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Life Cycle Reliability Engineering

Life Cycle Reliability Engineering

Guang Yang

ISBN: 978-0-471-71529-0

Feb 2007

544 pages

In Stock



As the Lead Reliability Engineer for Ford Motor Company, Guangbin Yang is involved with all aspects of the design and production of complex automotive systems. Focusing on real-world problems and solutions, Life Cycle Reliability Engineering covers the gamut of the techniques used for reliability assurance throughout a product's life cycle. Yang pulls real-world examples from his work and other industries to explain the methods of robust design (designing reliability into a product or system ahead of time), statistical and real product testing, software testing, and ultimately verification and warranting of the final product's reliability

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1. Reliability Engineering and Product Life Cycle.

1.1.Reliability Engineering.

1.2.Product Life Cycle.

1.3.Integration of Reliability Engineering into Product Life Cycle.

1.4.Reliability in Concurrent Product Realization Process.


2. Reliability Definition, Metrics and Product Life Distributions.


2.2.Reliability Definition.

2.3. Reliability Metrics.

2.4.Exponential Distribution.

2.5.Weibull Distribution.

2.6.Mixed Weibull Distribution.

2.7.Smallest Extreme Value Distribution.

2.8.Normal Distribution.

2.9.Lognormal distribution.


3. Reliability Planning and Specification.


3.2.Understanding Customer Expectations and Satisfaction.

3.3.Setting Reliability Requirements.

3.4.Reliability Program Development.

3.5.Reliability Design and Design for Six Sigma.


4. System Reliability Evaluation and Allocation.


4.2.Reliability Block Diagram.

4.3.Series Systems.

4.4.Parallel Systems.

4.5.Mixed Configurations.

4.6.k-out-of-n Systems.

4.7.Redundant Systems.

4.8.Reliability Evaluation of Complex Systems.

4.9.Confidence Intervals for System Reliability.

4.10. Measures of Component Importance.

4.11. Reliability Allocation.


5. Reliability Improvement Through Robust Design.


5.2.Reliability and Robustness.

5.3.Reliability Degradation and Quality Loss.

5.4.Robust Design Process.

5.5.Boundary Definition and Interaction Analysis.


5.7.Noise Effects Management.

5.8.Design of Experiments.

5.9.Experimental Life Data Analysis.

5.10. Experimental Degradation Data Analysis.

5.11. Design Optimization.

5.12. Robust Reliability Design of Diagnostic Systems.

5.13. A Case Study.

5.14. Advanced Topics on Robust Design.

Appendix: Orthogonal Arrays, Linear Graphs and Interaction Tables.


6. Potential Failure Mode Avoidance.


6.2.Failure Mode and Effects Analysis.

6.3.Advanced Topics on FMEA.

6.4.Fault Tree Analysis.

6.5.Advanced Topics on FTA.

6.6.Computer-Aided Design Controls.


7. Accelerated Life Tests.


7.2.Development of Test Plans.

7.3.Common Stresses and Their Effects.

7.4.Life-Stress Relationships.

7.5.Graphical Reliability Estimation at Individual Test Conditions.

7.6.Analytical Reliability Estimation at Individual Test Conditions.

7.7.Reliability Estimation at Use Condition.

7.8.Compromise Test Plans.

7.9.Highly Accelerated Life Tests.


8. Degradation Testing and Analysis.


8.2.Determination of Critical Performance Characteristic.

8.3.Reliability Estimation from Pseudo Life.

8.4.Degradation Analysis with Random-Effect Models.

8.5.Degradation Analysis for Destructive Inspections.

8.6.Stress-Accelerated Degradation Tests.

8.7.Accelerated Degradation Tests with Tightened Thresholds.

8.8.Accelerated Degradation Test Planning.


9. Reliability Verification Testing.


9.2.Planning Reliability Verification Tests.

9.3.Bogey Testing.

9.4.Sample Size Reduction by Tail-Testing.

9.5.Sequential Life Testing.

9.6.Reliability Verification Using Prior Information.

9.7.Reliability Verification Through Degradation Testing.


10. Stress Screening.

10.1 .Introduction.

10.2 . Concept of Screening Techniques.

10.3 . Design of Screen Plans.

10.4 .Principle of Degradation Screening.

10.5 .Part-Level Degradation Screening.

10.6 .Module-Level Screening.

10.7 .Module Reliability Modeling.

10.8 .Cost Modeling.

10.9 .Optimal Screen Plans.


11. Warranty Analysis.

11.1. Introduction.

11.2. Warranty Policies.

11.3. Warranty Data Mining.

11.4. Reliability Estimation from Warranty Claim Times.

11.5. Two-Dimensional Reliability Estimation.

11.6. Warranty Repair Modeling.

11.7. Warranty Cost Estimation.

11.8. Field Failure Monitoring.

11.9. Warranty Cost Reduction.


Appendix: Orthogonal Arrays, Linear Graphs, and Interaction Tables.



"This book is quite different from traditional books written on reliability engineering so far and is authored by a person who has a rich industrial experience of working with Ford Motor Company. The book is quite informative and provides a good insight of methodologies and techniques used in reliability engineering. This will go a long way in creating competitive products that perform well in the market and also provide customer satisfaction." (International Journal of Performability Engineering; 1/09)

"It is a very practical book which provides a comprehensive discussion on reliability engineering concepts and techniques throughout a product life cycle. The author has done a great job in explaining the up-to-date reliability techniques in a very practical manner and using simple and straightforward language. This book will prove very useful for reliability engineers, testing engineers, quality engineers and design engineers." (Reliability Review, December 2008)

"This book gives both starting and experienced engineers a very nice overview of the different methods and tools that can be used for reliability engineering. It is very nice that the book gives a lot of (often simplified) examples; it will therefore not be difficult to apply the theory in industrial practice." (Quality and Reliability Engineering International, 2008)

" This is a useful and an important book. It should be on the shelf of all reliability engineers and other engineers who have responsibility for product reliability. It will also be of interest to many of those doing research in the area. Overall, the book is well-written and easy to read." (Journal of Quality Technology, April 2008)

"The author has done a great job in explaining the practical and state-of-the-art techniques to access and enhance reliability throughout the product life cycle. This book deliberates on a wide range of topics in reliability engineering. Practical examples and exercises, mostly from the automotive industry, are used to illustrate the ideas and methodologies. Readers of this book are expected to have some knowledge of basic statistical inference, statistical modeling, and probability theory. This book will be of practical use for a variety of engineers, including reliability engineers, quality engineers, test engineers, systems engineers, or design engineers, who are working in different stages of the product life cycle. It will also serve well as a textbook or a reference book to students in a course on reliability, quality, or industrial engineering." (Technometrics, February 2008)