Ahad Ali, Ph.D. Assistant Professor  Department of Mechanical Engineering Lawrence Technological University 21000 West Ten Mile Road Southfield, MI 48075 Tel: 248-204-2531, Fax: 248-204-2576 Email: aali@ltu.edu

Center for Integrated Manufacturing Systems Intelligence (CSSI)

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EME 7303 - Design for Reliability

Fall 2007

Office: E037

Lecture:          Monday, 5:45 pm - 8:25 pm

Classroom:     E026

Office hours: Monday and Wednesday, 3:30 – 5:30pm or by appointment

Catalog Description:

This course explains the principles of reliability with emphasis on the problem of quantifying reliability in product design and testing. It explains the reliability point of views: reliability metric, customer perception, and things engineers do. It focuses on the reliability cycle, the functional activities in the design for reliability process. The students will apply reliability tools and methods for analysis of product reliability problems in the three phases of product design process, product reliability testing, and maintaining and/or improving reliability and quality in production. Topics include: analysis and diagnosis of reliability, static and dynamics reliability models, probabilistic engineering design, reliability testing and Weibull analysis, and reliability optimization. Competencies and collaborative e-learning will be demonstrated by students conducting design for reliability projects. A project report and an oral presentation are required from each team.

The Internet Course site: Blackboard - my.ltu.edu

Prerequisites:

Graduate standing and MCS3403 Probability & Statistics or equivalent

Course Objectives:

Upon completion of this course the students should be able to:

·        Define the three viewpoints of reliability.

·        Quantify reliability in product life cycle.

·        Apply reliability tools and methods for analysis and diagnosis of reliability concerns in all the phases of product design process.

·        Define the reliability requirements in the product requirement phase to ensure targets are satisfying customer want and needs.

·        Apply design for robustness and reliability approach.

·        Verify the product design by testing for reliability.

·         Maintain and improve product reliability and quality in production.

·         Improve product reliability and quality throughout the product life cycle.

Topics:

             I.      Introduction

I.1                Reliability Definition

I.2                Three Viewpoints of Reliability

          II.      Analyze and Diagnose Reliability

II.1             Failure Characteristics and Categories

II.2             Variation and Reliability Measurement

II.3             The Reliability and Hazard Function for Well-Known Distributions

II.4             Hazard Models and Product Life

II.5             Estimating the Hazard Function, Failure Density Function, and Reliability Function from Empirical Data

II.6             Analysis of warranty data, ROCOF and cumulative hazard plots

II.7             Life-Cycle Cost and Economic Analysis

       III.      Weibull Analysis

III.1           Introduction

III.2           Statistical Properties of the Weibull Distribution

III.3           Weibull Analysis

III.4           Analysis of Failure Test

III.5           The Nonzero Minimum Life Situation

III.6           Analysis of Suspended

III.7           Analysis of Product Comparison Experiments

III.8           Savings in Test Time Due to Censoring

        IV.      Static Reliability Models

IV.1          Series System

IV.2          Parallel System

IV.3          Series and Parallel Combinations System

IV.4          Complex System Analysis

IV.5          Reliability Considerations in Design

IV.6          Reliability Allocation Techniques

IV.7          Optimal Reliability Allocation

IV.8          Redundancy Optimization

           V.      Dynamic Reliability Models

V.1             Series System Model

V.2             Active Redundancy Model

V.3             Standby Redundancy Models

V.4             Shared Load Parallel Model

V.5             System Effectiveness Measures

        VI.      Probabilistic Engineering Design

VI.1          Introduction

VI.2          Probabilistic Design Methodology

VI.3          Strength and Stress Distributions

VI.4          Stress/Strength Interference

VI.5          Analysis of Stress/Strength Interference

VI.6          Graphical Approach for Empirically Determined Stress and Strength

VI.7          Optimization in Probabilistic Design

References:

1. An Introduction to Reliability and Maintainability Engineering, C.E. Ebeling, McGraw-Hill, Inc., 1997, ISBN# 0-07-018852-1. [Text]

2. Practical Reliability Engineering, 3rd Edition, P.D.T. O’Connor, John Wiley & Sons Inc., NY, 1991, ISBN# 0-471-92696-5.

3. Reliability-based design, S. S. Rao, McGraw-Hill, Inc., 1992, ISBN 0-07-051192-6.

4. Reliability in Engineering Design, K.C. Kapur and L.R. Lamberson, John Wiley & Sons Inc., NY, 1977, ISBN#:0-471-51191-9.

5. Statistical Design and Analysis of Engineering Experiments, Charles Lipson & Narendra J. Sheth, McGraw-Hill Co., 1973.

6. Life-Cycle Cost and Economic Analysis, W.J. Fabrycky, and B.S. Blanchard, Prentice Hall, Upper Saddle River, New Jersey, 1991.

7. Assurance Technologies- Principles & Practices, D.G. Raheja, McGraw-Hill Inc., Engineering & Technology Management Series, 1991. ISBN# 0-07-051212-4.

Grading:      

Homework                                           30 Points

Blackboard & Class Participations        10 Points

Midterm Exam                                      25 Points

Final Project                                         35 Points

A      4.0     91 – 100     A-        3.7        87 – 90

B+     3.3     83 – 86       B          3.0        80 – 82

B-     2.7     74 – 79       C+        2.3        67 – 73

C       2.0     60 – 66       F          < 60

Course Outlines:

Reliability Internet Resources:

1. Reliability Analysis Center www.rac.alionscience.com

2. Reliability Center, Inc. http://www.reliability.com/

3. Reliability Magazine http://www.reliability-magazine.com

4. Newsletter-Overall Equipment Effectiveness (OEE), http://www.managementsupport.com/nl3.htm

5. Probabilistic Software Inc. http://www.e-reliability.com/

6. ReliabilityWeb.com Network, a culture of reliability: http://www.reliabilityweb.com/

7. Maintenance and Reliability Discussion Forum, http://www.idcon.com/toastforum6503/toast/toast.asp

Reliability Related Journals:

·        IEEE Transactions on Reliability

·        International Journal of Quality & Reliability Management, Emerald

·        International Journal of Quality, Statistics, and Reliability

·        International Journal of Reliability and Safety (IJRS), Inderscience Publishers

·        International Journal of Reliability, Quality and Safety Engineering (IJRQSE), World Scientific Publishing 

·        Journal of Applied Reliability

·        Quality and Reliability Engineering International

·        Reliability Engineering

·        Reliability Engineering & System Safety, Elsevier

·        Reliability Review

Reliability Related Professional Organizations:

·        Society for Maintenance & Reliability Professionals, http://www.smrp.org/

·        Society of Reliability Engineers, http://www.sre.org/

·        IIE Quality Control/Reliability Division, http://www.iienet2.org/Landing.aspx?id=898

·        IEEE Reliability Society http://www.ieee.org/portal/site/relsoc

·        ASQ Reliability Division, http://www.asq.org/reliability/index.html

Reliability Related Conferences:

·        Annual Reliability and Maintainability Symposium, 2008 Symposium, Las Vegas , January 28-31, 2008, http://www.rams.org/

·        International Conference on Quality and Reliability, Nov. 5-7, 2007, Chiang Mai , Thailand . http://www.icqr2007.org/

·        Total Equipment Reliability Conference, May 15 - 18, 2006   San Antonio, Texas, Productivity Inc.

·        Society for Maintenance and Reliability Professionals 15th Annual Conference, October 7-10, 2007, http://www.smrp.org/Conference/2007/index.htm

·        International Applied Reliability Symposium, June 18 - 20, 2008, Reno , Nevada , http://www.arsymposium.org/

Reliability Related Programs/Centers:

• Maintenance and Reliability Center , University of Tennessee , http://www.engr.utk.edu/mrc/

• Reliability Engineering, University of Maryland , College Park , http://www.enre.umd.edu/

• Reliability Engineering Information Center , University of Maryland , http://www.enre.umd.edu/reinfo.htm

• Reliability Engineering Option, The University of Arizona, http://www.u.arizona.edu/~dimitri/MS_RE.htm

• Reliability and Risk Engineering and Management, Vanderbilt University , http://www.reliability-studies.vanderbilt.edu

• National Science Foundation (NSF) Industry University Cooperative Research Center for Quality and Reliability Engineering, Rutgers University and Arizona State University , http://coewww.rutgers.edu/~ie/qre/about.html

• National Science Foundation Industry University Cooperative Research Center for Intelligent Maintenance Systems (IMS), University of Cincinnati and University of Michigan-Ann Arbor, http://www.imscenter.net/

• The Center for System Reliability (CSR), Sandia National Laboratories, http://reliability.sandia.gov/

Reliability Software:

1. Reliability Engineering and Weibull Analysis Resources from ReliaSoft weibull.com is the premier source on the Internet for Reliability Engineering theory, discussion and resources. ... weibull.com provides resources for the professional in reliability engineering and related fields. ... www.weibull.com

2. Weibull Easy Software from Applications Research Inc. http://www.applicationsresearch.com/WeibullEase.htm

3. Weibull++ 6 Life Data Analysis (Weibull Analysis) Software from ReliaSoft ReliaSoft's Weibull++ 6 for life data analysis (Weibull analysis) utilizing multiple lifetime distributions, including all forms of the Weibull distribution, with a clear and concise interface geared toward reliability engineering. www.reliasoft.com/Weibull

4. WeibullPro from Isograph Weibull software for the analysis of failure and repair data. www.isograph-software.com