Series Editor''s Foreword xv Preface xvii Acknowledgments xxiii 1 Enchaining Lifecycle Reliability with Robust Engineering and Prognostic Health Management 1 1.1 Introduction 2 1.2 Purpose 3 1.3 Essentials of Robustness and Robust Design in Reliability Improvement 4 1.4 Effective Reliability Efforts in an Integrated Product Development Environment 4 1.5 Enhancing Reliability Integration into the Product Development Process 6 1.6 Physics of Failure (PoF) 7 1.7 Failure-mode Avoidance 9 1.

8 Design for Six Sigma 10 1.8.1 The Essence of Robustness Thinking 11 1.8.2 Robust Design as a Key Strategy 12 1.8.3 Paradigm Shift and Change 13 1.8.

4 DFSS Roadmap: Emphasizing Robustness 13 1.9 Design for Reliability 16 1.10 Prognostics and Health Management 17 1.10.1 Health Indicators in Prognostic Health Management: Critical-to-Quality (CTQ) and Critical-to-Reliability (CTR) 21 1.10.2 Critical-to-Quality (CTQ) Parameters 21 1.10.

3 Critical-to-Reliability (CTR) Parameters 21 1.10.4 Identification and Selection of CTQ and CTR Parameters 22 1.10.4.1 Robust Design for Reliability (RDfR) 22 1.10.5 Health Indicators in Prognostics and Health Management 22 1.

11 The Importance of Digital Quality in Lifecycle Reliability Through Robustness Development and Predictive Health Management 23 1.12 Digital Quality in Lifecycle Reliability 23 1.12.1 Robustness Development 24 1.13 Predictive Health Management (PHM) 25 1.13.1 Integration of Digital Quality, Robustness Development, and PHM 26 1.14 Critical Parameter Development and Management (CPD&M): A Comprehensive Overview 27 1.

14.1 The CPD&M Process 28 1.14.1.1 Initial Parameter Identification 28 1.14.1.2 The Seven Metrics 28 1.

14.2 Continuous Improvement 28 References 30 Further Reading 31 2 Robustness Thinking and Strategies for Reliability Development 33 2.1 Introduction 34 2.1.1 Failure-Mode Avoidance: A Comprehensive Approach to Reliability 34 2.2 What Is Robustness Thinking? 40 2.3 The Challenge and Limitation of Conventional Reliability Approach 44 2.3.

1 Uncertainty--Variation and Lack of Knowledge 44 2.3.1.1 Random Variation or Physical Uncertainty 46 2.3.1.2 Statistical Uncertainty 46 2.3.

1.3 Model Uncertainty 46 2.3.1.4 Among These Three Types of Uncertainties 46 2.3.2 Traditional Reliability Challenges 47 2.3.

3 Demand and Capacity--Statistical Modeling 53 2.3.4 Deterministic vs. Probabilistic Design 55 2.3.5 Understanding the Outer Array 59 2.3.6 Assessing Strength vs.

Stress 59 2.3.7 P-Diagram 60 2.4 Why Robust Design? 61 2.5 The Importance and Principle of Flow in Robustness Thinking 62 2.5.1 Defining Flow 64 2.5.

2 Transformation Systems, Flow, and Proactive Failure Creation 65 2.5.2.1 Load-Stress-Strength Thinking as a Proactive Reliability Framework 65 2.5.2.2 Margin, Limits, and Failure Distance 66 2.5.

2.3 Noise Factors and Robust Design for Proactive Reliability 66 2.5.2.4 Architecture Robustness and Failure Propagation 67 2.5.2.5 Reliability Creation During Concept and Design 67 2.

5.2.6 Summary: Robustness Thinking as Proactive Reliability 67 2.5.3 Importance of Flow in System Design and Optimization 67 2.5.4 Integrating Robustness Thinking and Robust Design Principles 67 2.5.

5 Barriers to Flow Due to Lack of Robustness Thinking 68 2.5.6 Overcoming Barriers to Flow with Robustness Thinking 69 2.5.7 Examples of Barriers to Flow 69 2.5.8 Addressing Barriers with Robustness Thinking 70 2.6 Robustness Development Strategy 71 2.

7 Three Phases of Robust Design 73 2.8 Understanding and Mitigating Mistakes in Design and Manufacturing 75 2.8.1 Improving Reliability by Reducing Mistakes 76 References 77 Further Reading 77 3 Robust Design Principles, Tactics, and Primary Tools 79 3.1 Introduction 79 3.2 Ideal Function: Ideal Transformation System Input and Output Relationship 80 3.3 Ideal Function and Quality Problems 81 3.4 Identification and Classification of Design Parameters: P-Diagram 82 3.

5 Opportunity for Robustness Development 87 3.6 Two-Step Optimization 89 3.7 Robustness Measurement: S/N Ratio 90 3.8 S/N Ratio Improvement and Variation Reduction 92 3.9 S/N Ratio, the Additive Model, and the Conservative Laws of Physics 93 3.10 The Static Signal-to-Noise Ratios 94 3.10.1 Nominal-the-Best (NTB) Case 94 3.

10.2 Smaller-the-Better (STB) 95 3.10.3 Larger-the-Better (LTB) 96 3.10.4 Operating Window (OW) Response 97 3.10.5 Classified Attribute Response 98 3.

11 Dynamic Signal-to-Noise Ratios 98 3.11.1 Zero-Point Proportional Response 98 3.12 Robust Parameter Design Strategy and Steps 100 3.12.1 Steps in Robust Parameter Design for Nominal-the-Best Characteristics 106 3.13 Quality Measurement: Loss Function 108 3.14 Robust Technology Development 109 References 114 4 Robust Design for Reliability (RDfR) A Comprehensive Approach to Product Excellence 117 4.

1 Introduction 117 4.2 Robust Design for Reliability: A Comprehensive Approach to Product Excellence 120 4.2.1 Preventing Failure Modes Through Vigilance 123 4.2.1.1 Understanding the Entropic Nature of Mistakes 123 4.2.

1.2 Strengthening Organizational Vigilance 123 4.3 Roadmap for Robust Design for Reliability Execution 127 4.3.1 Identify Phase 127 4.3.1.1 Identify Phase Purposes 129 4.

3.1.2 Identify Phase Activities 132 4.3.1.3 Identify Phase Deliverables 136 4.3.2 Design Phase 136 4.

3.3 Design Phase Purposes 137 4.3.3.1 Design Phase Deliverables 141 4.3.4 Optimize Phase 142 4.3.

4.1 Optimize Phase Purpose 142 4.3.4.2 Robustness "Rules of Engagement" 145 4.3.4.3 Optimize Phase Activities 146 4.

3.4.4 Optimize Phase Deliverables 148 4.3.5 Verify Phase 148 4.3.5.1 Verify Phase Purpose in Robust Design for Reliability 148 4.

3.5.2 Verify Phase Activities in Robust Design for Reliability 151 4.3.5.3 Verify Phase Deliverables 158 4.4 Robust Design Principles for Prognostic Health Management 159 4.5 Scorecard for Robust Design for Reliability Implementation 161 4.

6 Digital Quality Through Robust Design for Reliability 165 4.7 Critical Parameter Development and Management (CPD&M) Process and Phases 170 References 171 Further Reading 172 5 Predictive & Health Management 173 5.1 Justification for PHM in Robust System Design 173 5.2 System Components and Their Functions 176 5.2.1 PHM System Architecture 176 5.2.2 Integration with Existing Maintenance Operations 179 5.

2.2.1 Maintenance and Maintenance Strategies 179 5.2.2.2 Condition-based Maintenance (CBM) 179 5.2.3 Scalability and Adaptability in PHM Design 183 5.

2.3.1 Activities of PHM and Reliability Over the Product Lifecycle 183 5.2.3.2 Integration of Robust Design and PHM for Enhanced System Reliability 184 5.2.3.

3 The Power of Integrating Robust Engineering and PHM 184 5.2.3.4 Assignment of Reliability and PHM Activities Over the Product Lifecycle 185 5.2.3.5 The Role of PHM in the Product Lifecycle 186 5.2.

3.6 PHM System Development Process and Associated Standards 186 References 189 6 Characterizing Failure Signatures 191 6.1 Characterizing Failure Signatures 191 6.1.1 Identifying Degradation Patterns 191 6.1.1.1 Synergistic Integration: Robust Design, Physics of Failure, and Degradation Pattern Identification 192 6.

1.2 Signature Analysis for Different System Components 197 6.1.3 Signature Analysis Methods for Various System Components 200 6.1.4 The Role of Signatures in Failure Prediction 203 6.1.5 Data Collection for Signature Development 205 References 208 7 Guidelines for PHM System Implementation 209 7.

1 Enabling Technologies for PHM 210 7.1.1 Sensor Technology Selection and Integration 210 7.1.2 Developing Robust Sensor Technology and Integration Strategy for PHM 210 7.1.2.1 Sensor Technology Development for PHM 210 7.

1.2.2 Conducting Robustness Assessment of Sensors 211 7.2 Identifying and Selecting Robust Sensors for PHM 211 7.3 Integration and Validation for PHM-Ready Systems 211 7.4 Advanced Computing Platforms for PHM Analytics 213 7.4.1 Edge Computing 213 7.

4.2 Cloud Computing 213 7.4.3 Fog Computing 214 7.4.4 Distributed Computing Frameworks 214 7.4.5 High-performance Computing (HPC) 214 7.

5 AI-accelerated Hardware 214 7.6 Evaluation Metrics for PHM Systems 214 7.7 Robust PHM System 215 7.7.1 Modular Architecture for PHM Systems 215 7.7.2 Robustness, Redundancy, and Fault Tolerance in PHM System Design 216 7.7.

2.1 Redundancy in PHM Architecture 217 7.7.2.2 Fault Tolerance Mechanisms 217 7.7.2.3 Building for Long-Term Reliability and Cost Effectiveness 218 7.

7.3 User-centric Design for Ease of Integration 218 7.7.4 Implementation Measures of User-centric Design in PHM 219 7.8 Robust Prototype and Test-Bench Development for PHM System Validation 219 7.8.1 System-level Requirements with Robustness in Mind 219 7.9 Modular, Robust PHM Prototype Architecture 220 7.

10 Test-Bench Design for Robustness Validation.