System Safety, Maintainability, and Maintenance for Engineers

System Safety, Maintainability, and Maintenance for Engineers

by B.S. Dhillon
Released June 2023
Publisher(s): CRC Press
ISBN: 9781000892291

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Book description

The safety, maintainability, and maintenance of systems have become more important than ever before. Global competition and other factors are forcing manufacturers to produce highly safe and easily maintainable engineering systems. This means that there is a definite need for safety, maintainability, and maintenance professionals to work closely during the system design and other phases of a project, and this book will help with that.

System Safety, Maintainability, and Maintenance for Engineers presents, in a single volume, what engineers will need when designing systems from the fields of safety, maintainability, and maintenance of systems when they have to all work together on one project and it provides information that the reader will require no previous knowledge to understand. Also offered are sources in the reference section at the end of each chapter so that the reader is able to find further information if needed. For reader comprehension, examples along with their solutions are included at the end of each chapter.

This book will be useful to many people including design engineers; system engineers; safety specialists; maintainability engineers; maintenance engineers; engineering managers; graduate and senior undergraduate students of engineering; researchers and instructors of safety, maintainability, and maintenance; and engineers-at-large.

Table of contents

  1. Cover Page
  2. Half Title page
  3. Title Page
  4. Copyright Page
  5. Dedication
  6. Contents
  7. Preface
  8. Author
  9. 1 Introduction
    1. 1.1 Safety, Maintainability, and Maintenance History
      1. 1.1.1 Safety
      2. 1.1.2 Maintainability
      3. 1.1.3 Maintenance
    2. 1.2 Need for Safety, Maintainability, and Maintenance
    3. 1.3 Terms and Definitions
    4. 1.4 Useful Sources for Obtaining Information on Safety, Maintainability, and Maintenance
      1. 1.4.1 Journals
      2. 1.4.2 Books
      3. 1.4.3 Organizations
      4. 1.4.4 Data Information Sources
    5. Problems
    6. References
  10. 2 Safety, Maintainability, and Maintenance Mathematics
    1. 2.1 Introduction
    2. 2.2 Arithmetic Mean, Mean Deviation, and Standard Deviation
      1. 2.2.1 Arithmetic Mean
      2. 2.2.2 Mean Deviation
      3. 2.2.3 Standard Deviation
    3. 2.3 Boolean Algebra Laws
    4. 2.4 Probability Definition and Properties
    5. 2.5 Mathematical Definitions
      1. 2.5.1 Cumulative Distribution Function
      2. 2.5.2 Probability Density Function
      3. 2.5.3 Expected Value
      4. 2.5.4 Variance
      5. 2.5.5 Laplace Transform
      6. 2.5.6 Laplace Transforms of Common Functions
      7. 2.5.7 Laplace Transform: Final-Value Theorem
    6. 2.6 Probability Distributions
      1. 2.6.1 Binomial Distribution
      2. 2.6.2 Normal Distribution
      3. 2.6.3 Exponential Distribution
      4. 2.6.4 Rayleigh Distribution
      5. 2.6.5 Weibull Distribution
      6. 2.6.6 Gamma Distribution
    7. 2.7 Solving First-Order Differential Equations using Laplace Transforms
    8. Problems
    9. References
  11. 3 Introduction to Safety
    1. 3.1 Need for Safety and Engineering Safety Goals
    2. 3.2 Safety-Associated Facts and Figures
    3. 3.3 Engineers and Safety
    4. 3.4 Product Hazard Categories and Common Mechanical-Related Injuries
    5. 3.5 Product Liability Exposure Causes and Worker’s Compensation
    6. Problems
    7. References
  12. 4 Safety Analysis Methods
    1. 4.1 Introduction
    2. 4.2 Hazards and Operability Analysis (HAZOP)
    3. 4.3 FAULT Tree Analysis (FTA)
    4. 4.4 Technic of Operations Review (TOR)
    5. 4.5 Failure Modes and Effect Analysis (FMEA)
    6. 4.6 Job Safety Analysis (JSA)
    7. 4.7 Control Charts
    8. 4.8 Interface Safety Analysis (ISA)
    9. 4.9 Markov Method
    10. 4.10 Safety Indexes
      1. 4.10.1 Disabling Injury Frequency Rate (DIFR)
      2. 4.10.2 Disabling Injury Severity Rate (DISR)
    11. Problems
    12. References
  13. 5 Safety Management and Costing
    1. 5.1 Introduction
    2. 5.2 Safety Management-Related Principles and Developing a Safety Program Plan
    3. 5.3 Safety Department Functions
    4. 5.4 Qualifications and Functions of Safety Professionals
      1. 5.4.1 Safety Engineer
      2. 5.4.2 Safety Manager
    5. 5.5 Safety Committees and Motivating Employees to Work Safely
    6. 5.6 A Manufacturer’s Losses or Cost Due to Accident Involving Its Product
    7. 5.7 Safety Cost Estimation Models and Methods
      1. 5.7.1 Total Safety Cost Estimation Model
      2. 5.7.2 The Heinrich Method
      3. 5.7.3 The Simonds Method
    8. 5.8 Safety Cost Performance Measurement Indexes
      1. 5.8.1 Index I
      2. 5.8.2 Index II
      3. 5.8.3 Index III
    9. Problems
    10. References
  14. 6 Maintenance, Software, and Robot Safety
    1. 6.1 Introduction
    2. 6.2 Maintenance Safety
      1. 6.2.1 Facts, Figures, and Examples
      2. 6.2.2 Reasons for Safety-Related Problems in Maintenance and Factors Responsible for Dubious Safety Reputation in Maintenance Work
      3. 6.2.3 Maintenance Personnel Safety and Typical Human Behaviors
      4. 6.2.4 Useful Guidelines for Equipment Designers to Improve Safety in Maintenance
    3. 6.3 Software Safety
      1. 6.3.1 Facts and Figures
      2. 6.3.2 Software Safety versus Reliability
      3. 6.3.3 Software Hazard Causing Ways
      4. 6.3.4 Software Hazard Analysis Methods
        1. 6.3.4.1 Software Sneak Circuit Analysis
        2. 6.3.4.2 Proof of Correctness
        3. 6.3.4.3 Code Walk-Throughs
    4. 6.4 Robot Safety
      1. 6.4.1 Facts and Figures
      2. 6.4.2 Robot Safety-Related Problems
      3. 6.4.3 Types of Robot Accidents
      4. 6.4.4 Robot Safeguard Methods
    5. Problems
    6. References
  15. 7 Introduction to Maintainability
    1. 7.1 Need for Maintainability
    2. 7.2 Maintainability versus Maintenance
    3. 7.3 Maintainability’s Specific General Principles
    4. 7.4 Maintainability Functions
      1. 7.4.1 Maintainability Function for Exponential Distribution
      2. 7.4.2 Maintainability Function for Rayleigh Distribution
      3. 7.4.3 Maintainability Function for Weibull Distribution
      4. 7.4.4 Maintainability Function for Normal Distribution
      5. 7.4.5 Maintainability Function for Gamma Distribution
    5. Problems
    6. References
  16. 8 Maintainability Tools and Specific Maintainability Design-Related Considerations
    1. 8.1 Introduction
    2. 8.2 Cause-and-Effect Diagram
    3. 8.3 Failure Modes, Effects, and Criticality Analysis (FMECA)
    4. 8.4 Fault Tree Analysis (FTA)
    5. 8.5 Total Quality Management (TQM)
    6. 8.6 Maintainability Design Factors
    7. 8.7 Simplification and Accessibility
    8. 8.8 Interchangeability and Identification
    9. 8.9 Standardization and Modularization
    10. Problems
    11. References
  17. 9 Maintainability Management and Human Factors in Maintainability
    1. 9.1 Introduction
    2. 9.2 Maintainability Management Functions in the Product Life Cycle
    3. 9.3 Maintainability Organization Functions
    4. 9.4 Maintainability Program Plan
    5. 9.5 Maintainability Design Reviews
    6. 9.6 Typical Human Behaviors
    7. 9.7 Human Body Measurements and Sensory Capabilities
      1. 9.7.1 Human Body Measurements
      2. 9.7.2 Human Sensory Capabilities
        1. 9.7.2.1 Hearing
        2. 9.7.2.2 Sight
        3. 9.7.2.3 Touch
    8. 9.8 Auditory and Visual Warnings in Maintenance-Related Work
    9. 9.9 Human Factors-Related Formulas
      1. 9.9.1 Glare Constant Estimation
      2. 9.9.2 The Decibel
      3. 9.9.3 Lifting Load Estimation
      4. 9.9.4 Character Height Estimation Formulas
        1. 9.9.4.1 Formula I
        2. 9.9.4.2 Formula II
    10. Problems
    11. References
  18. 10 Maintainability Testing and Demonstration
    1. 10.1 Introduction
    2. 10.2 Planning and Control Requirements for Maintainability Testing and Demonstration
      1. 10.2.1 Category I: Developing a Demonstration Plan
      2. 10.2.2 Category II: Creating a Demonstration Model
      3. 10.2.3 Category III: Following MIL-STD-471 Guidelines
      4. 10.2.4 Category IV: Providing Appropriate Manpower
      5. 10.2.5 Category V: Specifying Parameters
      6. 10.2.6 Category VI: Taking Environment into Account
    3. 10.3 Maintainability Test Approaches
    4. 10.4 Testing Methods
      1. 10.4.1 The Mean Method
      2. 10.4.2 The Critical Maintenance Time or Man-Hours Method
      3. 10.4.3 The Mean Maintenance Time and Maximum Maintenance Time Method
      4. 10.4.4 The Critical Percentile Method
      5. 10.4.5 The Man-Hour Rate Method
      6. 10.4.6 The Percentiles and Maintenance Method
      7. 10.4.7 The Man-Hour Rate (Using Simulated Faults) Method
      8. 10.4.8 The Chargeable Maintenance Downtime per Flight Method
      9. 10.4.9 The Preventive Maintenance Times Method
      10. 10.4.10 The Median Equipment Repair Time Method
      11. 10.4.11 The Combined Mean/Percentile Requirement Method
    5. 10.5 Preparing for Maintainability Demonstrations and Evaluating the Results
    6. 10.6 Checklists for Maintainability Demonstration Plans, Procedures, and Reports
    7. Problems
    8. References
  19. 11 Introduction to Engineering Maintenance
    1. 11.1 Need for Maintenance
    2. 11.2 Engineering Maintenance Facts and Figures
    3. 11.3 Maintenance Engineering Objectives
    4. 11.4 Maintenance-Related Measures
      1. 11.4.1 Index I
      2. 11.4.2 Index II
      3. 11.4.3 Index III
      4. 11.4.4 Index IV
      5. 11.4.5 Index V
      6. 11.4.6 Index VI
      7. 11.4.7 Index VII
      8. 11.4.8 Index VIII
      9. 11.4.9 Index IX
    5. 11.5 Safety in Maintenance
    6. Problems
    7. References
  20. 12 Maintenance Management and Control
    1. 12.1 Introduction
    2. 12.2 Maintenance Management-Related Principles
    3. 12.3 Maintenance Department Organization and Functions
    4. 12.4 Effective Maintenance Management Elements
      1. 12.4.1 Maintenance Policy
      2. 12.4.2 Job Planning and Scheduling
      3. 12.4.3 Equipment Records
      4. 12.4.4 Material Control
      5. 12.4.5 Backlog Control and Priority System
      6. 12.4.6 Work Order System
      7. 12.4.7 Preventive and Corrective Maintenance
      8. 12.4.8 Performance Measurement
    5. 12.5 Questions for Evaluating Maintenance Program Effectiveness
    6. 12.6 Maintenance Project Control Methods
      1. 12.6.1 Activity Expected Duration Time Estimation
      2. 12.6.2 Critical Path Method (CPM)
      3. 12.6.3 Critical Path Determination Approach
      4. 12.6.4 CPM Benefits and Drawbacks
    7. 12.7 Maintenance Management Control Indices
      1. 12.7.1 Broad Indicators
        1. 12.7.1.1 Index I
        2. 12.7.1.2 Index II
        3. 12.7.1.3 Index III
      2. 12.7.2 Specific Indicators
        1. 12.7.2.1 Index IV
        2. 12.7.2.2 Index V
        3. 12.7.2.3 Index VI
        4. 12.7.2.4 Index VII
        5. 12.7.2.5 Index VIII
        6. 12.7.2.6 Index IX
        7. 12.7.2.7 Index X
        8. 12.7.2.8 Index XI
        9. 12.7.2.9 Index XII
        10. 12.7.2.10 Index XIII
        11. 12.7.2.11 Index XIV
        12. 12.7.2.12 Index XV
    8. Problems
    9. References
  21. 13 Preventive and Corrective Maintenance
    1. 13.1 Introduction
    2. 13.2 Preventive Maintenance Elements and a Principle for Selecting Items for Preventive Maintenance
    3. 13.3 Steps for Developing a Preventive Maintenance Program
    4. 13.4 Preventive Maintenance Measures
      1. 13.4.1 Median Preventive Maintenance Time
      2. 13.4.2 Mean Preventive Maintenance Time
    5. 13.5 Preventive Maintenance Mathematical Models
      1. 13.5.1 Model I
      2. 13.5.2 Model II
    6. 13.6 Preventive Maintenance Advantages and Disadvantages
    7. 13.7 Corrective Maintenance Types
    8. 13.8 Corrective Maintenance Steps, Downtime Components, and Strategies for Time Reduction at System Level
    9. 13.9 Corrective Maintenance-Related Measures
      1. 13.9.1 Median Active Corrective Maintenance Time
      2. 13.9.2 Mean Corrective Maintenance Time
    10. 13.10 Corrective Maintenance Mathematical Models
      1. 13.10.1 Mathematical Model I
      2. 13.10.2 Mathematical Model II
    11. Problems
    12. References
  22. 14 Software and Robotic Maintenance
    1. 14.1 Introduction
    2. 14.2 Software Maintenance-Related Facts and Figures
    3. 14.3 Software Maintenance Types
    4. 14.4 Guidelines for Reducing Software Maintenance and Software Maintenance Tools
      1. 14.4.1 Software Configuration Management
      2. 14.4.2 Impact Analysis
    5. 14.5 Software Maintenance Cost Estimation Models
      1. 14.5.1 Model I
      2. 14.5.2 Model II
    6. 14.6 Robot Maintenance Requirements and Types
    7. 14.7 Robot Parts and Tools for Maintenance and Repair
    8. 14.8 Robot Inspection
    9. 14.9 Useful Guidelines for Safeguarding Robot Maintenance Personnel
    10. 14.10 Model for Maximizing Income of Robot Subject to Repair
    11. Problems
    12. References
  23. 15 Reliability-Centered Maintenance
    1. 15.1 Introduction
    2. 15.2 RCM Goals and Principles
    3. 15.3 RCM Process
    4. 15.4 RCM Elements
      1. 15.4.1 Proactive Maintenance
        1. 15.4.1.1 Failed Item Analysis
        2. 15.4.1.2 Root Cause Failure Analysis
        3. 15.4.1.3 Reliability Engineering
        4. 15.4.1.4 Age Exploration (AE)
      2. 15.4.2 Preventive Maintenance (PM)
      3. 15.4.3 Reactive Maintenance
      4. 15.4.4 Predictive Testing and Inspection
    5. 15.5 RCM Application Advantages and Reasons for Its Failures
    6. 15.6 RCM Program Effectiveness Measurement Indicators
      1. 15.6.1 Indicator I: Equipment Availability
      2. 15.6.2 Indicator II: Emergency Percentage Index
      3. 15.6.3 Indicator III: Predicative Testing and Inspection (PTI)-Covered Equipment Index
      4. 15.6.4 Indicator IV: Maintenance Overtime Percentage Index
      5. 15.6.5 Indicator V: Preventive Maintenance (PM)/PTI-Reactive Maintenance Index
      6. 15.6.6 Indicator VI: Emergency-PM/PTI Work Index
    7. Problems
    8. References
  24. Index

Product information

  • Title: System Safety, Maintainability, and Maintenance for Engineers
  • Author(s): B.S. Dhillon
  • Release date: June 2023
  • Publisher(s): CRC Press
  • ISBN: 9781000892291