Industrial Organisation Class Notes uOttawa MCG 5171B

7/25/2019 Industrial Organisation Class Notes uOttawa MCG 5171B

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EMP5103 Lecture 1 Thursday, January 10, 2013

EMP 5103 Reliability, Quality and Safety Engineering

Dhillon, B, Reliaility, !uality and "a#ety #or En$ineers, %R% Press, Boca Raton, &lorida, 200'

Marks

Re(ort 30) Mar 2*

Mid Ter+ 30) &e 2*&inal Ea+ '0) -(r '

Report Format

Title

"u++ary, it is not an introduction to the re(ort. /hat is the +ain hi$hli$ht o# the

docu+ent /hat is contained in the re(ort

1. ntroduction #a+iliarie reader on to(ic sections.

2. Main Body 2.1, 2.2, etc3. %onclusions 4 #uture research and studies.

'. Re#erences

Boos

1. 6or+an, D, 7u+an Reliaility, Pro$ra+ Press, 8e9 :or, 1;*, -?ailale #ro+

the De(art+ent o# Mechanical En$ineerin$, @ni?ersity o# Atta9a, Antario,

%anada.

1


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Course Outline1. Reliaility ac$round and introductory +athe+atics.

2. &ailure data collection and "ources3. "tatic Reliaility E?aluation Models

"eries syste+

Parallel syste+

4out4n syste+,

series4(arallel syste+,

(arallel4series syste+

'. Dyna+ic Reliaility E?aluation Models

E(onential distriution

/eiull distriution

"eries, Parallel.

4out4n,

series4(arallel,

(arallel4series,

"tandy

5. Redundancy4 Related To(ics. Reliaility and Maintainaility Mana$e+ent

*. "a#ety Mana$e+ent;. Root Reliaility and "a#ety

10. !uality Mana$e+ent

11. !uality %ontrol %harts

1. Reliability Background and Introductory mathematics

Reliability Definition

Reliaility is the (roaility that an ite+ 9ill (er#or+ its #unction adeCuately #or the desired (eriod

o# ti+e 9hen o(erated accordin$ to s(eci#ied conditions.

History of Reliability Po9er syste+ (role+s 1;30sF

/orld /ar =1 and =2 rocetsF

@.". De(art+ent o# De#ense 1;'541;50F

-d?isory 6rou( on the Reliaility o# Electronic ECui(+ent -6REEFG1;50

-6REE re(ort 1;5>F it too -6REE > years to re(ort on the reliailityF

2


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2000 hrs

1000 hrs 1000 hrs


History of Quality Control

%.8. &raeo o# Tele(hone Laoratories +ade use o# statistical +ethods in ins(ection

(role+sG1;1 0 , and 0 & 1 t 0

nd ' = 0*+ and b = 1 to et t-e #-a!e abo.e for t-e bat-tubb= 0*+ / bat-tub 'ur.e

b=1 / xtree .a$ue di#tribution

b,' = #-a!e !araeter#

, = #'a$e !araeter#t = tie

Mean $i"e $o #ailure -M$$#.:

FDli+

FD

FDFD

0

0

0

#R233F

dttR233F

dtttf233Ft0

#

=

=

==

E(ponential 'istribution:

*


9/66

/arranty %lai+s

Product #ailurerelated data

6eneral data(roduct relatedF


11li+

1FD

1

FD

1FD

1FD

FD

0

0

0

=+

=

+=

===

=

===

=

#233F

##R

dte233F

etR

etF

dtet233Ft0

etf

#

t

t

t

t

t

/ #ailure 'ata ollection and Sources

2.1 Purposes of Collecting Failure Data

1. To calculate haard rate #ailure rateF o# an ite+.

2. To +ae decisions re$ardin$ the introduction o# a redundant ite+.

3. To (er#or+ trade4o## studies cost4reliaility studiesF.

'. To conduct the ite+s re(lace+ent studies.5. To (er#or+ (re?enti?e +aintenance studies o# the ite+.

. To deter+ine the +aintenance needs o# a ne9 ite+.*. To (er#or+ li#e cycle cost studies.

;. To (redict the reliaility and the a?ailaility o# the ite+.

10. To reco++end desi$n chan$es #or i+(ro?in$ the ite+s reliaility.11. Etc

2.2 Data Collection Sources

1. Past e(erience 9ith si+ilar or identical +aterial.

2. ns(ection data (roduced y Cuality control and +anu#acturin$ $rou(s.3. &ailure re(ortin$ syste+ de?elo(ed and used y custo+ers.

'. Re(orts $enerated y the re(air #acility.

5. Data otained durin$ the readoard or the de?elo(+ent o# the ite+.

. &actory acce(tance testin$ o# eCui(+ent, +odules, and asse+lies.

*. /arranty clai+sK

;


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6eneral DataK

o "erial nu+er and identi#ication o# +odel

o "tartin$ date o# the 9arranty

o Date o# (roductiono 8a+e o# the (roducin$ (lant

Product &ailure Related DataK

o &ailed (art

o &ailureK date, ty(e, and se?erity

o %ost o# re(air

o /arranty co?era$e ty(e

o -$e o# the (roduct at #ailure

o Etc

oern"ent 2ndustry 'ata E(c!ange Progra" -2'EP.Typical Deficiencies in Failure Data Sources:

1. Non-standardized data reporting.

2. Poor description of the item in question.3. Time-consuming data feedback.

4. Lack of accurac in repair times required for man parts.

!. "nconsistent and #ague definitions and terms on reporting forms.$. %ifficu&t in pinpointing the cause of fai&ure.

'. (o#ernment securit of compan proprietar c&assification of the data.). *tc+

Failure Data Forms:

1. %escription of the item in question.

2. Location of the hard,are.3. orm number.

4. eria& number of the fai&ed part.!. Name of the manufacturer.

$. ai&ure description.'. %ate the fai&ure occurred.

). %ate the fai&ure ,as detected./. %ate the fai&ure ,as corrected.

10. orm comp&etion date.11.eria& number of the rep&aced part.

12.anufacturer of the rep&aced part.13. Time taken for repair.

14.perating hours from pre#ious fai&ure.1!.ost of repair.

1$.Name of the repairperson.

1'.ignatures.1).*tc+

See pp. 22 and 23.

10


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MIL-HDB-2!": #ery important document t$at includes mat$ematical formulas

%failure rates&'. Best source for relia(ility %pp 23'.

Data Sources Information Documents:

1. %hi&&on 5. echanica& 6e&iabi&it 7merican "nstitute of 7eronautics and 7stronautics8ashington %.. 1/)). Lists o#er !! data sources.

2. %hi&&on 5. 9uman 6e&iabi&it ,ith 9uman actors Pergamon Press Ne, :ork 1/)$.

Lists 24 human re&iabi&it re&ated data sources.

3. %hi&&on 5. 6obot 6e&iabi&it and afet pringer-;er&ag Ne, :ork 1//1. List o#er !!data sources.

4. %hi&&on 5. Life c&e osting (ordon and 5reach cience Pub&isher. Lists o#er 20 data

sources.

See pp. 2).

MIL-HDB-2!":

*s constant

ea= acti#ation energ

C= constant

...e5b FF=

Fq= the factor ,hich takes into consideration the part qua&it &e#e&

Fe= the factor ,hich takes into consideration the inf&uence of en#ironment

' onstant fai&ure rate

*


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Failure ,ate #aluation of uipment:

=

=&

6

65,6t F51

FD

kC the number of different generic part c&assificationsqjC the Ethgeneric part quantit

FqC the Ethgeneric part qua&it factor

, C the constant fai&ure rate of the Eth component

3. Static ,elia(ility #aluation Models:

Series /onfi0uration:

Ei= uccessfu& e#ent i

=

==

==

&

i

i&S

ii

&&

RRRRRR

0PR7et

0P0P0P0000P

1

321

21321

...

FDK

FDF...DFDF...D

*2.0;.0*.0 ==SR

==

>&

i

iS

i

FR

R8FF

1

1

;5.0

@non-identica& unitsB

8here Fiis the fai&ure probabi&it of unit i.

or identica& units=

&FRS = 1

1 2 3

E1

E2

E3

E

1 2

R2I0.;R

1I0.*

12


13/66


1arallel /onfi0uration:

=

=

=

=

=

==

1

1

321321

1

FDK

FDF...DFDFDF...D

i

i!

i

i!

ii

!

FR

FF

0PF7et

0P0P0P0P0000PF

@for non-identica& unitsB

or identica& units=

FR! = 1

*


14/66


FR

FFFFR

!

!

=

===

1

;;>


15/66


not mentioned

-out-of--unit System:

R(

&

1

0.;0

0.*0

0.>0

0.5 0.< 0.> 0.* 0.; 1

I 1

I 2

I 3

I '

1

2

15


16/66

"to( here


( )

( )

RFRRRR

FRFFRRFR

FR

iii

9-ere

RRi

R

i

n

i

i

&i

ii

&

=+=

=+++=+

=+

=

=

=

=

1F.....1D3

133

1FD

FRDR

R

1

23

32

32233

1

@identica& unitsB

32233

32

3

3

33FD

FSFD1D1

FSD

FRFFRRFR

RR

#:#te1Para$$e$RR

#:#te1Serie#RR

&

!

S

+++=+

=

=

=

"yste+

Reliaility

1

0.*0

0.


17/66


+ample:

- (arallel syste+ is co+(osed o# three inde(endent and acti?e units. -t least t9o units +ust e

#unctionin$ success#ully #or syste+ success. The reliaility o# units 1, 2 and 3 is 0.*, 0.; and 0.>res(ecti?ely. %alculate the syste+s reliaility.

R1 &1FR2 &2FR3 &3F I 1

RiK is the units reliaility #or iI 1, 2, 3&iK is the units unreliaility #or iI 1, 2, 3

R1R2R3 R1R2&3 R1R3&2 R2R3&1 R1&2&3 R2&1&3 R3&1&2 &1&2&3I 1

R2H3 I R1R2R3 R1R2&3 R1R3&2 R2R3&1I R1R2R3 R1R214R3F R1R314R2F R2R314

R1F I 0.*0.;0.>0.*0.>140.;F..

SeriesParallel configuration:

"yste+

Reliaility

1

0.*0

0.

R I 0.5

1>


18/66


=

=r

i

6i!6 FR1

1&iK is the

th susyste+, ithunits unreliaility

= ==

==&

6

r

i

6i

&

6

!6#! FRR1 11

F1D

&or identical unitsK

[ ]

&r

#! FR =1

Ea+(leK

- syste+ is co+(osed o# t9o inde(endent, identical and acti?e susyste+s. Each susyste+ consistso# t9o identical units in (arallel. The units #ailure (roaility is 0.2. calculate the syste+s

reliaility.

& I 0.2 and r I 2 and I 2

[ ] [ ] ;21


19/66


( )

= ==

=

==

=

r

6

&

i

6i

r

6

#6!#

&

i

6i#6

RRR

RR

1 11

1

1111

&or identical unitsK

( ) r&!# RR = 11 9here R is the units reliailityEa+(leK

Rs(

1

0.*0

0.


20/66


I r I 2, & I 0.2

( ) ( ) *>0'.0*.01111 22 === r&!# RR ( )r&

!# RR = 11

1. Dyna+ic Reliaility E?aluation Models.

1.1.6eneral Reliaility &unction

( )

=

tdxx

etR 0FD

tK is ti+e and is units hazard rate or the instantaneous failure rate

=

==

tt

tdRtR

dtt

dt

tdR

tRtR

tft

00

FDFD

1FD

FD

FD

1

FD

FDFD

FD1FD

1FDFD

FDFD

FDFD

0

tFtR

tFtR

tfdt

tdF

dttftF

t

=

=+

=

=

t t=0; R(0) = 1

0.2

0.2

0.2

0.2

R(s

1

0.*0

0.


21/66


( )

=

==

=

t

dtt

t

tRt

etR

tRt

tdRtR

dtt

0

FD

0

FD

10

FD

FDlnFD

FDFD

1FD

Ea+(leK

tdt

eetR

t

t

=

=

=

0FD

FD

1.2.Mean Ti+e To &ailure MTT&F

FDli+S,

FDFDS,

FDli+FDli+

KS

FDFDSS

FDli+

KSSS

FDli+

FD

0

0

0

0

0

0

#R233F3-en

#

#R#fbut

#f#tf

tran#for17a!$a'e

dttRtf%-ere

dttR233F

re1e1berto-a.edont

#R233F

dttR233F

#

#t

t

t

t

#

=

=

=

=

=

=

=

Ea+(leK

21


22/66


( )

( )

=

==

=

=

=

=

0

1

1

0

1

11

FD

1

1

1

FD

K

SK

SK

K

FDFD

0

1

0

dtet

&

&dte233F

eeetR

ti1et

!ara1eter#'a$e

!ara1eter#-a!e&

9-ere

t&t

t

&

t

tdt&tdtt

&

&

&

t&

t

Ea+(leK

>0'>.0F50D

50

H00>.0

K

1

1

F50FD00>.0D ==

==

=

=

eR

-our#t

-ourfai$ure

9-ere

&

Series configuration:

&or ,

=

===

&

i

t&

i

#ietRtR

1

1

1

FDFD as 9e ha?eK tdtdtt eeetR

tt

10 10

11

FDFD

===

=

=

==

=

=

= &i

i

t&

i

t

## dtedtedttR233F

&

i ii

1

0

1

0 1

1

01

1FD 1

11

1

=

22

1

=

33

1

=

&&

1=

22


23/66


==

&

ii

# tR1

11FD

t #or

i

1t F U 0.05

%a&ard rate:

=

=

=

=

=

==

=

=

&

i

i#

t

t

&

i

i

#

i

i

#

##

##

&

i

i

&

i

i

e

e

t

$et

dt

tdR

tRtR

tft

1

1 FDFD

1K

FD

FD

1

FD

FDFD

1

1

05.01

KSK1

1FD

FD

1

1

1

=

=

=

tfortruettR

etR

i

&

i i

#

&

i

ti

Series Syste" ononstant #ailure Rate:

tt 666 +=FD

V1

V2

V3

V

1 2 3

23


24/66


( )

( )

[ ] [ ]

===

=

=

=

+

+=

++=

=

=

=

=

+

+

=

=

+

=

=

+

++

=

++

&

6

i

6

6

66

t

t

tot#

tot

&

6

itot

&

6

itot

tottot

tot#

&

6

&

6

6

6#

t

t&

i

#

tt

6

dtt

ettR

,a11at

$et

tR

t

ttR

etR

etR

etR

1

1

1

0

e(e(FD

K

K

1e(FD

1e(FD

FD

FD

FD

1

1

1

1

1

1

1

1

1

FD

Mean $i"e $o #ailure for 6arious Si"ple 7nit and Series Syste"s:

Syste" Structure M$$#

1

&2

11

1

1F1D

1

1+

++

+

1

1

&1

1

=

n

i11

1

WtFIV

WtFI#

WtFI#+

W1IV

1W

2IV

2W

3IV

3

2'


25/66


1

11

11

1F1D

1

1

+

=

++

+

1n

i

1

&

11

Parallel et8or4:

( )

=

=

=

=

=

=

1

1

1

1FD

K05.0K

11FD

FD

FD1FD

ii!

i

i

t!

ti

ii!

ttR

tfor

etR

etR

tFtR

i

i

&or identical units

( )-our#fai$ure#

etR t

!

H005.0

11FD

=

=

E$K V I 0.005 #ailuresHhr t I 100 hours

*'5.011F100D F100FD005.0D == eR!2 redundancy can e the est increasin$.

F1D1FD

t! etR

=

1t&


26/66


Mean $i"e $o #ailure -M$$#.:

=0

FD dttR233F

R(tF

1

0.*0

0.


27/66


( )

[ ]

( )

( )

2121

0

2121

0

FD

FD

111

FD

111FD

2121

2121

2121

21

++=

++

+

=

+=

+=

=

+

+

+

ttt

ttt!

ttt!

tt!

eee

dteee233F

eeetR

eetR

( )( )

+

=

+++

+=

+++

0

1

2121

1

FD

1111

1

1

11

11

11

dtet

&&&&1

1233F

t

1

1

111

Reliability and M$$# #unctions for 6arious Actie onfigurations for E(ponentially

'istributed #ailure $i"es 9 2dentical o"ponents:

Reliaility %on#i$uration

V1

V2

1t+

2t+

2>


28/66


n233F

1=

=

=1

i i

233F1

11

= =

+

=

n

6

61

i

6

i6

n233F

1 1

1 1F1D1

1 2 3 n

V V V V

V

V

V1

2

+

V

V

V1

2

+

V

V

V1

2

+

V

V

V1

2

+

1 / n

2*


29/66


12

11=233F

=

=1

i in

233F

1

11

=

=1

&i

233F

1ofout&

1

11

SSS

Syste" Reliability Plots for 6arious onfigurations:

1

2

+

1 / n

V

V

V1

2

+

V

2;


30/66


Standby Syste":

-ssu+(tionsK1;. s9itch (er#ectX

20. standy units re+ain as $ood as ne9

21. unit #ailures are inde(endent22. identical units

=

==

=

0

1

0

FD

R

FDFD

&dttR233F

6

tetR

#

&

6

tt

#

Appro(i"ate Reliability Euations for 4outofn type of Syste"s 9 2dentical o"ponents:

Reliaility

1

0.*0

0.


31/66


Situation #or"ula R-t. Appro(i"ation R-t.

1 unit o# 2 +ust

e 9orin$ #orsuccess

tt ee 22 ( ) 21 t

1 unit o# 3 +uste 9orin$ #or

success

ttt eee 3233 + ( ) 31 t

1 unit o# ' +ust

e 9orin$ #or

success

tttt eeee '32 '


32/66


&ault Tree "y+olsK

A' ate:

The -8D $ate denotes that an out(ut e?ent occurs i# and only i# all the in(ut e?ents occur.

;R ate:

The AR $ate denotes that an out(ut e?ent occurs i# any one or +ore o# the in(ut e?ents occur.

Resultant eent:

- rectan$le denotes an e?ent 9hich results #ro+ the co+ination o# #ault e?ents throu$h the in(ut o#

a lo$ic $ate.

+asic fault eent:

out(ut

in(uts

out(ut

in(uts

32


33/66


- circle re(resents a asic #ault e?ent or the #ailure o# an ele+entary co+(onent. The #ailure

(ara+eters such as una?ailaility (roaility, #ailure and re(air rates o# a #ault e?ent are otained

#ro+ the e+(irical data or other sources.

Ea+(leK

Build the constant a #ault tree o# a si+(le syste+ concernin$ a roo+ containin$ a s9itch and a li$htul. -ssu+e the s9itch only #ails to close. n addition, the to( e?ent is dar roo+.

( )

=

=

++++

=++++

+=+

n

iin

n

iin

XPXXXXP

XPXXXXP

BP)PBP)PB)P

1321

1321

FDF...D

FD11F...D

FDFDFDFDFD

FDFDF.D BP)PB)P =

Ea+(leK

Dar Roo+

"9itch #ails

to close

Po9er o## Bul urnt

out

&use #ailurePo9er#ailure

out(ut

in(uts

33


34/66


1 2

3 '

>

*

5 1

3.1.Reliaility De?elo(+ent and De+onstration Testin$

The oecti?es o# reliaility and de+onstration tests areK1. To deter+ine i# the desi$n +ust e i+(ro?ed to +eet the reliaility reCuire+ent

2. To indicate any desi$n chan$es needed

3. To ?eri#y i+(ro?e+ents in desi$n reliaility

3.2.!uali#ication and -cce(tance Testin$

The oecti?es o# Cuali#ication and acce(tance tests areK1. To deter+ine i# a (art, asse+ly, or an end ite+ should e acce(ted or reected either on an

indi?idual or lot asisF2. To deter+ine i# a (articular desi$n should e considered as Cuali#ied #or its intended

a((lication

3.3.A(erational Testin$

perational Testin0:

'0


41/66


The obEecti#es of operationa& testing=

To #erif the re&iabi&it ana&sis performed during the proEect.

To pro#ide data indicating necessar modifications of operationa& procedures and

po&icies as the affect re&iabi&it and maintainabi&it.

To pro#ide information to be used in &ater acti#ities.

Tests for t$e alidity of 4ssumed Failure Time Distri(utions:

5art&ett test @e

ln

12

,here it is the ithtime to fai&ure and & is the tota& number of fai&ures in the samp&e.

7 samp&e of at &east 20 fai&ures is necessar for the test to discriminate effecti#e&. "f the fai&ure

times are e


42/66


20 4! 111 1)!

1/ $3 112 2$$

34 $4 141 2$'

Ta(le !

( )

( ) '3.1'

1F20FD>D

20

*311.*2F10.;


43/66


To estimate confidence inter#a&s there are t,o cases to consider= @1B the test is terminated at a

specified time Mt and @2B the test is terminated at a specified number of fai&ures.

Test Terminated at Time6 Mt :

( )

+

f!

f!

2,2

1

2,

22,2

2

22

Test Terminated at Specified Failures6 Mf :

f!

f!

2,2

1

2,

2,2

2

22

The tpe of test determines the #a&ue of for e mean time bet,een fai&ures and mean &ife upper and &o,er confidence &imits ,ith

/0G confidence &e#e&.ai&ed repaired back to its as good as ne, state=

1*

1500

hours1500F100FD15D

=====

==

==

f

!

'3

lo9erli+it

u((erli+it

lo9er

li+it

u((er

li+it


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Hpper &imit= [ ] hours;.3> )./1 10.12 30.14 32.)!

2= /.!/ 10.)! 31.41 34.1'

2! 12.40 13.)! 3$.42 3/.3$

Handout 2: Ta(le ".! < /$i-Suare Distri(ution

De0reesof

Freedom

1ro(a(ility

=.>"? =.>? =.>= =.=? =.=2? =.=!

2 0.0! 0.10 0.21 !.// '.3) /.21

; 0.4) 0.'1 1.0$ /.4! 11.14 13.2)

@ 1.24 1.$4 2.20 12.!/ 14.4! 1$.)1

) 2.1) 2.'3 3.4/ 1!.!1 1'.!3 20.0/!= 3.2! 3./4 4.)' 1).31 20.4) 23.21

!2 4.40 !.23 $.30 21.03 23.34 2$.22

!; !.$3 $.!' '.'/ 23.$/ 2$.12 2/.14

!@ $./1 './$ /.31 2$.30 2).)! 32.00

!) ).23 /.3/ 10.)' 2).)' 31.!3 34.)1

2= /.!/ 10.)! 12.44 31.41 34.1' 3'.!'

". ,elia(ility and Maintaina(ility Mana0ement

1. %hi&&on 5. *ngineering 6e&iabi&it anagement "*** Aourna& on e&ected 7reas inommunications ;o&. 4 1/)$ pp. 101!-102!.

2. %hi&&on 5. 6eiche 9. 6e&iabi&it M aintainabi&it anagement ;ari Nostrand 6einho&dNe, :ork 1/)!.

History:

1/!) D H7 D 6e&iabi&it Program anagement %ocument *


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8estinghouse *&ectric orporation.

7ppoint a manager to &ook after re&iabi&it.

%irect the manager to re#ie, present effort.

*stab&ish a high &e#e& re&iabi&it pane& composed of sa qua&it contro& engineering

purchasing and manufacturing managers.

%efine the pane&>s responsibi&ities D ha#e it report to top management.

*stab&ish an o#era&& re&iabi&it and maintainabi&it po&ic of the compan. Pro#ide training to peop&e in re&iabi&it.

et re&iabi&it goa&s and refine them as necessar.

%esign products that are re&iab&e.

onduct #erification ana&sis of product re&iabi&it.

Produce the products that are re&iab&e.

7udit re&iabi&it program on regu&ar basis.

ake use of ser#ices pro#ided b the centra& re&iabi&it staff.

,elia(ility n0ineerin0 Department ,esponsi(ilities:

*stab&ishing re&iabi&it po&ic p&an and procedures.

6e&iabi&it a&&ocation.

6e&iabi&it prediction @"L-9%5F-21'B.

pecification and design re#ie,s ,ith respect to re&iabi&it.

6e&iabi&it gro,th monitoring.

Pro#iding re&iabi&it re&ated inputs to design specification and proposa&s.

6e&iabi&it demonstration @"L-T%-4'1B.

Training re&iabi&it manpo,er and performing re&iabi&it-re&ated research and

de#e&opment ,ork.

onitoring subcontractors> if an re&iabi&it acti#ities.

7uditing the re&iabi&it acti#ities.

ai&ure data co&&ection and reporting.

ai&ure data ana&sis.

onsu&ting.

*tc+

TasAs of a ,elia(ility n0ineer:

To be continued ne


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3).*tc+

,elia(ility /ost /ate0ories:

6e&iabi&it cost C P 7 " *P= Pre#ention ost

7= 7ppraisa& ost"= "nterna& ai&ure ost

*= *s cost.4'.pare parts in#entor.

4).*tc+

+ternal Failure /ost:4/.ost to fai&ure or repair.

!0.6ep&aced parts cost.

!1.ost of fai&ure ana&sis.!2.8arrant administration and reporting cost.!3. Liabi&it insurance.

!4.*tc+

,elia(ility 1ro0ram /ost stimation:

,4M %,elia(ility and Maintaina(ility' 1ro0ram 1lan %in man $ours':C 2.'3 @NTB2

8here NT C number of "L-T%-')! tasks required.

in D 4

a< D 22

,elia(ility Modelin0 and 4llocation:

C 4.0! @7B2@N;B8here=

7= ode&&ing and 7&&ocation omp&e


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in D 'a< D 44!

,elia(ility 1rediction:

C 4.!4@L%B2@6B2@PB8here=

L%= Le#e& of detai&1 D Prediction e


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Safety 1eriodicals:$). Aourna& of ccupationa& 7ccident

$/.Professiona& afet'0.oncern

'1. Aourna& of afet 6esearch'2.Protection

'3.Nationa& afet Ne,s'4.Nuc&ear afet

'!.7ccident Pre#ention'$.7ccident acts

''.afet anagement Aourna&').*tc+

Selecti#e Te+ts on Safety:1. 9einrich 9.8. "ndustria& 7ccident Pre#ention c(ra, 9i&& Ne, :ork 1)312. 9and&e "ndustria& afet 9andbook c(ra, 9i&& Ne, :ork 1/$/

3. (&oss %. "ntroduction to afet *ngineering 8i&e Ne, :ork 1//4

4. 9ammer 8. Product afet and *ngineering Prentice 9a&& Ne, Aerse 1/)0!. %hi&&on 5. afet 7ssessment 7 Juantitati#e 7pproach Le,is Pub&ish Ne, :ork.

1//4

Safety-,elated Data Sources:

'/.(o#ernment "ndustr %ata *


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System Safety 4nalysis Met$ods:101. au&t tree ana&sis.

102. ai&ure ode and *ffect 7na&sis @*7B.103. *#ent tree ana&sis.

104. Aob safet ana&sis.10!. ing&e point fai&ure ana&sis.

10$. *tc+

Fault tree analysis in Safety Studies:

%hi( in eye 6rindin$F

Person 9ithout sa#ety $lasses other thano(erator s close to o(eration

A(erator #ailsto 9ear sa#ety

$lasses

Peo(le in thearea +oti?e to

$o into area y

non o(eratorF

Machineo(eratin$

"a#ety $lassesnot 9orn

A(erator

#ails to

sto(oeration

52


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Formulas C Models ,elated to Safety:10'. 7merican Nationa& tandard "nstitute @7N"B Q-1$01 1/)!. Tit&e= ethod of

6ecording and 8ork "nEur *


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%"6 C %isab&ing "nEur e#erit 6ate% C Tota& number of das charged

S$ortcomin0s:

10). Not sensiti#e enough to ser#e to ser#e as accurate indicator of safeteffecti#eness.

10/. The sma&&er the ,ork force the &ess re&iab&e the frequenc rate se#erit rate.110. an accidents particu&ar& the &ess se#ere ones are ne#er reported.

111. *tc+

>. ,o(ot ,elia(ility and Safety

112. !000 D *gptians bui&t ,ater-po,ered c&ocks. hinese and (reeks bui&t ,ater and

steam po,ered tos.113. 7ristot&e= K"f e#er instrument cou&d accomp&ish its o,n ,ork obeing or

anticipating the ,i&& of others+114. 1)1) D an he&&e ,rote the science fiction Krankenstein Kachine onster

11!. 1/20 D Far& apek ,rote the science fiction K6ossums Hni#ersa& 6obots.11$. 1/42 D 7simo# D 3 &a,s=

o 7 robot ma not inEure a person nor through inaction a&&o, a person to come to

harm.

o 7 robot must a&,as obe orders from peop&e e


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13$. Te


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1$3. eta& ,orking @1$ accidentsB1$4. thers @3 accidentsB

7.. 4ccidents:

1$!. 2$23 robots1$$. ur#e 3' robot sstems different designs

1$'. 7ppro


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Some Solutions to Safety-,elated 1ro(lems:4 "mpro#ing robot re&iabi&it.

4 "mpro#ing design of mechanica& hard,are components.

4 Pro#iding appropriate safet training to peop&e concerned ,ith maintenance operation

and testing.

4 %e#e&oping an effecti#e sensor detection capabi&it of the robots.

4 Paing proper attention to human factors during the design of human ,orkstation&aout.

4 Paing more attention to human factor during the design of the robot sstems.

4 *tc+

,o(ot ,elia(ility:

4 *


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=RP

>3>3RPPAR23RP

=

P96 is the production hours of the robot.

N6P is the number of robot-re&ated prob&ems.%T%T6P is the do,ntime due to robot-re&ated prob&ems e


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!!ffo!fo

!!ffo!foo

t

!!ffo!foo

tPtPtP

dt

tdP

tPtPtPt

tPttP

ttPttPttPtPttP

FDFDFDFDFD

FDFDFDFDFDFD

li+

FDFDFDFDFDFD

0

+++=

+++=

+

+++=+

0F0DF0D,1F0D,0SS

FDFDFD

FDFDFD

====

=+

=+

f!o

fofff

!o!!!

PPPtti1e)t

tPtPdt

tdP

tPtPdt

tdP

=0

FDFD

KS

dtt!e#!

tran#for17a!$a'e

#t

FDt! FD#!

at

e

a#+1

dt

td! FD F0DFD !##!

ina& #a&ue Theorem= FDli+FDli+00

##ftf#t

=

[ ][ ]

BP

BP

B

##PP)

#)

##P

#)

##P

##)

###

###P

#P#P#P##P

#P#P#P#P##P

f!f

!ff

!ff!!f

!ff!!f

!fo

#o##

f!f

!f!

!ff!!ff!!f

!ff!!ff!!f

!f

o

ff!!o!fo

ff!!o!foo

=

=

++=

++===

+=

+=

+++++++=

+++++++

++=

+=++

+=++

FDli+

FDFD

FDFD

FD

FD

FFDDFD

FDFDFDFD1FD

FDFDFDFDFDFD

0

2

2

5;


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2

FD'FDFD,

FDFDFD

FDFDFD

FD

FFDD

FD

FFDDFD

2

21

212

2

211

1

21

212

2

211

1

21

212

22

211

11

21

21

21

21

!ff!!ff!!f!ff!

t&ft&!ff!ff

t&ft&f!!f!!

t&f!t&f!!fo

&&

e&&&

&e

&&&

&

&&tP

e&&&

&e

&&&

&

&&tP

e&&&

&&e

&&&

&&

&&tP

++++++++=

+

++=

+

++=

++

+++=

Ma+imiin0 Income of a ,o(ot System Su(Gect to Failure and ,epair:

0F0D,1F0D,0SS

FDFDFD

FDFDFD

10

011

100

===

+=

+=

PPtti1e)t

tPtPdt

tdP

tPtPdt

tdP

$it:una.ai$abietPt"

t:a.ai$abi$ietPt)

t

t

=++==

=+

++

==

+

+

FD1

FD0

FDFD

FDFD

Root @(

0

Root Do9n

1

V

Y


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do9nti1eu!ti1e

u!ti1e

233F233R

233F

233R233F

233R)## +=

+=

+=

+=

11

1

Periodic ost of the robot sstem maintenance cre, is gi#en b=

233R

&&24 ==

,here=k is the robot sstem maintenance cost @constantB depending on the nature of the robot

sstem.

The e


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( ) ( )

( )1

M

0

2H1

22

=

=++

=

+

=

=

&

233F8

233F233R

233R

&

233R233F

233F8

d233R

d=8

233R

&

233R233F

233F8=8

2408=8

r

!=. Euality Mana0ement.

Euality /ontrol:

This is a management function ,hereb contro& of the qua&it of manufactured item and ra,materia&s is e qua&it requirements ha#e been rising at a a&arming rate

4 5ecause of the abo#e factors present methods and practices associated ,ith qua&it are

rapid& becoming outmoded.

Functions of t$e Euality /ontrol n0ineerin0:4 Process qua&it contro& @manufacturing aspectB

4 Jua&it contro& in ne, design

4 Jua&it contro& of incoming materia&

4 "n#entor e#a&uation qua&it contro&

4 pecia& studies concerning qua&it contro&

Euality /ontrol Manual:

4 5enefits=


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o "t becomes usefu& ,hen making qua&it-re&ated decisions.

o "t ser#es as a reference document.

o "t can be used as a te


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t!ur'-a#e3-e4

t5ua$it:.endor3-e4

indexe!erfor1an't5ua$it:t-eofBa$ueC8

4

44C8

!

.5

!

!.5

cosSSK

cosSSSK

SScosSSSSK

+=

QIC 1.1 or more indicates that there is an immediate need for correcti#e measures.*


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Euality /ontrol /$arts:

1. The p-chart.

2. The X-chart

3. The 6-chart4. The c-chart

T$e p-c$art:omponents ,ith defects #ersus components free of defects.Hpper contro& &imit= HLp C 3X

Lo,er contro& &imit= LLp C - 3X= the mean of the binomia& distribution

X= the standard de#iation of the binomia& distribution

1

==

8here =

N= is the tota& number of defecti#es in c&assification

3\3\

;;.>)


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m= is the size of the samp&e

= is the number of samp&es

( ) 21

1

=

1

*

Industrial Organisation Class Notes uOttawa MCG 5171B

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Transcript of Industrial Organisation Class Notes uOttawa MCG 5171B