Simulation Example: Stock Control to Optimise Availability

Monte Carlo Simulation using Random Number Generation

Reliability Analysis Software using Monte Carlo Simulation

Linear Programming

Case Study: Optimisation of Maintenance

Design for Operability and its Effect on Human Reliability

Integrated Logistic Support (ILS) – the Interface with Reliability

Queuing Theory: Its use in setting maintenance staff numbers

Project Management: Its use in Retrofits and Outage Management

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Edgar Bradley is a Consultant, specializing in Benchmarking, Human Capital Evaluation and RAM work (Reliability, Availability, and Maintainability). His qualifications include a Bachelor’s degree in Mechanical Engineering from the University of the Witwatersrand, Johannesburg, South Africa (1964) and a Master’s degree in Mechanical Engineering from the University of Akron, Ohio, USA (1969) as well as an MBA from Cranfield University, in the UK (1975). For over 40 years he has also served as a lecturer in the Faculty of Industrial Engineering at the University of the Witwatersrand, lecturing and developing courses on the MSc programme on inter alia, Reliability Engineering, Maintenance Engineering, Project Management, Industrial Marketing and Systems Engineering. He has also lectured in Reliability Engineering at the University of Pretoria. In 2013 he was appointed as lecturer in Quality at the Namibian University of Science and Technology. He has commenced lectures in Reliability Engineering this year at North West University as well. For the past seven years he has worked as a Mechanical Consulting Engineer, giving consulting and training to the petroleum and other industries in the Middle East and in Southern Africa.


"Unique approach between theory and practice throughout the life cycle, with many real case study examples from all branches of engineering. An ideal text at the post graduate level for all engineers responsible for maintenance management."
—John Sheer, University of the Witwatersrand, South Africa

"This is an excellent introduction to the subject of reliability for the non-technical reader. In addition, it’s also a very good, and quite thorough, review and reference for the technically proficient. The authors descriptions of the various operations involved in reliability calculations were clear and precise. I was particularly impressed with the use of numerical examples of calculations as this allows the student and/or reader to check himself out on these procedures. The use of graphics was excellent as I believe this contributes much more to understanding concepts than are paragraphs of words alone."
—John M. Berner, Applications Research, Inc., USA