Designing Capable and Reliable Products

Preface......Page 9
Notation......Page 13
Abbreviations......Page 15
1.1 Statement of the problem......Page 17
1.2 The costs of quality......Page 24
1.3 How and why products fail......Page 33
1.4 Risk as a basis for design......Page 38
1.5 Designing for quality......Page 41
1.6 Designing for reliability......Page 46
1.7 Summary......Page 50
2.1 Manufacturing capability......Page 53
2.2 Component Manufacturing Variability Risks Analysis......Page 59
2.3 Assembly capability......Page 74
2.4 Component Assembly Variablility Risks Analysis......Page 79
2.5 The effects of non-conformance......Page 83
2.6 Objectives, application and guidance for an analysis......Page 90
2.7 Case studies......Page 104
2.8 Summary......Page 122
3.1 Introduction......Page 125
3.2 Background......Page 126
3.3 Tolerance stack models......Page 129
3.4 A methodology for assembly stack analysis......Page 130
3.5 Application issues......Page 136
3.6 Cash study - revisiting the solenoid design......Page 138
3.7 Summary......Page 147
4.1 Deterministic versus probabilistic design......Page 148
4.2 Statistical methods for probabilistic design......Page 153
4.3 Variables in probabilistic design......Page 168
4.4 Stress-strength interface (SSI) analysis......Page 192
4.5 Elements of stress analysis and failure theory......Page 207
4.6 Setting reliability targets......Page 212
4.7 Application issues......Page 217
4.8 Case studies......Page 219
4.9 Summary......Page 265
5.1 Introduction......Page 268
5.2 Product development models......Page 272
5.3 Tools and techniques in product development......Page 278
5.4 Supporting issues in effective product development......Page 284
5.5 Summary......Page 291
Statistical representation of data......Page 293
Representing data using histograms......Page 294
Properties of the Normal distribution......Page 296
The Standard Normal distribution......Page 298
Process capability concepts......Page 304
Process capability index......Page 305
A Failure Mode and Effects Analysis (FMEA)......Page 311
B Quality Function Deployment (QFD)......Page 317
C Design for Assembly/Design for Manufacture (DFA/DFM)......Page 320
D Design of Experiments (DOE)......Page 324
Index to maps......Page 329
Sheet A Casting processes......Page 333
Sheet B Casting processes (continued)......Page 334
Sheet C Casting processes (continued)......Page 335
Sheet D Hot forging processes......Page 336
Sheet E Cold forming processes......Page 337
Sheet F Cold drawing and rolling processes......Page 338
Sheet G Extrusion processes......Page 339
Sheet H Sheet metalworking processes......Page 340
Sheet I Sheet metalworking processes (continued)......Page 341
Sheet K Machining processes......Page 342
Sheet L machining processes (continued)......Page 343
Sheet M Powder metallurgy processes......Page 344
Sheet N Plastic moulding processes......Page 345
Sheet P Elastomer and composite moulding processes......Page 346
Sheet Q Non-traditional machining processes......Page 347
Sheet R Non-traditional maching processes (continued)......Page 348
Appendix 5 Sample case studies used in validation......Page 349
A Miscellaneous operations......Page 360
B Later mechanical deformation......Page 361
C Adhesive bonding......Page 362
D Brazing and soldering......Page 363
E Resistance welding......Page 364
F Fusion welding......Page 365
A Variability risks results table......Page 366
B Conformability matrix......Page 367
Appendix 8 Assembly problems with two tolerances......Page 368
A Probability Density Functions (PDF)......Page 371
B Equivalent mean and standard deviation......Page 372
C Cumulative Distribution Functions (CDF)......Page 373
A Cumulative ranking equations......Page 376
C Distribution parameters from linear regression constants A0 and A1......Page 377
A Partial derivative method......Page 379
B Finite difference method......Page 381
C Monte Carlo simulation......Page 384
D Sensitivity analysis......Page 387
Appendix 12 Simpson\'s Rule for numerical integration......Page 389
Example 1......Page 390
Example 2......Page 392
Area under a Function......Page 394
References......Page 397
Bibliography......Page 410
Index......Page 411