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E-raamat: Reliability, Maintainability, and Supportability: Best Practices for Systems Engineers

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Focuses on the core systems engineering tasks of writing, managing, and tracking requirements for reliability, maintainability, and supportability that are most likely to satisfy customers and lead to success for suppliers

This book helps systems engineers lead the development of systems and services whose reliability, maintainability, and supportability meet and exceed the expectations of their customers and promote success and profit for their suppliers. This book is organized into three major parts: reliability, maintainability, and supportability engineering. Within each part, there is material on requirements development, quantitative modelling, statistical analysis, and best practices in each of these areas. Heavy emphasis is placed on correct use of language. The author discusses the use of various sustainability engineering methods and techniques in crafting requirements that are focused on the customers needs, unambiguous, easily understood by the requirements stakeholders, and verifiable. Part of each major division of the book is devoted to statistical analyses needed to determine when requirements are being met by systems operating in customer environments. To further support systems engineers in writing, analyzing, and interpreting sustainability requirements, this book also





Contains Language Tips to help systems engineers learn the different languages spoken by specialists and non-specialists in the sustainability disciplines Provides exercises in each chapter, allowing the reader to try out some of the ideas and procedures presented in the chapter Delivers end-of-chapter summaries of the current reliability, maintainability, and supportability engineering best practices for systems engineers



Reliability, Maintainability, and Supportability is a reference for systems engineers and graduate students hoping to learn how to effectively determine and develop appropriate requirements so that designers may fulfil the intent of the customer.
Foreword xviii
Acknowledgments xxii
Part I Reliability Engineering
1 Systems Engineering and the Sustainability Disciplines
3(17)
1.1 Purpose of this Book
3(5)
1.1.1 Systems Engineers Create and Monitor Requirements
3(1)
1.1.2 Good Requirements are a Key to Success
4(2)
1.1.3 Sustainability Requirements are Important Too
6(1)
1.1.4 Focused Action is Needed to Achieve the Goals Expressed by the Requirements
7(1)
1.2 Goals
8(2)
1.3 Scope
10(2)
1.3.1 Reliability Engineering
10(1)
1.3.2 Maintainability Engineering
11(1)
1.3.3 Supportability Engineering
12(1)
1.4 Audience
12(2)
1.4.1 Who Should Read This Book?
12(1)
1.4.2 Prerequisites
13(1)
1.4.3 Postrequisites
13(1)
1.5 Getting Started
14(1)
1.6 Key Success Factors for Systems Engineers in Reliability, Maintainability, and Supportability Engineering
15(2)
1.6.1 Customer-Supplier Relationships
15(1)
1.6.2 Language and Clarity of Communication
16(1)
1.6.3 Statistical Thinking
17(1)
1.7 Organizing a Course Using this Book
17(2)
1.7.1 Examples
18(1)
1.7.2 Exercises
18(1)
1.7.3 References
18(1)
1.8
Chapter Summary
19(1)
References
19(1)
2 Reliability Requirements
20(64)
2.1 What to Expect from this
Chapter
20(1)
2.2 Reliability for Systems Engineers
21(15)
2.2.1 "Reliability" in Conversation
21(1)
2.2.2 "Reliability" in Engineering
21(1)
2.2.3 Foundational Concepts
21(4)
2.2.4 Reliability Concepts for Systems Engineers
25(3)
2.2.5 Definition of Reliability
28(4)
2.2.6 Failure Modes, Failure Mechanisms, and Failure Causes
32(2)
2.2.7 The Stress-Strength Model
34(1)
2.2.8 The Competing Risk Model
35(1)
2.3 Reliability, Maintainability, and Supportability are Mutually Reinforcing
36(5)
2.3.1 Introduction
36(4)
2.3.2 Mutual Reinforcement
40(1)
2.4 The Structure of Reliability Requirements
41(5)
2.4.1 Reliability Effectiveness Criteria
41(2)
2.4.2 Reliability Figures of Merit
43(1)
2.4.3 Quantitative Reliability Requirements Frameworks
44(2)
2.5 Examples of Reliability Requirements
46(7)
2.5.1 Reliability Requirements for a Product
46(2)
2.5.2 Reliability Requirements for a Flow Network
48(2)
2.5.3 Reliability Requirements for a Standing Service
50(1)
2.5.4 Reliability Requirements for an On-Demand Service
51(2)
2.6 Interpretation of Reliability Requirements
53(12)
2.6.1 Introduction
53(1)
2.6.2 Stakeholders
54(1)
2.6.3 Interpretation of Requirements Based on Effectiveness Criteria
55(3)
2.6.4 Interpretation of Requirements Based on Figures of Merit
58(4)
2.6.5 Models and Predictions
62(1)
2.6.6 What Happens When a Requirement is Not Met?
63(2)
2.7 Some Additional Figures of Merit
65(8)
2.7.1 Cumulative Distribution Function
65(1)
2.7.2 Measures of Central Tendency
65(4)
2.7.3 Measures of Dispersion
69(1)
2.7.4 Percentiles
70(1)
2.7.5 The Central Limit Theorem and Confidence Intervals
71(2)
2.8 Current Best Practices in Developing Reliability Requirements
73(6)
2.8.1 Determination of Failure Modes
74(1)
2.8.2 Determination of Customer Needs and Desires for Reliability and Economic Balance with Reliability Requirements
74(2)
2.8.3 Review All Reliability Requirements for Completeness
76(1)
2.8.4 Allocation of System Reliability Requirements to System Components
76(3)
2.8.5 Document Reliability Requirements
79(1)
2.9
Chapter Summary
79(2)
2.10 Exercises
81(1)
References
82(2)
3 Reliability Modeling for Systems Engineers
84(69)
3.1 What to Expect from this
Chapter
84(1)
3.2 Introduction
85(2)
3.3 Reliability Effectiveness Criteria and Figures of Merit for Nonmaintained Units
87(33)
3.3.1 Introduction
87(3)
3.3.2 The Life Distribution and the Survivor Function
90(5)
3.3.3 Other Quantities Related to the Life Distribution and Survivor Function
95(7)
3.3.4 Some Commonly Used Life Distributions
102(9)
3.3.5 Quantitative Incorporation of Environmental Stresses
111(5)
3.3.6 Quantitative Incorporation of Manufacturing Process Quality
116(2)
3.3.7 Operational Time and Calendar Time
118(2)
3.3.8 Summary
120(1)
3.4 Ensembles of Nonmaintained Components
120(26)
3.4.1 System Functional Decomposition
120(1)
3.4.2 Some Examples of System and Service Functional Decompositions
121(3)
3.4.3 Reliability Block Diagram
124(1)
3.4.4 Ensembles of Single-Point-of-Failure Units: Series Systems
125(6)
3.4.5 Ensembles Containing Redundant Elements: Parallel Systems
131(7)
3.4.6 Structure Functions
138(1)
3.4.7 Path Set and Cut Set Methods
139(5)
3.4.8 Reliability Importance
144(1)
3.4.9 Non-Service-Affecting Parts
145(1)
3.5 Reliability Modeling Best Practices for Systems Engineers
146(1)
3.6
Chapter Summary
146(1)
3.7 Exercises
146(3)
References
149(4)
4 Reliability Modeling for Systems Engineers
153(37)
4.1 What to Expect from this
Chapter
153(1)
4.2 Introduction
154(1)
4.3 Reliability Effectiveness Criteria and Figures of Merit for Maintained Systems
154(8)
4.3.1 Introduction
154(1)
4.3.2 System Reliability Process
155(1)
4.3.3 Reliability Effectiveness Criteria and Figures of Merit Connected with the System Reliability Process
156(5)
4.3.4 When is a Maintainable System Not a Maintained System?
161(1)
4.4 Maintained System Reliability Models
162(19)
4.4.1 Types of Repair and Service Restoration Models
162(1)
4.4.2 Systems with Renewal Repair
163(3)
4.4.3 Systems with Revival Repair
166(5)
4.4.4 More-General Repair Models
171(1)
4.4.5 The Separate Maintenance Model
172(5)
4.4.6 Superpositions of Point Processes and Systems with Many Single Points of Failure
177(2)
4.4.7 State Diagram Reliability Models
179(2)
4.5 Stability of Reliability Models
181(1)
4.6 Software Resources
182(1)
4.7 Reliability Modeling Best Practices for Systems Engineers
182(4)
4.7.1 Develop and Use a Reliability Model
183(1)
4.7.2 Develop the Reliability-Profitability Curve
183(1)
4.7.3 Budget for Reliability
184(2)
4.7.4 Design for Reliability
186(1)
4.8
Chapter Summary
186(1)
4.9 Exercises
187(1)
References
188(2)
5 Comparing Predicted and Realized Reliability with Requirements
190(29)
5.1 What to Expect from this
Chapter
190(1)
5.2 Introduction
190(1)
5.3 Effectiveness Criteria, Figures of Merit, Metrics, and Predictions
191(3)
5.3.1 Review
191(1)
5.3.2 Example
192(1)
5.3.3 Reliability Predictions
193(1)
5.4 Statistical Comparison Overview
194(5)
5.4.1 Quality of Knowledge
194(1)
5.4.2 Three Comparisons
195(3)
5.4.3 Count Data from Aggregates of Systems
198(1)
5.4.4 Environmental Conditions
198(1)
5.5 Statistical Comparison Techniques
199(13)
5.5.1 Duration Requirements
199(9)
5.5.2 Count Requirements
208(4)
5.6 Failure Reporting and Corrective Action System
212(2)
5.7 Reliability Testing
214(2)
5.7.1 Component Life Testing
214(1)
5.7.2 Reliability Growth Testing
215(1)
5.7.3 Software Reliability Modeling
216(1)
5.8 Best Practices in Reliability Requirements Comparisons
216(1)
5.8.1 Track Achievement of Reliability Requirements
216(1)
5.8.2 Institute a FRACAS
216(1)
5.9
Chapter Summary
216(1)
5.10 Exercises
217(1)
References
218(1)
6 Design for Reliability
219(43)
6.1 What to Expect from this
Chapter
219(1)
6.2 Introduction
220(1)
6.3 Techniques for Reliability Assessment
221(3)
6.3.1 Quantitative Reliability Modeling
221(2)
6.3.2 Reliability Testing
223(1)
6.4 The Design for Reliability Process
224(4)
6.4.1 Information Sources
226(2)
6.5 Hardware Design for Reliability
228(8)
6.5.1 Printed Wiring Boards
228(7)
6.5.2 Design for Reliability in Complex Systems
235(1)
6.6 Qualitative Design for Reliability Techniques
236(15)
6.6.1 Fault Tree Analysis
236(7)
6.6.2 Failure Modes, Effects, and Criticality Analysis
243(8)
6.7 Design for Reliability for Software Products
251(1)
6.8 Robust Design
252(5)
6.9 Design for Reliability Best Practices for Systems Engineers
257(1)
6.9.1 Reliability Requirements
257(1)
6.9.2 Reliability Assessment
258(1)
6.9.3 Reliability Testing
258(1)
6.9.4 DFR Practices
258(1)
6.10 Software Resources
258(1)
6.11
Chapter Summary
259(1)
6.12 Exercises
259(1)
References
260(2)
7 Reliability Engineering for High-Consequence Systems
262(20)
7.1 What to Expect from this
Chapter
262(1)
7.2 Definition and Examples of High-Consequence Systems
262(3)
7.2.1 What is a High-Consequence System?
262(1)
7.2.2 Examples of High-Consequence Systems
263(2)
7.3 Reliability Requirements for High-Consequence Systems
265(2)
7.4 Strategies for Meeting Reliability Requirements in High-Consequence Systems
267(11)
7.4.1 Redundancy
267(2)
7.4.2 Network Resiliency
269(1)
7.4.3 Component Qualification and Certification
270(7)
7.4.4 Failure Isolation
277(1)
7.5 Current Best Practices in Reliability Engineering for High-Consequence Systems
278(1)
7.6
Chapter Summary
279(1)
7.7 Exercises
280(1)
References
280(2)
8 Reliability Engineering for Services
282(21)
8.1 What to Expect from this
Chapter
282(1)
8.2 Introduction
282(3)
8.2.1 On-Demand Services
283(1)
8.2.2 Always-On Services
284(1)
8.3 Service Functional Decomposition
285(1)
8.4 Service Failure Modes and Failure Mechanisms
286(8)
8.4.1 Introduction
286(2)
8.4.2 Service Failure Modes
288(2)
8.4.3 Service Failure Mechanisms
290(4)
8.5 Service Reliability Requirements
294(2)
8.5.1 Examples of Service Reliability Requirements
294(1)
8.5.2 Interpretation of Service Reliability Requirements
295(1)
8.6 Service-Level Agreements
296(1)
8.7 SDI Reliability Requirements
297(1)
8.8 Design for Reliability Techniques for Services
298(1)
8.8.1 Service Fault Tree Analysis
299(1)
8.8.2 Service FME(C)A
299(1)
8.9 Current Best Practices in Service Reliability Engineering
299(1)
8.9.1 Set Reliability Requirements for the Service
299(1)
8.9.2 Determine Infrastructure Reliability Requirements from Service Reliability Requirements
300(1)
8.9.3 Monitor Achievement of Service Reliability Requirements
300(1)
8.10
Chapter Summary
300(1)
8.11 Exercises
301(1)
References
302(1)
9 Reliability Engineering for the Software Component of Systems and Services
303(22)
9.1 What to Expect from this
Chapter
303(1)
9.2 Introduction
304(1)
9.3 Reliability Requirements for the Software Component of Systems and Services
305(5)
9.3.1 Allocation of System Reliability Requirements to the Software Component
305(3)
9.3.2 Reliability Requirements for Security and Other Novel Areas
308(1)
9.3.3 Operational Time and Calendar Time
309(1)
9.4 Reliability Modeling for Software
310(2)
9.4.1 Reliability Growth Modeling for the Sequence of Failure Times
310(2)
9.4.2 Other Approaches
312(1)
9.5 Software Failure Modes and Failure Mechanisms
312(3)
9.5.1 Software Failure Modes
312(1)
9.5.2 Software Failure Mechanisms
313(2)
9.6 Design for Reliability in Software
315(3)
9.6.1 Software Fault Tree Analysis
316(1)
9.6.2 Software FME(C)A
317(1)
9.6.3 Some Software Failure Prevention Strategies
317(1)
9.7 Current Best Practices in Reliability Engineering for Software
318(1)
9.7.1 Follow Good Software Engineering Practices
318(1)
9.7.2 Conduct Design Reviews Focused on Reliability
318(1)
9.7.3 Reuse Known Good Software
319(1)
9.7.4 Encourage a Prevention Mindset
319(1)
9.8
Chapter Summary
319(1)
9.9 Exercises
320(1)
References
320(5)
Part II Maintainability Engineering
10 Maintainability Requirements
325(31)
10.1 What to Expect from this
Chapter
325(1)
10.2 Maintainability for Systems Engineers
326(11)
10.2.1 Definitions
326(1)
10.2.2 System Maintenance Concept
327(2)
10.2.3 Use of Maintainability Effectiveness Criteria and Requirements
329(2)
10.2.4 Use of Preventive Maintenance
331(1)
10.2.5 Levels of Maintenance
331(1)
10.2.6 Organizational Responsibilities
332(1)
10.2.7 Design Features
333(1)
10.2.8 Maintenance Environment
333(1)
10.2.9 Warranties
334(1)
10.2.10 Preventive Maintenance and Corrective Maintenance
334(1)
10.2.11 Maintainability for Services
335(2)
10.3 Maintainability Effectiveness Criteria and Figures of Merit
337(3)
10.3.1 Products and Systems
337(3)
10.3.2 Services
340(1)
10.4 Examples of Maintainability Requirements
340(2)
10.5 Maintainability Modeling
342(2)
10.5.1 Duration and Labor-Hour Effectiveness Criteria and Figures of Merit
342(2)
10.5.2 Count Effectiveness Criteria and Figures of Merit
344(1)
10.6 Interpreting and Verifying Maintainability Requirements
344(5)
10.6.1 Duration Effectiveness Criteria and Figures of Merit
344(2)
10.6.2 Count Effectiveness Criteria and Figures of Merit
346(2)
10.6.3 Cost and Labor-Hour Effectiveness Criteria and Figures of Merit
348(1)
10.6.4 Three Availability Figures of Merit
348(1)
10.7 Maintainability Engineering for High-Consequence Systems
349(2)
10.8 Current Best Practices in Maintainability Requirements Development
351(2)
10.8.1 Determine Customer Needs for Maintainability
351(1)
10.8.2 Balance Maintenance with Economics
351(1)
10.8.3 Use Quantitative Maintainability Modeling to Ensure Support for Maintainability Requirements
352(1)
10.8.4 Manage Maintainability by Fact
352(1)
10.9
Chapter Summary
353(1)
10.10 Exercises
354(1)
References
355(1)
11 Design for Maintainability
356(23)
11.1 What to Expect from this
Chapter
356(1)
11.2 System or Service Maintenance Concept
356(2)
11.3 Maintainability Assessment
358(4)
11.3.1 Maintenance Functional Decomposition and Maintainability Block Diagram
358(2)
11.3.2 Quantitative Maintainability Modeling
360(2)
11.4 Design for Maintainability Techniques
362(10)
11.4.1 System Maintenance Concept
362(1)
11.4.2 Level of Repair Analysis
363(6)
11.4.3 Preventive Maintenance
369(1)
11.4.4 Reliability-Centered Maintenance (RCM)
369(3)
11.5 Current Best Practices in Design for Maintainability
372(2)
11.5.1 Make a Deliberate Maintainability Plan
372(1)
11.5.2 Determine Which Design for Maintainability Techniques to Use
372(1)
11.5.3 Integration
373(1)
11.5.4 Organizational Factors
373(1)
11.6
Chapter Summary
374(1)
11.7 Exercises
374(1)
References
374(5)
Part III Supportability Engineering
12 Support Requirements
379(17)
12.1 What to Expect from this
Chapter
379(1)
12.2 Supportability for Systems Engineers
380(3)
12.2.1 Supportability as a System Property
380(2)
12.2.2 Factors Promoting Supportability
382(1)
12.2.3 Activities Included in Supportability Engineering
382(1)
12.2.4 Measuring and Monitoring Supportability
383(1)
12.2.5 Developing and Interpreting Support Requirements
383(1)
12.3 System or Service Support Concept
383(1)
12.4 Support Effectiveness Criteria and Figures of Merit
384(3)
12.5 Examples of Support Requirements
387(2)
12.5.1 Support Elapsed Time (Duration) Requirements
387(1)
12.5.2 Support Count Requirements
388(1)
12.6 Interpreting and Verifying Support Requirements
389(2)
12.7 Supportability Engineering for High-Consequence Systems
391(1)
12.8 Current Best Practices in Support Requirements Development
391(3)
12.8.1 Identify Support Needs
392(1)
12.8.2 Balance Support with Economics
393(1)
12.8.3 Use Quantitative Modeling to Promote Rationally Based Support Requirements
393(1)
12.8.4 Manage Supportability by Fact
394(1)
12.9
Chapter Summary
394(1)
12.10 Exercises
395(1)
References
395(1)
13 Design for Supportability
396(23)
13.1 What to Expect from this
Chapter
396(1)
13.2 Supportability Assessment
397(4)
13.2.1 Quantitative Supportability Assessment
397(3)
13.2.2 Qualitative Supportability Assessment
400(1)
13.3 Implementation of Factors Promoting Supportability
401(5)
13.3.1 Diagnostics and Fault Location
401(1)
13.3.2 Tools and Equipment
402(1)
13.3.3 Documentation and Workflow Management
402(1)
13.3.4 Staff Training
403(1)
13.3.5 Layout of Repair Facility and Workstation Design
403(1)
13.3.6 Design of Maintenance Procedures
404(1)
13.3.7 Spare Parts, Repair Parts, and Consumables Inventory
404(2)
13.3.8 Transportation and Logistics
406(1)
13.4 Quantitative Design for Supportability Techniques
406(8)
13.4.1 Performance Analysis of a Maintenance Facility
406(6)
13.4.2 Staff Sizing: The Machine Servicing Model
412(2)
13.5 Current Best Practices in Design for Supportability
414(2)
13.5.1 Customer Needs and Supportability Requirements
414(1)
13.5.2 Team Integration
415(1)
13.5.3 Modeling and Optimization
415(1)
13.5.4 Continual Improvement
415(1)
13.6
Chapter Summary
416(1)
13.7 Exercises
416(1)
References
417(2)
Index 419
Michael Tortorella is a Visiting Professor at RUTCOR (Rutgers Center for Operations Research) at Rutgers University, New Jersey, USA, and an Adjunct Professor of Systems Engineering at Stevens Institute of Technology, USA. He is the Founder and Managing Director of Assured Networks LLC, USA, a next-generation networks design, performance, and reliability consultancy. Tortorella was a Distinguished Member of Technical Staff at Bell Laboratories, USA, where he was recognized as a thought leader in design for reliability processes and technologies and network design and performance analysis. He holds the Ph. D. degree from Purdue University, Indiana, USA.
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