THE HOMEPAGE OF
Published 2001 by John Wiley & Sons Ltd.
or buy from Amazon.com (link below)
OUTLINE
Testing is usually the most expensive, time-consuming and difficult activity during the development of engineering products and systems. Development testing must be performed to ensure that designs meet requirements for performance, safety, durability, reliability, statutory aspects, etc. Most manufactured items must be tested to ensure that they are correctly made. However, much of the testing that is performed in industry is based upon traditions, standards and procedures that do not provide the optimum balance of assurance versus cost and time. There is often pressure to reduce testing because of the high costs involved, without appreciation of the effects on performance, reliability. etc. Misperceptions are commonplace, particularly the idea that tests should not stress products in excess of their operating levels.
The main reason for this situation seems to be that engineers have not developed a consistent philosophy and methodology for testing. Testing is seldom taught as part of engineering curricula, and there are no books on the subject. Specialist areas are taught, for example fatigue testing to mechanical engineers and digital device testing to electronics engineers. However, a wide range is untaught, particularly multidisciplinary and systems aspects. Testing is not just an engineering issue. Because of the importance and magnitude of the economic and business aspects testing is an issue for management. Testing is perceived as a high cost activity, when it should be considered as a value-adding process.
The objective of this book is, therefore, to propose a philosophy of engineering test and to describe the necessary technologies and methods that will provide a foundation for all plans, methods and decisions related to testing of engineered products and systems. The book will help those who must manage and conduct this most difficult and uncertain task. It will also provide a text which can be used as the basis for teaching the principles of testing to all engineering students.
The book contains information on test organisations, standards, software, services, and equipment.
The contents are listed below.
This site provides lists, with links to Internet sites. These lists will be maintained, and readers are invited to contribute additions and corrections. The main lists are:
- Suppliers of test software test software
- Suppliers of test services, equipment and information test services
- Test-related standards, etc. standards
The book is closely linked to my book "Practical Reliability Engineering" (4th. edition 2002). For details visit PracticalReliability
Buy Test Engineering from your regular bookseller or direct from J.Wiley
For details of training based on the book, visit courses
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Information on other books and articles
Contact me on pat@pat-oconnor.co.uk
BOOK CONTENTS
Preface
1. INTRODUCTION
Why test? (causes of failure; reliability/durability; environments)
How to test? (test to succeed, test to fail?; accelerated test; testing components, systems, technologies, processes)
Analysis and simulation
Good and bad testing
Test economics
Managing the test programme
2. STRESS, STRENGTH AND FAILURE OF MATERIALS
Introduction
Mechanical stress and fracture (fracture; fatigue; creep; vibration/shock)
Temperature effects
Wear
Corrosion
Humidity and condensation
Materials and components selection (metals, plastics, etc.)
3. ELECTRICAL AND ELECTRONICS STRESS, STRENGTH AND FAILURE
Introduction
Stress effects (current; voltage; temperature; power)
Component types and failure mechanisms (ICs; discrete semiconductors; passives; E-O; solder; cables/connectors; insulation)
Circuit and system aspects (distortion/jitter; timing/interference;intermittents, others)
4. VARIATION AND RELIABILITY
Variation in engineering
Load-strength interference
Time-dependent variation
Multiple variations and statistical experiments (Including Taguchi)
Discrete variation
Confidence and significance
Reliability
Introduction
Quality function deployment
Design analysis methods (mathematical; mechanical (FEA, CFD, etc.); electrical/electronic (EDA, EM, etc.); systems)
Analysis methods for reliability and safety (FMEA, etc.)
Design analysis for processes ("Poka Yoke"; testability; etc.)
Software for design analysis
Limitations of design analysis
Using analysis results for test planning
6. DEVELOPMENT TESTING PRINCIPLES
Introduction
Functional testing
Testing for reliability and durability (accelerated test; highly accelerated life test (HALT))
Testing for variation: Taguchi method
Process testing
"Beta" testing
7. MATERIALS AND SYSTEMS TESTING
Materials (strength; hardness; toughness; wear; corrosion; etc.)
Assemblies and systems (temperature; vibration/shock,other conditions, combined environments, facilities for accelerated test)
System aspects (Power and rotating machinery, fluid systems, humans, large systems)
Data collection and analysis
Standard test methods
Test centres
8. ELECTRONICS
Introduction
Circuit test principles (analog, digital)
Test equipment (manual, ATE)
Test data acquisition
Design for test (test capability; test software; scan design; built-in self-test (BIST))
Electronic component test (discretes, ICs; IC design for test)
EMI/EMC testing
9. SOFTWARE
Introduction
Software in engineering systems
Software errors (specification, design, code)
Preventing errors (specification, structure, style, checking, analysis, fault tolerance, etc.)
Languages
Analysis of software system design
Data reliability
Software testing
10. MANUFACTURING TEST
Introduction
Manufacturing test principles (Value added testing; test capability; test criteria; test stresses)
Manufacturing test economics
Inspection and measurement
Test methods (mechanical, electronics; systems)
Stress screening (ESS, HASS)
Electronics manufacturing test options and economics (board; assembly; integrating stress screening; economics)
Testing electronic components
Statistical process control and acceptance sampling
Introduction
In-service test economics
Test schedules
Mechanical and systems
Electronic and electrical (built-in test; "no fault found")
Software
Reliability centred maintenance
Stress screening of repaired items
Calibration
12. DATA COLLECTION AND ANALYSIS
Introduction
Failure reporting, analysis, and corrective action system (FRACAS)
Failure data analysis: the "7 tools"
Acceptance sampling
Probability and hazard plotting
Time series analysis
Software for data collection and analysis
Reliability demonstration and growth measurement
General comments on data analysis
Sources of data
13. LAWS, REGULATIONS AND STANDARDS
Introduction
Laws and regulations (safety and product liability)
Main regulatory agencies (USA, Europe)
Standards (international; NATO; USA; Europe; UK; etc.)
"Generic" standards (ISO9000; IEC60300; ISO/IEC61508)
Industry/technology standards (aviation/aerospace; automotive; other)
Conclusions (advice, guidance)
14. MANAGEMENT
Introduction
Organisation and responsibilities (test departmen, design)
Procedures for test
The development test programme (what, how many to test?; system levels; purchased items; allocations; methods; economics; external facilities; regulations and standards)
The project test plan
Manufacturing and maintenance
Training and education for test
The future of test (virtual test; intelligent CAE; Internet; new hardware, test education)
Conclusions
APPENDICES