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PRACTICAL RELIABILITY
ENGINEERING
2-DAY INTRODUCTORY
COURSE
Patrick D.T. O'Connor
This course describes the methods
that should be used to ensure high reliability. It covers design analysis, including
reliability prediction, failure modes, effects and criticality analysis, stress
analysis, variation analysis, etc. It covers reliability aspects of mechanical,
electronic and software design, development, test and production, reliability
data analysis and management aspects such as specifications, contracts and standards.
The course is based on O'Connor's
book "Practical Reliability Engineering" (4th. Edition 2002), a copy of which
will be given to each attendee.
Introduction
- terminology, history
- causes & patterns of failure
- economics of reliability, life cycle costs
- course objectives
Probability & statistics
revision
- reliability & probability
- statistical models in reliability
- probability plots
Variation in engineering design
- sources, patterns & effects of variation
- measuring & understanding variation;
interactions
- experimental design, Taguchi methods
- CAE & simulation
- practical engineering & management
aspects
Stress-strength interaction
- load & strength distributions
- safety margin, loading roughness
- time-dependent strength variation
Reliability prediction
- reasons for reliability prediction
- prediction methods & databases
- limitations, accuracy
- practical methods
System reliability assessment
1
- system reliability models
- block diagram analysis
- fault tree analysis
- redundancy, common mode failures safety
/hazard assessment
System reliability assessment
2
- failure modes, effects & criticality
analysis
- design inputs
- uses: test, production, etc
- FMECA software
- use of CAE & simulation
- sneak analysis
Reliability of mechanical components
& systems
- fracture, fatigue, wear, corrosion, other
failure mechanisms
- component/material selection & evaluation
Electronics 1
- semiconductor technology trends
- failure physics
- passive devices
- connectors & connections
- component selection & test
Electronics 2
- System design aspects: thermal, mechanical
- EMI/EMC/ESD
- design for manufacture and test
- CAE/EDA
Software
- software failure causes
- software design for reliability
- analysis & test methods
- reliability prediction and measurement
Reliability testing
- test methods & environments
- accelerated test, HALT
- test data reporting & analysis
- subassembly & assembly test, interfaces,
test sample sizes
- integrated test program
Reliability in manufacture
- design for manufacture ("off-line " QC)
- production test, ESS, HASS
- control of variation, spc, quality circles,
"7 tools," improvement/kaizen
- integrated Q&R
Maintenance & maintainability
- design for maintenance
- maintainability prediction & demonstration
- reliability centred maintenance
Reliability data analysis
- reliability analysis of repairable systems,
time series analysis
- reliability demonstration (MIL-STD-781)
- reliability growth , Duane method
Reliability programme management
- reliability plan
- organization
- training
- subcontractors & suppliers, specs
- reliability program economics
- ISO 9000 & other standards (MIL, DEF,
etc.)
- leadership & motivation (work of Drucker,
Deming, Ishikawa, Hutchins, etc.)
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