1st Edition

Reliability Engineering A Life Cycle Approach

By Edgar Bradley Copyright 2017
    390 Pages 116 B/W Illustrations
    by CRC Press

    392 Pages 116 B/W Illustrations
    by CRC Press

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    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.

    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


    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