"vii© 2025 SAE InternationalPreface xvAcronyms xviiNomenclature xxxiC H A P T E R 1 6Holistic Reliability 116.1. Systemic Approach to Reliability 116.2. Split-Plot Design 316.2.1. How to Generate a Split-Plot Design 416.
2.2. Analysis of Variance (ANOVA) for Two-Factor Split-Plot Design 516.2.3. Analysis of Variance (ANOVA) for Split-Split-Plot Design 1116.2.4.
Split-Plot Response Surface 1216.2.5. D-Optimal Split-Plot Designs 1316.2.6. Fractional Factorial Design (2K-P × 2U-V)R 1416.3.
Strip-Plot Design 1516.3.1. How to Build a Strip-Plot Design 1616.3.2. Why Strip-Plot Design 1616.3.
3. Analysis of Variance (ANOVA) for a Strip-Plot Design 1716.3.4. Strip Design Example--Open-Circuit Voltage (OCV) of Battery 1916.3.5. Fractional Factorial Design of Two Levels in Uncoupled Strata 2216.
3.6. Fractional Factorial Design of Two Levels in Coupled Strata 2316.4. Minimum Aberration Fractional Factorial Split-Plot Design 2416.4.1. Simplified Analysis by Engineering Significance 2716.
4.2. Statistical Significance by Analysis of Variance (ANOVA) 31ContentsContentsviii16.5. Crossed-Nested Factorial Design with Two Fixed and One Random Variable 3216.5.1. Fixed-Effect Factor and Random Effect Factor 3216.
5.2. Staggered-Nested Design with Three Factors 3316.5.3. Crossed-Nested Design with Three Random Factors 3716.5.4.
Further Explanation of Staggered-Nested Design with Fixed Factors A and B 4016.6. System Reliability by Mixed Weibull Statistics 4116.6.1. Finite Mixed Weibull Distribution with Alternative Failures 4116.6.2.
Product Reliability with Components in Series 4316.6.3. Product Reliability with Components in Parallel 4516.6.4. Product Reliability with Series-Parallel Subsystems 4616.6.
5. Approximating Normal and Lognormal Distributions by Two-ParameterWeibull Statistics 4616.7. Adaptive DOEs by Cross-Validation 4716.7.1. Error Messages for Adaptive DOEs 4716.7.
2. Leave-One-Out Cross-Validation (LOOCV) 4816.7.3. DOE with Dependent Variable Transformations by Leave-One-OutCross-Validation (LOOCV) 5116.7.4. Leave-One-Out Cross-Validation (LOOCV) with Adaptive Sampling 5516.
7.5. More Cross-Validation Techniques 5616.8. Adaptive DOEs by Expected Improvement 5716.8.1. Adaptive DOE Process Based on Expected Improvement 5816.
8.2. Probability of Improvement 5916.8.3. Exploitation by Expected Improvement 5916.8.4.
Exploration versus Exploitation 6116.8.5. Mutual Information 6116.8.6. Probability in the Target Range 6216.8.
7. Conventional DOE or Adaptive DOE: Illustrated Using a Case Study 6216.9. Fault Tree Analysis (FTA) 6516.9.1. Events 6616.9.
2. Gates 6616.9.3. Transfer 6816.9.4. Minimal Cut Sets 6916.
9.5. Bridge-Networked Logic Gate 6916.9.6. Causes of Failure 6916.9.7.
Qualitative Fault Tree Analysis (FTA) 7016.9.8. Quantitative Fault Tree Analysis (FTA) 7116.9.9. Sensitivity Analysis of a Fault Tree via DOEs 75References 75Problems 79Contents ixC H A P T E R 1 7Supply Chain Reliability 8117.1.
Supply Chain Management (SCM) 8117.1.1. Design for Supply Chain Reliability 8217.1.2. Automotive Supply Chain Reliability 8317.2.
Operating Profit of a Four-Echelon Supply Chain 8317.3. Supply Chain Operation through DOEs 8517.3.1. Demand Management and Inventory Management 8517.3.2.
DOEs for a Supply Chain Node 8717.3.3. Fill Rate 8817.3.4. On-Hand Inventory (OHI) 9117.3.
5. Inventory Cost 9717.4. Supplier Selection by DOEs 10317.4.1. Wear of Piston Kit 10417.4.
2. Mixed Lubrication Regime and Friction in Sliding Mode 10417.4.3. Depth of Wear in Dry Sliding Mode 10617.4.4. Reliability Demonstration Test 10617.
4.5. Reliability Growth Tests Using Fractional Factorial Design 2IV8-4 10817.4.6. Predictive Equation for Depth of Wear 11117.4.7.
Diagnostic Checking 11417.4.8. Conclusion from Case Study of Piston Kit Wear 11517.5. Multivariate Statistical Process Control 11517.5.1.
Hotelling''s T 2 for Two Variables 11617.5.2. Hotelling''s T 2 for Multiple Variables 12017.6. Supply Chain Reliability Attributed to Network Mechanism 12017.6.1.
Network Reliability by DOEs 12117.6.2. Monte Carlo Simulations for System Identification of a Large Supply Chain 12417.7. Risk Assessment of Supply Chains Using Dynamic Fault Tree Analysis(DFTA) 12417.7.1.
Main-Backup Supply Chain 12617.7.2. Mutual-Assistance Supply Chain 12917.8. Automotive Supply Chain Management (SCM) Process and Documentation 13117.8.1.
Advanced Product Quality Planning (APQP) 13217.8.2. Production Part Approval Process (PPAP) 133References 136Problems 138ContentsxC H A P T E R 1 8Operational Reliability in Production Engineering 13918.1. Operational Reliability in Production Process 13918.1.1.
Cost of Unreliability 14018.1.2. Flexible Production 14118.1.3. Improving Production Yield by Simulations Based on DOEs 14218.2.
Indices of Production Reliability 14418.2.1. Mean Time to Failure (MTTF) 14418.2.2. Mean Time between Failures (MTBF) 14518.2.
3. Mean Down Time (MDT) 14618.2.4. Mean Time between Replacements (MTBR) 14618.2.5. Mean Time between Maintenance (MTBM) 14618.
2.6. Mean Time between Failures with Scheduled Replacements (MTBF-SR) 14718.2.7. Availability and Unavailability 14718.2.8.
Failure Frequencies 14818.2.9. Functional Redundancy 14918.2.10. Derating 14918.3.
Quality Function Deployment (QFD) Enhanced by DOEs 15018.3.1. Quality House 15018.3.2. DOEs for Quality Functional Deployment 15418.4.
Design for Testability (DFT) and Closed-Loop Control 15418.4.1. Testability Analysis 15518.4.2. Testability Metrics in FMEA and Quality Measure of Built-in Tests (BITs) 15618.4.
3. Closed-Loop Control via DOEs 16018.5. Total Productive Maintenance (TPM) 16118.5.1. Corrective Maintenance (CM) 16118.5.
2. Preventive Maintenance (PM) 16218.5.3. Condition-Based Preventive Maintenance (PM) 16218.5.4. Predictive Maintenance 16218.
5.5. Adaptive Maintenance 16318.5.6. Overall Equipment Efficiency (OEE) 16318.5.7.
Total Effective Equipment Performance (TEEP) 16418.5.8. Developing Controlled Process Flow 16418.5.9. Production Process Improvement by DOEs 16518.6.
DOEs for Project Management 16718.6.1. Project Management by DOEs 16718.6.2. Engineering Changes 16918.6.
3. Process Flow and Control 17118.6.4. Value Stream Mapping (VSM) 173Contents xi18.7. Operational Arbitration by Kappa Coefficients and DOEs 17318.7.
1. Kappa Coefficient 17318.7.2. Cohen''s Kappa Coefficient 17418.7.3. Fleiss'' Kappa Coefficient 17718.
7.4. Operational Arbitration by DOE 18018.8. Design for Six Sigma (DFSS) 18218.8.1. Define 18318.
8.2. Measure 18318.8.3. Analyze 18318.8.4.
Design 18318.8.5. Verify 18318.8.6. Implementation of Kaizen-Five Steps (DMAIC Process) 18418.8.
7. Lockheed''s Design for Six Sigma (DFSS) 18418.9. Design for Manufacture and Assembly (DFMA) 18418.9.1. Simplifying the Design and Reducing the Number of Parts 18518.9.
2. Standardizing and Using Common Parts and Materials 18518.9.3. Design for Ease of Fabrication 18518.9.4. Design within Process Capabilities and without Un-Needed Surface Finish 18618.
9.5. Foolproof 18618.9.6. Production-Oriented Product Engineering (POPE) 18718.9.7.
Minimizing Flexible Parts and Interconnections 18718.9.8. Utilizing Simple Patterns of Movement 18718.9.9. Using Effective and Efficient Joining 18818.9.
10. Modular Products 18818.9.11. Design for Automated Production 188References 188Problems 192C H A P T E R 1 9Operational Reliability of EVs 19319.1. Automotive Electrification 19319.1.
1. Lithium-ion (Li-ion) Batteries (LIBs) 19419.1.2. Li-Air Batteries 19519.1.3. Hydrogen Fuel Cells 19619.
1.4. Autonomous and Automated Vehicles 19719.1.5. Transport Infrastructures 19719.2. Battery Electric Vehicles (BEVs) 19719.
2.1. Travel with BEVs 19719.2.2. State of Charge (SOC) 19819.2.3.
State of Health (SOH) 200Contentsxii19.2.4. Battery Capacity 20019.2.5. Operation of a Battery-Powered Vehicle 20119.3.
Lithium-ion (Li-ion) Batteries (LIBs) 20419.3.1. Electric Resistance of Graphite/NMC Li-Ion Cells 20519.3.2. Temperature Rise of LIBs at Discharge 20819.3.
3. Solid Electrolytes for LIBs 21319.3.4. Packing Cathodes for LIBs 21719.3.5. Composite Carbon Cathodes for a Solid-State LIB 21919.
3.6. Loss of Mobile Li Ions to Side Reactions in SEIs 22219.3.7. Range Extension of EV 22219.3.8.
Test Standards and Regulations for Reliability of Automotive LIBs 22319.4. Integrity of Battery Separators 22319.4.1. Heterogeneity in Composite Separators 22419.4.2.
DOEs to Detect Irregular Transport of Ions 22519.5. Automotive Battery Packaging 23019.5.1. Electrical Interconnection 23419.5.2.
Thermal Management and Pressure Venting 23419.5.3. Structural Integrity--Fastening 23419.5.4. Structural Integrity--Sealing 23419.5.
5. Structural Integrity--Crush/Crashworthiness 23419.6. Li-Air Batteries 23519.6.1. Mechanism of Li-Air Batteries 23519.6.
2. Solid Electrolytes for Li-Air Batteries 23719.7. Sodium-ion Batteries (SIBs) 23719.7.1. Cathodes 23819.7.
2. Anodes 23819.7.3. Solid Electrolytes 23819.7.4. Merits of Solid-State SIBs 23819.
8. HFCVs 23819.8.1. Proton Exchange Membrane Fuel Cell (PEMFC) 23919.8.2. Supply Chain of Hydrogen 24319.
8.3. Physical Storage Vessels for Compressed Hydrogen 24519.8.4. Physisorptive Storage of Hydrogen 24619.8.5.
Embrittlement of Materials by H2 248References 248Problems 252Contents xiiiC H A P T E R 2 0Marketing Reliability 25520.1. Product Value 25520.1.1. Evolutionary Techniques for Improving Product Value 25620.1.2.
Product Features That Delight Customers 25720.2. Voice of the Customer (VOC) 25820.2.1. Gathering Information 25820.2.2.
Creating a VOC Matrix 25920.2.3. Customer Experience Management (CEM) 26020.3. Value Engineering and Value Analysis (VEVA) 26120.3.1.
FAST 26220.3.2. Identifying Opportunities and Design Alternatives 26420.4. Benchmarking with Data Envelopment Analysis (DEA) 26420.4.1.
Benchmarking with Regression Analysis 26520.4.2. Market Value by DEA 26520.4.3. Returns to Scale 26720.4.
4. Output-Oriented DEA 26820.4.5. Input-Oriented DEA 27220.5. Conjoint Analysis 27520.5.
1. Social Acceptance of Hybrid EV 27520.5.2. Financial Services Marketing 27820.5.3.