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Improving Product Reliability and Software Quality: Strategies, Tools, Process and Implementation 2nd edition [Kõva köide]

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, (Teradyne, Inc., California, USA), (Teradyne, Inc., California, USA)
  • Formaat: Hardback, 456 pages, kõrgus x laius x paksus: 241x173x28 mm, kaal: 907 g
  • Sari: Quality and Reliability Engineering Series
  • Ilmumisaeg: 19-Apr-2019
  • Kirjastus: John Wiley & Sons Inc
  • ISBN-10: 1119179394
  • ISBN-13: 9781119179399
Teised raamatud teemal:
Improving Product Reliability and Software Quality: Strategies, Tools, Process and Implementation 2nd editionSuurem pilt
  • Formaat: Hardback, 456 pages, kõrgus x laius x paksus: 241x173x28 mm, kaal: 907 g
  • Sari: Quality and Reliability Engineering Series
  • Ilmumisaeg: 19-Apr-2019
  • Kirjastus: John Wiley & Sons Inc
  • ISBN-10: 1119179394
  • ISBN-13: 9781119179399
Teised raamatud teemal:
Püsilink: https://www.kriso.ee/db/9781119179399.html
Märksõnad:

The authoritative guide to the effective design and production of reliable technology products, revised and updated

While most manufacturers have mastered the process of producing quality products, product reliability, software quality and software security has lagged behind. The revised second edition of Improving Product Reliability and Software Quality offers a comprehensive and detailed guide to implementing a hardware reliability and software quality process for technology products. The authors – noted experts in the field – provide useful tools, forms and spreadsheets for executing an effective product reliability and software quality development process and explore proven software quality and product reliability concepts.

The authors discuss why so many companies fail after attempting to implement or improve their product reliability and software quality program. They outline the critical steps for implementing a successful program. Success hinges on establishing a reliability lab, hiring the right people and implementing a reliability and software quality process that does the right things well and works well together. Designed to be accessible, the book contains a decision matrix for small, medium and large companies. Throughout the book, the authors describe the hardware reliability and software quality process as well as the tools and techniques needed for putting it in place. The concepts, ideas and material presented are appropriate for any organization. This updated second edition: 

  • Contains new chapters on Software tools, Software quality process and software security.
  • Expands the FMEA section to include software fault trees and software FMEAs.
  • Includes two new reliability tools to accelerate design maturity and reduce the risk of premature wearout.
  • Contains new material on preventative maintenance, predictive maintenance and Prognostics and Health Management (PHM) to better manage repair cost and unscheduled downtime.
  • Presents updated information on reliability modeling and hiring reliability and software engineers.
  • Includes a comprehensive review of the reliability process from a multi-disciplinary viewpoint including new material on uprating and counterfeit components.
  • Discusses aspects of competition, key quality and reliability concepts and presents the tools for implementation.

Written for engineers, managers and consultants lacking a background in product reliability and software quality theory and statistics, the updated second edition of Improving Product Reliability and Software Quality explores all phases of the product life cycle. 

About the Authors xix
List of Figures xxi
List of Tables xxv
Series Editor's Foreword xxvii
Series Foreword Second Edition xxix
Series Foreword First Edition xxxi
Foreword First Edition xxxiii
Preface Second Edition xxxv
Preface First Edition xxxvii
Acknowledgments xli
Glossary xliii
Part I Reliability and Software Quality - It's a Matter of Survival 1(36)
1 The Need for a New Paradigm for Hardware Reliability and Software Quality
3(12)
1.1 Rapidly Shifting Challenges for Hardware Reliability and Software Quality
3(2)
1.2 Gaining Competitive Advantage
5(1)
1.3 Competing in the Next Decade - Winners Will Compete on Reliability
5(1)
1.4 Concurrent Engineering
6(2)
1.5 Reducing the Number of Engineering Change Orders at Product Release
8(1)
1.6 Time-to-Market Advantage
9(1)
1.7 Accelerating Product Development
10(1)
1.8 Identifying and Managing Risks
11(1)
1.9 ICM, a Process to Mitigate Risk
11(1)
1.10 Software Quality Overview
12(1)
References
13(1)
Further Reading
13(2)
2 Barriers to Implementing Hardware Reliability and Software Quality
15(10)
2.1 Lack of Understanding
15(1)
2.2 Internal Barriers
16(1)
2.3 Implementing Change and Change Agents
17(2)
2.4 Building Credibility
19(1)
2.5 Perceived External Barriers
20(1)
2.6 Time to Gain Acceptance
21(1)
2.7 External Barrier
22(1)
2.8 Barriers to Software Process Improvement
23(2)
3 Understanding Why Products Fail
25(8)
3.1 Why Things Fail
25(3)
3.2 Parts Have Improved, Everyone Can Build Quality Products
28(1)
3.3 Hardware Reliability and Software Quality - The New Paradigm
28(1)
3.4 Reliability vs. Quality Escapes
29(1)
3.5 Why Software Quality Improvement Programs Are Unsuccessful
30(1)
Further Reading
31(2)
4 Alternative Approaches to Implementing Reliability
33(4)
4.1 Hiring Consultants for HALT Testing
33(1)
4.2 Outsourcing Reliability Testing
33(1)
4.3 Using Consultants to Develop and Implement a Reliability Program
34(1)
4.4 Hiring Reliability Engineers
34(3)
Part II Unraveling the Mystery 37(168)
5 The Product Life Cycle
39(10)
5.1 Six Phases of the Product Life Cycle
39(2)
5.2 Risk Mitigation
41(4)
5.2.1 Investigate the Risk
41(1)
5.2.2 Communicate the Risk
41(3)
5.2.3 Mitigate the Risk
44(1)
5.3 The ICM Process for a Small Company
45(1)
5.4 Design Guidelines
46(1)
5.5 Warranty
46(1)
Further Reading
47(1)
Reliability Process
47(1)
DFM
48(1)
6 Reliability Concepts
49(24)
6.1 The Bathtub Curve
50(1)
6.2 Mean Time between Failure
51(2)
6.2.1 Mean Time between Repair
52(1)
6.2.2 Mean Time between Maintenance (MTBM)
52(1)
6.2.3 Mean Time between Incidents (MTBI)
52(1)
6.2.4 Mean Time to Failure (MTTF)
52(1)
6.2.5 Mean Time to Repair (MTTR)
52(1)
6.2.6 Mean Time to Restore System (MTTRS)
52(1)
6.3 Warranty Costs
53(2)
6.4 Availability
55(2)
6.4.1 On-site Manufacturer Service Personnel
56(1)
6.4.2 Trained Customer Service Personnel
56(1)
6.4.3 Manufacturer Training for Customer Service Personnel
56(1)
6.4.4 Easy-to-Use Service Manuals
56(1)
6.4.5 Rapid Diagnosis Capability
56(1)
6.4.6 Repair and Spare Parts Availability
57(1)
6.4.7 Rapid Response to Customer Requests for Service
57(1)
6.4.8 Failure Data Tracking
57(1)
6.5 Reliability Growth
57(2)
6.6 Reliability Demonstration Testing
59(3)
6.7 Maintenance and Availability
62(7)
6.7.1 Preventative Maintenance
63(1)
6.7.2 Predictive Maintenance
64(1)
6.7.3 Prognostics and Health Management (PHM)
64(5)
6.8 Component Derating
69(1)
6.9 Component Uprating
70(1)
Reference
71(1)
Further Reading
72(1)
Reliability Growth
72(1)
Reliability Demonstration
72(1)
Prognostics and Health Management
72(1)
7 FMEA
73(28)
7.1 Benefits of FMEA
73(1)
7.2 Components of FMEA
74(12)
7.2.1 The Functional Block Diagram (FBD)
74(4)
7.2.1.1 Generating the Functional Block Diagram
75(1)
7.2.1.2 Filling in the Functional Block Diagram
76(2)
7.2.2 The Fault Tree Analysis
78(2)
7.2.2.1 Building the Fault Tree
78(1)
7.2.2.2 Brainstorming
79(1)
7.2.3 Failure Modes and Effects Analysis Spreadsheet
80(6)
7.3 Preparing for the FMEA
86(3)
7.4 Barriers to the FMEA Process
89(2)
7.5 FMEA Ground Rules
91(1)
7.6 Using Macros to Improve FMEA Efficiency and Effectiveness
92(2)
7.7 Software FMEA
94(3)
7.8 Software Fault Tree Analysis (SFTA)
97(1)
7.9 Process FMEAs
97(2)
7.10 FMMEA
99(2)
8 The Reliability Toolbox
101(38)
8.1 The HALT Process
101(20)
8.1.1 Types of Stresses Applied in HALT
104(1)
8.1.2 The Theory behind the HALT Process
105(4)
8.1.3 HALT Testing Liquid Cooled Products
109(1)
8.1.4 Planning for HALT Testing
110(11)
8.2 Highly Accelerated Stress Screening (HASS)
121(6)
8.2.1 Proof of Screen (POS)
122(1)
8.2.2 Burn-In
123(1)
8.2.3 Environmental Stress Screening (ESS)
124(1)
8.2.4 Economic Impact of HASS
125(1)
8.2.5 The HASA Process
126(1)
8.3 HALT and HASS Test Chambers
127(1)
8.4 Accelerated Reliability Growth (ARG)
128(3)
8.5 Accelerated Early Life Test (ELT)
131(1)
8.6 SPC Tool
132(1)
8.7 FIFO Tool
132(2)
References
134(1)
Further Reading
134(1)
FMEA
134(1)
HALT
135(1)
HASS
136(1)
Quality
136(1)
Burn-in
136(1)
ESS
137(1)
Up Rating
137(2)
9 Software Quality Goals and Metrics
139(12)
9.1 Setting Software Quality Goals
139(1)
9.2 Software Metrics
140(2)
9.3 Lines of Code (LOC)
142(1)
9.4 Defect Density
142(2)
9.5 Defect Models
144(1)
9.6 Defect Run Chart
145(2)
9.7 Escaped Defect Rate
147(1)
9.8 Code Coverage
148(1)
References
149(1)
Further Reading
150(1)
10 Software Quality Analysis Techniques
151(8)
10.1 Root Cause Analysis
151(1)
10.2 The 5 Whys
151(1)
10.3 Cause and Effect Diagrams
152(1)
10.4 Pareto Charts
153(1)
10.5 Defect Prevention, Defect Detection, and Defensive Programming
154(3)
10.6 Effort Estimation
157(1)
Reference
158(1)
Further Reading
158(1)
11 Software Life Cycles
159(8)
11.1 Waterfall
159(2)
11.2 Agile
161(1)
11.3 CMMI
162(3)
11.4 How to Choose a Software Life Cycle
165(1)
Reference
166(1)
Further Reading
166(1)
12 Software Procedures and Techniques
167(16)
12.1 Gathering Requirements
167(2)
12.2 Documenting Requirements
169(3)
12.3 Documentation
172(1)
12.4 Code Comments
173(1)
12.5 Reviews and Inspections
174(5)
12.6 Traceability
179(1)
12.7 Defect Tracking
179(1)
12.8 Software and Hardware Integration
180(2)
References
182(1)
Further Reading
182(1)
13 Why Hardware Reliability and Software Quality Improvement Efforts Fail
183(16)
13.1 Lack of Commitment to the Reliability Process
183(2)
13.2 Inability to Embrace and Mitigate Technologies Risk Issues
185(1)
13.3 Choosing the Wrong People for the Job
186(1)
13.4 Inadequate Funding
186(5)
13.5 Inadequate Resources
191(1)
13.6 MIL-HDBK 217 - Why It Is Obsolete
192(3)
13.7 Finding But Not Fixing Problems
195(1)
13.8 Nondynamic Testing
196(1)
13.9 Vibration Testing Too Difficult to Implement
196(1)
13.10 The Impact of Late Hardware or Late Software Delivery
196(1)
13.11 Supplier Reliability
196(1)
Reference
197(1)
Further Reading
197(2)
14 Supplier Management
199(6)
14.1 Purchasing Interface
199(1)
14.2 Identifying Your Critical Suppliers
200(1)
14.3 Develop a Thorough Supplier Audit Process
200(1)
14.4 Develop Rapid Nonconformance Feedback
201(1)
14.5 Develop a Materials Review Board (MRB)
202(1)
14.6 Counterfeit Parts and Materials
202(3)
Part III Steps to Successful Implementation 205(40)
15 Establishing a Reliability Lab
207(14)
15.1 Staffing for Reliability
207(1)
15.2 The Reliability Lab
208(2)
15.3 Facility Requirements
210(1)
15.4 Liquid Nitrogen Requirements
210(1)
15.5 Air Compressor Requirements
211(1)
15.6 Selecting a Reliability Lab Location
212(1)
15.7 Selecting a Halt Test Chamber
213(7)
15.7.1 Chamber Size
214(1)
15.7.2 Machine Overall Height
214(2)
15.7.3 Power Required and Consumption
216(1)
15.7.4 Acceptable Operational Noise Levels
216(1)
15.7.5 Door Swing
216(1)
15.7.6 Ease of Operation
217(1)
15.7.7 Profile Creation, Editing, and Storage
217(1)
15.7.8 Temperature Rates of Change
217(1)
15.7.9 Built-In Test Instrumentation
217(1)
15.7.10 Safety
217(1)
15.7.11 Time from Order to Delivery
217(1)
15.7.12 Warranty
218(1)
15.7.13 Technical/Service Support
218(1)
15.7.14 Compressed Air Requirements
218(1)
15.7.15 Lighting
218(1)
15.7.16 Customization
218(2)
Reference
220(1)
16 Hiring and Staffing the Right People
221(8)
16.1 Staffing for Reliability
221(4)
16.1.1 A Reliability Engineering Background
221(1)
16.1.2 HALT/HASS and ESS
221(2)
16.1.3 Shock and Vibration Testing
223(1)
16.1.4 Statistical Analysis
223(1)
16.1.5 Failure Budgeting/Estimating
223(1)
16.1.6 Failure Analysis
224(1)
16.1.7 Conducting Reliability Training
224(1)
16.1.8 Persuasive in Implementing New Concepts
224(1)
16.1.9 A Degree in Engineering and/or Physics
225(1)
16.2 Staffing for Software Engineers
225(1)
16.3 Choosing the Wrong People for the Job
226(3)
17 Implementing the Reliability Process
229(16)
17.1 Reliability Is Everyone's Job
229(1)
17.2 Formalizing the Reliability Process
230(1)
17.3 Implementing the Reliability Process
231(1)
17.4 Rolling Out the Reliability Process
231(4)
17.5 Developing a Reliability Culture
235(1)
17.6 Setting Reliability Goals
236(1)
17.7 Training
237(1)
17.8 Product Life Cycle Defined
238(3)
17.8.1 Concept Phase
239(1)
17.8.2 Design Phase
240(1)
17.8.3 Production Phase
241(1)
17.8.4 End-of-Life and Obsolescence Phase
241(1)
17.9 Proactive and Reactive Reliability Activities
241(3)
Further Reading
244(1)
Reliability Process
244(1)
Part IV Reliability and Quality Process for Product Development 245(124)
18 Product Concept Phase
247(10)
18.1 Reliability Activities in the Product Concept Phase
247(1)
18.2 Establish the Reliability Organization
248(1)
18.3 Define the Reliability Process
249(1)
18.4 Define the Product Reliability Requirements
249(1)
18.5 Capture and Apply Lessons Learned
249(3)
18.6 Mitigate Risk
252(3)
18.6.1 Filling Out the Risk Mitigation Form
253(6)
18.6.1.1 Identify and Analyze Risk
253(1)
18.6.1.2 Risk Severity
254(1)
18.6.1.3 Date Risk Is Identified
254(1)
18.6.1.4 Risk Accepted
254(1)
18.6.1.5 High-Level Mitigation Plan
254(1)
18.6.1.6 Resources Required
254(1)
18.6.1.7 Completion Date
255(1)
18.6.1.8 Success Metric
255(1)
18.6.1.9 Investigate Alternative Solutions
255(1)
18.6.2 Risk Mitigation Meeting
255(2)
19 Design Concept Phase
257(16)
19.1 Reliability Activities in the Design Concept Phase
257(2)
19.2 Set Reliability Requirements and Budgets
259(4)
19.2.1 Requirements for Product Use Environment
259(1)
19.2.2 Product Useful Life Requirements
260(1)
19.2.3 Subsystem and Printed Circuit Board Assembly (PCBA) Reliability Budgets
261(2)
19.2.4 Service and Repair Requirements
263(1)
19.3 Define Reliability Design Guidelines
263(1)
19.4 Revise Risk Mitigation
264(4)
19.4.1 Identifying Risk Issues
264(1)
19.4.2 Reflecting Back (Capturing Internal Lessons Learned)
265(1)
19.4.3 Looking Forward (Capturing New Risk Issues)
265(3)
19.5 Schedule Reliability Activities and Capital Budgets
268(1)
19.6 Decide Risk Mitigation Sign-off Day
269(2)
19.7 Reflect on What Worked Well
271(2)
20 Product Design Phase
273(26)
20.1 Product Design Phase
273(1)
20.2 Reliability Estimates
274(2)
20.3 Implementing Risk Mitigation Plans
276(9)
20.3.1 Mitigating Risk Issues Captured Reflecting Back
276(2)
20.3.1.1 Design Out (or Use an Alternate Part/Supplier)
276(1)
20.3.1.2 Change Use Conditions
277(1)
20.3.1.3 Fix Part
278(1)
20.3.1.4 Fix Process
278(1)
20.3.2 Mitigating Risk Issues Captured Looking Forward
278(7)
20.3.2.1 Accelerated Life Testing
280(4)
20.3.2.2 Risk Mitigation Progress
284(1)
20.4 Design for Reliability Guidelines (DFR)
285(4)
20.4.1 Derating Guidelines
288(1)
20.5 Design FMEA
289(1)
20.6 Installing a Failure Reporting Analysis and Corrective Action System
290(1)
20.7 HALT Planning
291(1)
20.8 HALT Test Development
292(3)
20.9 Risk Mitigation Meeting
295(1)
Further Reading
296(1)
FMEA
296(1)
HALT
296(3)
21 Design Validation Phase
299(22)
21.1 Design Validation
299(2)
21.2 Using HALT to Precipitate Failures
301(12)
21.2.1 Starting the HALT Test
304(2)
21.2.2 Room Ambient Test
306(1)
21.2.3 Tickle Vibration Test
306(1)
21.2.4 Temperature Step Stress Test and Power Cycling
306(2)
21.2.5 Vibration Step Stress Test
308(1)
21.2.6 Combinational Temperature and Vibration Test
308(1)
21.2.7 Rapid Thermal Cycling Stress Test
309(1)
21.2.8 Slow Temperature Ramp
310(1)
21.2.9 Combinational Search Pattern Test
311(1)
21.2.10 Additional Nonenvironmental Stress Tests
312(1)
21.2.11 HALT Validation Test
312(1)
21.3 Proof of Screen (POS)
313(2)
21.4 Highly Accelerated Stress Screen (HASS)
315(1)
21.5 Operate FRACAS
315(2)
21.6 Design FMEA
317(1)
21.7 Closure of Risk Issues
317(1)
Further Reading
318(1)
FMEA
318(1)
Acceleration Methods
318(1)
ESS
318(1)
HALT
319(2)
22 Software Testing and Debugging
321(14)
22.1 Unit Tests
321(2)
22.2 Integration Tests
323(1)
22.3 System Tests
324(1)
22.4 Regression Tests
324(2)
22.5 Security Tests
326(1)
22.6 Guidelines for Creating Test Cases
327(1)
22.7 Test Plans
328(1)
22.8 Defect Isolation Techniques
329(2)
22.8.1 Simulation
329(2)
22.9 Instrumentation and Logging
331(3)
Further Reading
334(1)
23 Applying Software Quality Procedures
335(6)
23.1 Using Defect Model to Create Defect Run Chart
336(1)
23.2 Using Defect Run Chart to Know When You Have Achieved the Quality Target
336(2)
23.3 Using Root Cause Analysis on Defects to Improve Organizational Quality Delivery
338(1)
23.4 Continuous Integration and Test
338(1)
Further Reading
339(2)
24 Production Phase
341(18)
24.1 Accelerating Design Maturity
341(5)
24.1.1 Product Improvement Tools
343(3)
24.1.1.1 FRACAS
344(1)
24.1.1.2 Design Issue Tracking
345(1)
24.2 Reliability Growth
346(5)
24.2.1 Accelerated Reliability Growth (ARG)
349(1)
24.2.2 Accelerated Early Life Testing (ELT)
350(1)
24.3 Design and Process FMEA
351(4)
24.3.1 Quality Control Tools
351(4)
24.3.1.1 SPC
352(2)
24.3.1.2 Six Sigma
354(1)
24.3.1.3 HASS and HASA
355(1)
Further Reading
355(1)
FMEA
355(1)
Quality
356(1)
Reliability Growth
356(1)
Burn-In
357(1)
HASS
357(2)
25 End-of-Life Phase
359(4)
25.1 Managing Obsolescence
359(1)
25.2 Product Termination
360(1)
25.3 Project Assessment
360(1)
Further Reading
361(2)
26 Field Service
363(6)
26.1 Design for Ease of Access
363(1)
26.2 Identify High Replacement Assemblies (FRUs)
363(2)
26.3 Wearout Replacement
365(1)
26.4 Preemptive Servicing
365(1)
26.5 Servicing Tools
365(1)
26.6 Service Loops
366(1)
26.7 Availability or Repair Time Turnaround
367(1)
26.8 Avoid System Failure Through Redundancy
367(1)
26.9 Random versus Wearout Failures
367(1)
Further Reading
368(1)
Appendix A 369(18)
A.1 Reliability Consultants
369(3)
A.2 Graduate Reliability Engineering Programs and Reliability Certification Programs
372(4)
A.3 Reliability Professional Organizations and Societies
376(1)
A.4 Reliability Training Classes
377(2)
A.5 Environmental Testing Services
379(2)
A.6 HALT Test Chambers
381(1)
A.7 Reliability Websites
382(1)
A.8 Reliability Software
383(1)
A.9 Reliability Seminars and Conferences
384(2)
A.10 Reliability Journals
386(1)
Appendix B 387(12)
B.1 MTBF, FIT, and PPM Conversions
387(1)
B.2 Mean Time Between Failure (MTBF)
387(9)
B.3 Estimating Field Failures
396(3)
B.3.1 Comparing Repairable to Nonrepairable Systems
397(2)
Index 399
MARK A. LEVIN is the Reliability Manager for Product Development at Teradyne, Inc., USA. He has over 36 years of electronics experience working in manufacturing, design and research.

TED T. KALAL is a retired Reliability Manager. He has held many positions as a contract engineer and consultant where he focused on design, quality and reliability tasks.

JONATHAN RODIN is a Software Engineering Manager at Teradyne, Inc., USA. Jon has 39 years of experience developing software either as a programmer or managing software development projects.