1st Edition
Affordable Reliability Engineering Life-Cycle Cost Analysis for Sustainability & Logistical Support
How Can Reliability Analysis Impact Your Company’s Bottom Line?
While reliability investigations can be expensive, they can also add value to a product that far exceeds its cost. Affordable Reliability Engineering: Life-Cycle Cost Analysis for Sustainability & Logistical Support shows readers how to achieve the best cost for design development testing and evaluation and compare options for minimizing costs while keeping reliability above specifications. The text is based on the premise that all system sustainment costs result from part failure. It examines part failure in the design and sustainment of fielded parts and outlines a design criticality analysis procedure that reflects system design and sustainment.
Achieve the Best Cost for Life-Cycle Sustainment
Providing a framework for managers and engineers to develop and implement a reliability program for their organizations, the authors present the practicing professional with the tools needed to manage a system at a high reliability at the best cost. They introduce analytical methods that provide the methodology for integrating part reliability, failure, maintainability, and logistic math models. In addition, they include examples on how to run reliability simulations, highlight tools that are commercially available for such analysis, and explain the process required to ensure a design will meet specifications and minimize costs in the process.
This text:
- Demonstrates how to use information gathered from reliability investigations
- Provides engineers and managers with an understanding of a reliability engineering program so that they can perform reliability analyses
- Seeks to resolve uncertainty and establish the value of reliability engineering
Affordable Reliability Engineering: Life-Cycle Cost Analysis for Sustainability & Logistical Support focuses on reliability-centered maintenance and is an ideal resource for reliability engineers and managers. This text enables reliability professionals to determine the lowest life-cycle costs for part selection, design configuration options, and the implementation of maintenance practices, as well as spare parts strategies, and logistical resources.
Scope of Reliability-Based Life-Cycle Economical Analysis
Background
Reliability Engineering Approaches
Reliability Engineering Economics
Reliability Engineering Analysis Impacts on Life-Cycle Costs
Reliability Analysis for Part Design
Failure
Criticality Items List and Database
Proposed Criticality Analysis Procedure
Reliability Block Diagram
Qualitative Part Failure Analysis
Quantitative Failure Analysis
Assembly Reliability Functions
Fitting Reliability Data to Reliability Math Models
Exponential Reliability Math Models
Weibull Reliability Math Models
Qualitative Maintainability Analysis
Quantitative Maintainability Analysis
System Logistics Downtime Math Model
Summary of Reliability Math Models
Availability
Application of Reliability Math Models
Reliability Analysis for System Sustainment
Baseline Reliability Analysis
Failure Report, Analysis, Corrective Action System—FRACAS
Prerepair Logistics Downtime
Postrepair Logistics Downtime
Quantitative Reliability Analysis
Exponential Reliability Math Models
Weibull Reliability Math Models
Quantitative Maintainability Analysis
Mean Maintenance Time
Mean Downtime
System Logistics Downtime Math Model
Summary of Reliability Math Models
Availability
Application of Reliability Math Models
Engineering Economic Analysis
Engineering Economic Analysis Information
Fundamental Economic Concepts
Amounts versus Equivalent Value
Cost Estimation
Classifications of Sources and Uses of Estimated Cash
Cash Flow Timeline
Equivalent Values
Example 1: Project Cash Flow Timeline: m =
Example 2: Project Cash Flow Timeline: m =
Example 3: Project Cash Flow Timelines for Three Projects: m =
Example 4: Project Cash Flow Timelines for Three Projects: m =
Application to Reliability Based Life-Cycle Economic Analysis
Reliability-Based Logistical Economic Analysis
Failure Math Model
Repair Math Model
Logistics Downtime Math Model
Impact of Preventive Maintenance on Logistics Downtime
Special Cause Variability in Logistics Downtime
Cost Objective Function
Spare Parts Acquisition Strategies
Specialty Tools
Cash Flow Timeline
Life-Cycle Economic Analysis
Selection
Cautionary Note
Preventive Maintenance
Life-Cycle Simulation Approach
System Reliability Analysis
Spare Parts Strategy
Standby Design Configuration
Reliability-Centered Maintenance
Choosing the Correct Maintenance Plan
RCM Challenges
RCM Benefits
Reliability Database
Segment 1: Criticality Analysis
Segment 2: Qualitative Failure Analysis
Segment 3: Quantitative Failure Analysis
Segment 4: Quantitative Repair Analysis
Segment 5: Pre-Repair Logistics Downtime Quantitative Analysis
Segment 6: Post-Repair Logistics Downtime Quantitative Analysis
Segment 7: Spare Part Strategy
Reliability Simulation and Analysis
Reliability Simulations
Assembly and System Simulations
Summary
A: Reliability Failure Math Models and Reliability Functions
Exponential Reliability Math Modeling Approach
Weibull Reliability Math Modeling Approach
B: Maintainability Math Models and Maintainability Functions
Time-to-Repair Math Model, Log-Normal Distribution Approach
Time-to-Repair Math Model, Weibull Distribution Approach
Comparison between the Log-Normal and Weibull Approach
Logistics Downtime Functions
Engineering Economics Functions
Cost Estimation: Present Amount
Cost Estimation: Future Amount
Equivalent Present Value: Future Amount
Cost Estimation: Uniform Recurring Amounts
Recurring Amounts with Linear Gradient
Recurring Amounts with Geometric Gradient
Capital Recovery
Sinking Fund
Net Present Value and Equivalent Uniform Recurring Amount
Less Common Engineering Economics Functions
References
Biography
Bill Wessels
has over 45 years of experience in system design and sustainability. He currently works at the University of Alabama in Huntsville, where he cofounded the Reliability and Failure Analysis Laboratory and performs basic and applied research in design-for-reliability, reliability-based maintainability, and reliability-based life-cycle economic analysis. Wessels has a BS in engineering from the United States Military Academy at West Point, an MBA in decision sciences from the University of Alabama in Tuscaloosa, and a PhD in systems engineering from the University of Alabama in Huntsville. He is a registered professional mechanical engineer and a certified reliability engineer.Daniel S. Sillivant
is a researcher at the University of Alabama in Huntsville performing basic and applied research and investigations in reliability life-cycle modeling for aviation and sensors systems. He is published in peer-reviewed proceedings for the International Mechanical Engineering Congress and Exposition; Reliability, Availability, Maintainability Workshop; and Industry, Engineering, and Management Systems. Sillivant has a bachelor’s degree in chemical engineering and a master’s degree in industrial/reliability engineering from UAH. He has begun his dissertation research in reliability based life-cycle economic modeling for implementation of reliability-centered maintenance. In addition, he holds certificates in Lean Concepts Training and Six Sigma Green Belt."… an excellent reference book … written in an interesting and different way than traditional reliability books. The focus on economics of reliability will be welcome by both engineers and managers. … The book is based on many years’ experience of the authors and the coverage reflects the importance and priority and needs of industry. I will share more of these thoughts with my students in class."
—Min Xie, City University of Hong Kong"… provides technical information and facts that will help improve the communication and understanding of important reliability life cycle concepts and principles among fellow technical and managerial professionals. … will attract the well-deserved attention of the expert and novice alike. The focus on life-cycle cost analysis brings to the engineering community something new and significant that helps to better underscore important role of reliability analysis in the in the total life cycle process."
—Dr. Russell A. Vacante, RMS Partnership Inc.
