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| Preface | |
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| Notation | |
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| Abbreviations | |
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| Introduction to quality and reliability engineering | |
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| Statement of the problem | |
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| The costs of quality | |
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| Cases studies in failure costs | |
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| Quality-cost estimating methods | |
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| How and why products fail | |
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| Failure mechanisms | |
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| The link between variability and failure | |
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| Risk as a basis for design | |
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| The role of FMEA in designing capable and reliable products | |
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| Designing for quality | |
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| Designing for reliability | |
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| Summary | |
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| Designing capable components and assemblies | |
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| Manufacturing capability | |
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| Variability factors in manufacturing | |
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| Cost-tolerance relationships | |
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| Process capability and tolerances | |
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| Component Manufacturing Variability Risks Analysis | |
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| Process capability maps | |
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| Surface roughness chart | |
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| Validation of the Component Manufacturing Variability Risks Analysis | |
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| Assembly capability | |
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| Design for assembly techniques | |
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| Assembly sequence diagrams | |
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| Component Assembly Variability Risks Analysis | |
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| The effects of non-conformance | |
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| Design acceptability | |
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| Map of quality costs | |
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| Objectives, application and guidance for an analysis | |
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| Objectives | |
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| Application modes | |
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| Analysis procedure | |
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| Example - Component Manufacturing Variability Risks Analysis | |
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| Example - Component Assembly Variability Risks Analysis | |
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| Completing the Conformability Matrix | |
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| Case studies | |
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| Electronic power assisted steering hub design | |
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| Solenoid security cover | |
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| Telescopic lever assembly | |
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| Solenoid end assembly | |
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| Summary | |
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| Designing capable assembly stacks | |
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| Introduction | |
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| Background | |
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| Tolerance stack models | |
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| A methodology for assembly stack analysis | |
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| Application of the process capability estimates from CA | |
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| Model for centred distributions | |
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| Model for shifted distributions | |
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| Application issues | |
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| Case study - revisiting the solenoid design | |
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| Paper-based analysis | |
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| CAPRAtol software analysis | |
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| Summary | |
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| Designing reliable products | |
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| Deterministic versus probabilistic design | |
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| Statistical methods for probabilistic design | |
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| Modelling data using statistical distributions | |
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| Fitting distributions to data | |
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| The algebra of random variables | |
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| Variables in probabilistic design | |
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| Material strength | |
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| Dimensional variability | |
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| Service loads | |
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| Stress-Strength Interference (SSI) analysis | |
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| Derivation of reliability equations | |
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| Reliability determination with a single load application | |
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| Reliability determination with multiple load application | |
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| Reliability determination when the stress is a maximum value and strength is variable | |
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| Example - calculation of reliability using different loading cases | |
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| Extensions to SSI theory | |
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| Elements of stress analysis and failure theory | |
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| Simple stress systems | |
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| Complex stress systems | |
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| Fracture mechanics | |
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| Setting reliability targets | |
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| Reliability target map | |
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| Example - assessing the acceptability of a reliability estimate | |
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| System reliability | |
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| Application issues | |
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| Case studies | |
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| Solenoid torque setting | |
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| Foot pedal optimum design | |
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| Torque transmitted by a shrink fit | |
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| Weak link design | |
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| Design of a structural member | |
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| Bimetallic strip deflection | |
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| Design of a con-rod and pin | |
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| Summary | |
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| Effective product development | |
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| Introduction | |
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| Product development models | |
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| Overview of product development models | |
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| Industrial models | |
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| Tools and techniques in product development | |
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| Overview of tools and techniques | |
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| Utilization of tools and techniques | |
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| The integration of tools and techniques in the product development process | |
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| Supporting issues in effective product development | |
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| Team approach to engineering design | |
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| Quality philosophy of the company | |
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| Product design specifications | |
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| External supplier quality | |
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| Design scheme generation | |
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| Design reviews | |
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| Summary | |
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| Appendices | |
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| Introductory statistics | |
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| Process capability studies | |
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| Overview of the key tools and techniques | |
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| Failure Mode and Effects Analysis (FMEA) | |
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| Quality Function Deployment (QFD) | |
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| Design for Assembly/Design for Manufacture (DFA/DFM) | |
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| Design of Experiments (DOE) | |
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| Process capability maps | |
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| Sample case studies used in validation | |
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| Additional assembly process risk charts | |
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| Miscellaneous operations | |
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| Later Mechanical deformation | |
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| Adhesive bonding | |
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| Brazing and soldering | |
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| Resistance welding | |
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| Fusion welding | |
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| Blank conformability analysis tables | |
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| Variability risks (q[subscript m] and q[subscript a]) results table | |
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| Conformability matrix | |
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| Assembly problems with two tolerances | |
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| Properties of continuous distributions | |
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| Probability Density Functions (PDF) | |
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| Equivalent mean ([mu]) and standard deviation ([sigma]) | |
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| Cumulative Distribution Functions (CDF) | |
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| Fitting distributions to data using linear regression | |
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| Cumulative ranking equations | |
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| Linear rectification equations and plotting positions | |
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| Distribution parameters from linear regression constants A0 and A1 | |
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| Solving the variance equation | |
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| Partial derivative method | |
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| Finite difference method | |
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| Monte Carlo simulation | |
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| Sensitivity analysis | |
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| Simpson's Rule for numerical integration | |
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| References | |
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| Bibliography | |