Design for Maintainability

Name: Design for Maintainability
Brand: Wiley-Scrivener
Price: 119.99 EUR
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Louis J. Gullo Jack Dixon(Herausgeber*in)

Wiley-Scrivener (Verlag)

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Erschienen am 26. März 2021

400 Seiten

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Inhalt

Cover
Title Page
Copyright
Contents
Series Editor's Foreword by Dr Andre Kleyner
Preface
Acknowledgments
Introduction: What You Will Learn
Chapter 1 Design for Maintainability Paradigms
1.1 Why Design for Maintainability?
1.1.1 What is a System?
1.1.2 What is Maintainability?
1.1.3 What is Testability?
1.2 Maintainability Factors for Design Consideration
1.2.1 Part Standardization
1.2.2 Structure Modularization
1.2.3 Kit Packaging
1.2.4 Part Interchangeability
1.2.5 Human Accessibility
1.2.6 Fault Detection
1.2.7 Fault Isolation
1.2.8 Part Identification
1.3 Reflections on the Current State of the Art
1.4 Paradigms for Design for Maintainability
1.4.1 Maintainability is Inversely Proportional to Reliability
1.4.2 Maintainability is Directly Proportional to Testability and Prognostics and Health Monitoring
1.4.3 Strive for Ambiguity Groups No Greater Than 3
1.4.4 Migrate from Scheduled Maintenance to Condition-based Maintenance
1.4.5 Consider the Human as the Maintainer
1.4.6 Modularity Speeds Repairs
1.4.7 Maintainability Predicts Downtime During Repairs
1.4.8 Understand the Maintenance Requirements
1.4.9 Support Maintainability with Data
1.5 Summary
References
Chapter 2 History of Maintainability
2.1 Introduction
2.2 Ancient History
2.3 The Difference Between Maintainability and Maintenance Engineering
2.4 Early Maintainability References
2.4.1 The First Maintainability Standards
2.4.2 Introduction to MIL-STD-470
2.5 Original Maintainability Program Roadmap
2.5.1 Task 1: The Maintainability Program Plan
2.5.2 Task 2: Maintainability Analysis
2.5.3 Task 3: Maintenance Inputs
2.5.4 Task 4: Maintainability Design Criteria
2.5.5 Task 5: Maintainability Trade Studies
2.5.6 Task 6: Maintainability Predictions
2.5.7 Task 7: Vendor Controls
2.5.8 Task 8: Integration
2.5.9 Task 9: Maintainability Design Reviews
2.5.10 Task 10: Maintainability Data System
2.5.11 Task 11: Maintainability Demonstration
2.5.12 Task 12: Maintainability Status Reports
2.6 Maintainability Evolution Over the Time Period 1966 to 1978
2.7 Improvements During the Period 1978 to 1997
2.8 Introduction of Testability
2.9 Introduction of Artificial Intelligence
2.10 Introduction to MIL-HDBK-470A
2.11 Summary
References
Chapter 3 Maintainability Program Planning and Management
3.1 Introduction
3.2 System/Product Life Cycle
3.3 Opportunities to Influence Design
3.3.1 Engineering Design
3.3.2 Design Activities
3.3.3 Design Reviews
3.4 Maintainability Program Planning
3.4.1 Typical Maintainability Engineering Tasks
3.4.2 Typical Maintainability Program Plan Outline
3.5 Interfaces with Other Functions
3.6 Managing Vendor/Subcontractor Maintainability Efforts
3.7 Change Management
3.8 Cost-effectiveness
3.9 Maintenance and Life Cycle Cost (LCC)
3.10 Warranties
3.11 Summary
References
Suggestions for Additional Reading
Chapter 4 Maintenance Concept
4.1 Introduction
4.2 Developing the Maintenance Concept
4.2.1 Maintainability Requirements
4.2.2 Categories of Maintenance
4.2.2.1 Scheduled Maintenance
4.2.2.2 Unscheduled Maintenance
4.3 Levels of Maintenance
4.4 Logistic Support
4.4.1 Design Interface
4.4.2 Design Considerations for Improved Logistics Support
4.4.2.1 Tools
4.4.2.2 Skills
4.4.2.3 Test/Support Equipment - Common and Special
4.4.2.4 Training
4.4.2.5 Facilities
4.4.2.6 Reliability
4.4.2.7 Spares Provisioning
4.4.2.8 Backshop Support
4.5 Summary
References
Suggestions for Additional Reading
Chapter 5 Maintainability Requirements and Design Criteria
5.1 Introduction
5.2 Maintainability Requirements
5.2.1 Different Maintainability Requirements for Different Markets
5.3 The Systems Engineering Approach
5.3.1 Requirements Analysis
5.3.1.1 Types of Requirements
5.3.1.2 Good Requirements
5.3.2 System Design Evaluation
5.3.3 Maintainability in the Systems Engineering Process
5.4 Developing Maintainability Requirements
5.4.1 Defining Quantitative Maintainability Requirements
5.4.2 Quantitative Preventive Maintainability Requirements
5.4.3 Quantitative Corrective Maintainability Requirements
5.4.4 Defining Qualitative Maintainability Requirements
5.5 Maintainability Design Goals
5.6 Maintainability Guidelines
5.7 Maintainability Design Criteria
5.8 Maintainability Design Checklists
5.9 Design Criteria that Provide or Improve Maintainability
5.10 Conclusions
References
Suggestions for Additional Reading
Additional Sources of Checklists
Chapter 6 Maintainability Analysis and Modeling
6.1 Introduction
6.2 Functional Analysis
6.2.1 Constructing a Functional Block Diagram
6.2.2 Using a Functional Block Diagram
6.3 Maintainability Analysis
6.3.1 Objectives of Maintainability Analyses
6.3.2 Typical Products of Maintainability Analyses
6.4 Commonly Used Maintainability Analyses
6.4.1 Equipment Downtime Analysis
6.4.2 Maintainability Design Evaluation
6.4.3 Testability Analysis
6.4.4 Human Factors Analysis
6.4.5 Maintainability Allocations
6.4.5.1 Failure Rate Complexity Method
6.4.5.2 Variation of the Failure Rate Complexity Method
6.4.5.3 Statistically-based Allocation Method
6.4.5.4 Equal Distribution Method
6.4.6 Maintainability Design Trade Study
6.4.7 Maintainability Models and Modeling
6.4.7.1 Poisson Distribution in Maintainability Models
6.4.8 Failure Modes, Effects, and Criticality Analysis - Maintenance Actions (FMECA-MA)
6.4.9 Maintenance Activities Block Diagrams
6.4.10 Maintainability Prediction
6.4.11 Maintenance Task Analysis (MTA)
6.4.12 Level of Repair Analysis (LORA)
6.4.12.1 Performing a Level of Repair Analysis
6.4.12.2 Managing LORA Data
6.4.12.3 Level of Repair Analysis Outcomes
6.5 Summary
References
Suggestion for Additional Reading
Chapter 7 Maintainability Predictions and Task Analysis
7.1 Introduction
7.2 Maintainability Prediction Standard
7.3 Maintainability Prediction Techniques
7.3.1 Maintainability Prediction Procedure I
7.3.1.1 Preparation Activities
7.3.1.2 Failure Verification Activities
7.3.1.3 Failure Location Activities
7.3.1.4 Part Procurement Activities
7.3.1.5 Repair Activities
7.3.1.6 Final Test Activities
7.3.1.7 Probability Distributions
7.3.2 Maintainability Prediction Procedure II
7.3.2.1 Use of Maintainability Predictions for Corrective Maintenance
7.3.2.2 Use of Maintainability Predictions for Preventive Maintenance
7.3.2.3 Use of Maintainability Predictions for Active Maintenance
7.3.3 Maintainability Prediction Procedure III
7.3.4 Maintainability Prediction Procedure IV
7.3.5 Maintainability Prediction Procedure V
7.4 Maintainability Prediction Results
7.5 Bayesian Methodologies
7.5.1 Definition of Bayesian Terms
7.5.2 Bayesian Example
7.6 Maintenance Task Analysis
7.6.1 Maintenance Task Analysis Process and Worksheets
7.6.2 Completing a Maintenance Task Analysis Sheet
7.6.3 Personnel and Skill Data Entry
7.6.4 Spare Parts, Supply Chain, and Inventory Management Data Entry
7.6.5 Test and Support Equipment Data Entry
7.6.6 Facility Requirements Data Entry
7.6.7 Maintenance Manuals
7.6.8 Maintenance Plan
7.7 Summary
References
Chapter 8 Design for Machine Learning
8.1 Introduction
8.2 Artificial Intelligence in Maintenance
8.3 Model-based Reasoning
8.3.1 Diagnosis
8.3.2 Health Monitoring
8.3.3 Prognostics
8.4 Machine Learning Process
8.4.1 Supervised and Unsupervised Learning
8.4.2 Deep Learning
8.4.3 Function Approximations
8.4.4 Pattern Determination
8.4.5 Machine Learning Classifiers
8.4.6 Feature Selection and Extraction
8.5 Anomaly Detection
8.5.1 Known and Unknown Anomalies
8.6 Value-added Benefits of ML
8.7 Digital Prescriptive Maintenance (DPM)
8.8 Future Opportunities
8.9 Summary
References
Chapter 9 Condition-based Maintenance and Design for Reduced Staffing
9.1 Introduction
9.2 What is Condition-based Maintenance?
9.2.1 Types of Condition-based Maintenance
9.3 Condition-based Maintenance vs. Time-based Maintenance
9.3.1 Time-based Maintenance
9.3.2 Types of Time-based Maintenance
9.3.3 Calculating Time-based Maintenance Intervals
9.3.4 The P-F Curve
9.3.5 Calculating Condition-based Maintenance Intervals
9.4 Reduced Staffing Through CBM and Efficient TBM
9.5 Integrated System Health Management
9.6 Prognostics and CBM+
9.6.1 Essential Elements of CBM+
9.7 Digital Prescriptive Maintenance
9.8 Reliability-centered Maintenance
9.8.1 History of RCM
9.8.2 What is RCM?
9.8.3 Why RCM?
9.8.4 What we Learned from RCM
9.8.4.1 Failure Curves
9.8.5 Applying RCM in Your Organization
9.8.5.1 Inner Workings of RCM
9.9 Conclusion
References
Suggestion for Additional Reading
Chapter 10 Safety and Human Factors Considerations in Maintainable Design
10.1 Introduction
10.2 Safety in Maintainable Design
10.2.1 Safety and its Relationship to Maintainability
10.2.2 Safety Design Criteria
10.2.3 Overview of System Safety Engineering
10.2.4 Risk Assessment and Risk Management
10.2.4.1 Probability
10.2.4.2 Consequences
10.2.4.3 Risk Evaluation
10.2.5 System Safety Analysis
10.2.5.1 Operating and Support Hazard Analysis
10.2.5.2 Health Hazard Analysis
10.3 Human Factors in Maintainable Design
10.3.1 Human Factors Engineering and its Relationship to Maintainability
10.3.2 Human Systems Integration
10.3.3 Human Factors Design Criteria
10.3.4 Human Factors Engineering Analysis
10.3.5 Maintainability Anthropometric Analysis
10.4 Conclusion
References
Suggestion for Additional Reading
Chapter 11 Design for Software Maintainability
11.1 Introduction
11.2 What is Software Maintainability?
11.3 Relevant Standards
11.4 Impact of Maintainability on Software Design
11.5 How to Design Software that is Fault-tolerant and Requires Zero Maintenance
11.6 How to Design Software that is Self-aware of its Need for Maintenance
11.7 How to Develop Maintainable Software that was Not Designed for Maintainability at the Start
11.8 Software Field Support and Maintenance
11.8.1 Software Maintenance Process Implementation
11.8.2 Software Problem Identification and Software Modification Analysis
11.8.3 Software Modification Implementation
11.8.4 Software Maintenance Review and Acceptance
11.8.5 Software Migration
11.8.6 Software Retirement
11.8.7 Software Maintenance Maturity Model
11.9 Software Changes and Configuration Management
11.10 Software Testing
11.11 Summary
References
Chapter 12 Maintainability Testing and Demonstration
12.1 Introduction
12.2 When to Test
12.3 Forms of Testing
12.3.1 Process Reviews
12.3.2 Modeling or Simulation
12.3.3 Analysis of the Design
12.3.4 In-process Testing
12.3.5 Formal Design Reviews
12.3.6 Maintainability Demonstration (M-Demo)
12.3.6.1 M-Demo Test Plan
12.3.6.2 M-Demo Maintenance Task Sample Selection
12.3.6.3 M-Demo Test Report
12.3.6.4 AN/UGC-144 M-Demo Example
12.3.7 Operational Maintainability Testing
12.4 Data Collection
12.5 Summary
References
Suggestions for Additional Reading
Chapter 13 Design for Test and Testability
13.1 Introduction
13.2 What is Testability?
13.3 DfT Considerations for Electronic Test at All Levels
13.3.1 What is Electronic Test?
13.3.2 Test Coverage and Effectiveness
13.3.3 Accessibility Design Criteria Related to Testability
13.4 DfT at System or Product Level
13.4.1 Power-On Self-Test and On-Line Testing
13.5 DfT at Electronic Circuit Board Level
13.6 DfT at Electronic Component Level
13.6.1 System in Package/Multi-chip Package Test and DfT Techniques
13.6.2 VLSI and DfT Techniques
13.6.3 Logic Test and Design For Test
13.6.4 Memory Test and Design for Test
13.6.5 Analog and Mixed-Signal Test and DfT
13.6.6 Design and Test Tradeoffs
13.7 Leveraging DfT for Maintainability and Sustainment
13.7.1 Built-In-Test/Built-In Self-Test
13.8 BITE and External Support Equipment
13.9 Summary
References
Suggestions for Additional Reading
Chapter 14 Reliability Analyses
14.1 Introduction
14.2 Reliability Analysis and Modeling
14.3 Reliability Block Diagrams
14.4 Reliability Allocation
14.5 Reliability Mathematical Model
14.6 Reliability Prediction
14.7 Fault Tree Analysis
14.7.1 What is a Fault Tree?
14.7.2 Gates and Events
14.7.3 Definitions
14.7.4 Methodology
14.7.5 Cut Sets
14.7.6 Quantitative Analysis of Fault Trees
14.7.7 Advantages and Disadvantages
14.8 Failure Modes, Effects, and Criticality Analysis
14.9 Complementary Reliability Analyses and Models
14.10 Conclusions
References
Suggestions for Additional Reading
Chapter 15 Design for Availability
15.1 Introduction
15.2 What is Availability?
15.3 Concepts of Availability
15.3.1 Elements of Availability
15.3.1.1 Time-related Elements
15.3.1.2 Mean Metrics
15.4 Types of Availability
15.4.1 Inherent Availability
15.4.2 Achieved Availability
15.4.3 Operational Availability
15.4.3.1 Ao Method 1
15.4.3.2 Ao Method 2
15.4.3.3 Ao Method 3
15.4.3.4 Ao Method 4
15.5 Availability Prediction
15.5.1 Data for Availability Prediction
15.5.2 Calculating Availability
15.5.3 Steps to Availability Prediction
15.5.3.1 Define the Problem
15.5.3.2 Define the System
15.5.3.3 Collect the Data
15.5.3.4 Build the Model
15.5.3.5 Verify the Model
15.5.3.6 Design the Simulation
15.5.3.7 Run the Simulation
15.5.3.8 Document and Use the Results
15.6 Conclusion
References
Chapter 16 Design for Supportability
16.1 Introduction
16.2 Elements of Supportability
16.2.1 Product Support Management
16.2.2 Design Interface
16.2.3 Sustaining Engineering
16.2.4 Supply Support
16.2.5 Maintenance Planning and Management
16.2.6 Packaging, Handling, Storage, and Transportation (PHS&T)
16.2.7 Technical Data
16.2.8 Support Equipment
16.2.9 Training and Training Support
16.2.10 Manpower and Personnel
16.2.11 Facilities and Infrastructure
16.2.12 Computer Resources
16.3 Supportability Program Planning
16.3.1 Supportability Analysis
16.4 Supportability Tasks and the ILS Plan
16.5 Summary
References
Suggestion for Additional Reading
Chapter 17 Special Topics
17.1 Introduction
17.2 Reducing Active Maintenance Time with Single Minute Exchange of Dies (SMED)
17.2.1 Incorporating Lean Methods into PM Optimization
17.2.1.1 Understanding Waste
17.2.1.2 Apply Lean Techniques to Eliminate Waste
17.2.1.3 Continually Improve the PM Routine
17.2.2 Summary
17.3 How to use Big Data to Enable Predictive Maintenance
17.3.1 Industry Use
17.3.2 Predicting the Future
17.3.3 Summary
17.4 Self-correcting Circuits and Self-healing Materials for Improved Maintainability, Reliability, and Safety
17.4.1 Self-correcting Circuits
17.4.2 Self-healing Materials
17.4.3 Summary
17.5 Conclusion and Challenge
References
Suggestions for Additional Reading
Chapter A System Maintainability Design Verification Checklist
A.1 Introduction
A.2 Checklist Structure
Index
EULA

Introduction: What You Will Learn

Chapter 1: Design for Maintainability Paradigms (Gullo and Dixon)

This chapter describes what it means to Design for Maintainability (DfMn) and why DfMn is important. This chapter includes maintainability factors for design consideration and 9 DfMn paradigms. The paradigms as shown in this chapter and throughout this book provide the reader with the means to achieve a maintainable design. Using this book as a guide, the reader will be equipped with the basic elements of maintainable design that can be applied to any system or product, given an adequate amount of preparation and forethought, so that the resulting system or product design can be easily and economically maintained to obtain customer satisfaction.

Chapter 2: History of Maintainability (Gullo)

This chapter explores the history, origins, and evolution of maintainability and maintenance engineering. It covers their definitions and the key standards that launched maintainability as an important engineering discipline. This chapter also explains the difference between maintainability and maintenance engineering. It also describes in detail the original maintainability program roadmap that was developed at the advent of DfMn. The various important maintainability-related tasks are described. The chapter concludes with a brief description of MIL-HDBK-470, which provides a culmination of the beneficial standards, requirements, and lessons learned over the last 60 years.

Chapter 3: Maintainability Program Planning and Management (Franck and Meixner)

This chapter describes the tasks involved in designing for maintainability, the need for maintainability program management, the basic elements of a maintainability program plan, and the relationship of maintainability engineering to other engineering disciplines. This chapter provides an introduction to the system/product life-cycle and stresses the importance of early considerations of maintainability to ensure proper design. The earlier that the design characteristics are measured against requirements, the less time and funding are required to make changes to the design. This chapter also emphasizes that thorough and thoughtful maintainability program planning is the most effective tool in the maintainability manager's toolkit. It is important to successful design that maintainability engineering be integrated into the overall design team throughout the development program.

Chapter 4: Maintenance Concept (Franck)

This chapter describes the maintenance concept as one of the most basic guiding principles for comprehensive system, subsystem, and component design. This chapter explains how the maintenance concept is central to defining and influencing sustainment plans and capabilities to allow for full life-cycle operability. The chapter includes an introduction to maintainability requirements, the categories of maintenance, the levels of maintenance, and an introduction to Integrated Logistics Support (ILS), along with the 12 elements of Integrated Product Support (IPS).

Chapter 5: Maintainability Requirements and Design Criteria (Gullo and Dixon)

A full explanation of maintainability requirements, guidelines, and design criteria is provided in this chapter, along with a tie-in to Appendix A, System Maintainability Design Verification Checklist. This chapter describes how requirements are developed and evolve through the systems engineering process. This chapter has focused on developing, implementing, and using maintainability requirements, guidelines, criteria, and checklists. It explains the use of design criteria in the evaluation process and as input to the design process and equipment selection. Application of the design criteria by the design team is emphasized because it will ensure compliance with maintainability requirements and will support the optimization of the system's sustainability. The development of good requirements is strongly emphasized throughout this chapter since they are the key to developing a system that successfully meets the needs of the customer, and they will allow for the efficient and cost-effective maintenance of the system or product.

Chapter 6: Maintainability Analysis and Modeling (Kovacevic)

The chapter describes the various types of maintainability modeling and analysis techniques, including functionality analysis, functional block diagrams, maintainability allocations, maintainability design trade studies, maintainability design evaluations, maintainability task analysis, maintainability modeling, and Level of Repair Analyses (LORAs) as well as numerous additional types of maintainability analyses. The reader will be encouraged to conduct or participate in multiple design iterations in an effort to balance the maintainability, reliability, and cost of the system in the given operating environments.

Chapter 7: Maintainability Predictions and Task Analysis (Gullo and Kovacevic)

This chapter describes various methodologies for performing maintainability predictions based on a popular standard, and describes the method for performing a Maintenance Task Analysis (MTA), which is used to support the maintainability prediction process. Maintainability predictions and a detailed MTA are crucial steps to ensuring that the asset will be able to achieve the desired performance objectives over its life-cycle. Using these techniques iteratively, the designer and asset owners can ensure that the best possible design is put forth within the assigned or estimated financial constraints for maintenance and logistics support over the asset's life-cycle.

Chapter 8: Design for Machine Learning (Gullo)

This chapter discusses the meaning of Machine Learning and Deep Learning, and the differences between Machine Learning (ML), Artificial Intelligence (AI), and Deep Learning (DL). This chapter explains what Machine Learning is and how it supports Design for Maintainability activities that facilitate Preventative Maintenance Checks and Services (PMCS), Digital Prescriptive Maintenance (DPM), Prognostics and Health Management (PHM), Condition-based Maintenance (CBM), Reliability-Centered Maintenance (RCM), Remote Maintenance Monitoring (RMM), Long Distance Support (LDS), and Spares Provisioning (SP).

Chapter 9: Condition-based Maintenance and Design for Reduced Staffing (Gullo and Kovacevic)

This chapter explains how Condition-based Maintenance (CBM) is a predictive maintenance technique to enable smart maintenance decisions by monitoring the conditions of an asset and interpreting these data to detect off-nominal behaviors or anomalies. This chapter further explains how CBM is able to dramatically reduce the man-hours needed to maintain an asset by performing maintenance only when it is needed on the specific components of the asset. Several methods are described, which will help the reader identify what maintenance should be performed on the asset. Two methods are discussed in detail in this chapter. One is Failure Modes and Effects Analysis (FMEA), which identifies the failure modes of an asset and is used to develop risk mitigation actions. A second topic is Reliability-centered Maintenance (RCM), which utilizes the FMEA and a logic tree to decide what maintenance or design actions to take.

Chapter 10: Safety and Human Factors Considerations in Maintainable Design (Dixon)

This chapter is divided into two sections: one section for safety considerations, and a second section for human factors considerations. This chapter provides an understanding of how maintainability, safety, and human factors are intimately related to each other and how they interact to help achieve a successful maintainable design. As with other areas of concern discussed in this book, it is imperative that the human user be considered early and throughout the entire design and development process. This chapter provides a sampling of the considerations needed to ensure that systems are designed to be safe and ergonomically effective to use. This chapter also presents a sampling of the analysis techniques that can be used by the reader to achieve cost-effective maintenance while protecting the maintenance personnel and making their job easier.

Chapter 11: Design for Software Maintainability (Gullo)

This chapter describes what software maintainability is and how maintainability impacts the software design. It also presents three basic types of software maintenance methods and the five primary life-cycle processes that may be performed during the software life-cycle. The chapter also highlights some of the most relevant IEEE standards. The information in this chapter will help the reader in their effort to design for software maintainability so that maintenance will be performed economically, effectively, and efficiently over the system's life-cycle.

Chapter 12: Maintainability Testing and Demonstration (Franck)

This chapter explains the...

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