----

------

The Authors
Dr. Bryan Dodson

Dr. Dodson is currently Executive Engineer for SKF. He formerly held positions of
Senior Director Corporate Quality & Continuous Improvement for Collins & Aikman,
Associate Director of Quality & Reliability Engineering for Visteon, and Manager of
Reliability Engineering and Quality Information Systems at Continental-Teves. Dr.
Dodson has authored several books including: the Reliability Engineering
Handbook, Practical Accelerated Testing, Weibull Analysis: with Software, the Six
Sigma Black Belt Study Guide, CQE Quick Reference Notes, and the CRE
Examination Study Guide. Dr. Dodson has developed software packages including:
the Training Pro Interactive Study Guides, the Reliability & Maintenance Analyst, and
Measurement Assurance. Dr. Dodson has published numerous articles and teaches
courses for technical societies and universities. Dr. Dodson earned a 8.5. in
petroleum engineering, an M.S. in industrial engineering, an M.B.A from Louisiana
Tech University, and a Doctor of Business Administration from Nova Southeastern
University. Dr. Dodson is a CQE, CRE, and is a licensed professional engineer.

Robert A. Davich

Our friend Robert Davich passed in March, 2009. Formerly, Mr. Dovich was the
Quality Manager at Ingersoll Cutting Tool Company in Rockf ord, IL. Mr. Dovich has
written over sixty articles on quality and statistical issues and has been a featured
speaker at Quality Expo Time and other national conferences. Bob was a part-time
college instructor in the field of Quality and Reliability and was the author of both
Reliability Statistics and Quality Engineering Statistics, published by ASQ Quality
Press. Bob had a M.S. degree from the University of Massachusetts-Amherst, a B.A.
degree from Western Illinois University, and an A.A.S. degree in Quality Assurance
Technology from Rock Valley College. In addition to being an ASQ Fellow, Mr.
Dovich was an ASQ Certified Quality and Reliability Engineer.

Neville B. Edenborough

Mr. Edenborough has over 30 years experience in quality. His career began at Los
Alamos Scientific Laboratory, working in nondestructive testing. In 1969 he moved
to Indianapolis, beginning a 23 year career with GM's Allison Gas Turbine Division.
At Allison, Mr. Edenborough had a number of positions, including section chief,
nondestructive testing, manager of experimental manufacturing operations, manager
of quality engineering, and manager of systems engineering. In his last position, he
was responsible for the reliability and growth of a major turbine engine development
program. Since retirement, Mr. Eden borough has been a private consultant working
with companies to improve their quality system and prepare for ISO registration.
Neville has conducted training sessions in CQE and CRE preparation and internal
auditing. He authored the Quality System Handbook for Complete ISO
Documentation. Mr. Edenborough is a Registered Professional Engineer, ASQ
certified (CRE, CQE, and CQA), and a Fellow of ASNT. He has a BSEE degree from
the University of Oklahoma. \_.I

CRE 2018 INTR0-4 © QUALITY COUNCIL OF INDIANA

 The Authors {Continued)
Wesley R. Richardson

Wesley R. Richardson is the Quality Knowledge Manager at Quality Council of

Indiana (QCI). In this capacity he writes, edits, and reviews materials created and
published by QCI. He has over 35 years of quality management experience,
including working at a commercial metallurgical testing laboratory, a medical device
manufacturer making MRI scanners, and a company manufacturing tungsten carbide
products for the coal mining and metal cutting industries. Wes has a BS in
Metallurgy from Massachusetts Institute of Technology, an MS in Metallurgy from
Case Western Reserve University, and an MBA from the University of Kentucky. Wes
is a Senior Member of ASQ and currently holds 14 ASQ certifications including the
CRE.

Bill L. Wortman

Bill Wortman is the CEO of Quality Council of Indiana - a quality publishing firm
located in Terre Haute, Indiana. He is a Senior Member of ASQ, former Chairman of
Section 0919, and Deputy Director of Region 9. Mr. Wortman currently holds nine
ASQ Certifications including the CRE. Bill has instructed over 9,000 individuals in
quality fundamentals, including certification training for six ASQ Certifications. Mr.
Wortman has a 8.5. in Metallurgical Engineering from N.C. State University. He
worked most of his professional life in the aluminum industry in a variety of
progressive technical and production management positions before starting Quality
Council of Indiana in 1988. Mr. Wortman has been author, co-author, or editor of
more than 42 quality related books and training CDs.

CRE 2018 INTRO -7 © QUALITY COUNCIL OF INDIANA

 CRE Primer Contents
I. CERTIFICATION OVERVIEW ................... 1-1 VI. RELIABILITY PLANNING ........................ Vl-1
CRE EXAM .......................... ..... 1-3 RELIABILITY TEST STRATEGIES ................ Vl-2
CRE BODY OF KNOWLEDGE ............... 1-6 ENVIRONMENTAL/USE FACTOR ................ Vl-20
BLOOM'S TAXONOMY .................... 1-15 FAILURE CONSEQUENCES .................... Vl-24
CRE PRIMER CONTENT ................... 1-16 FAILURE CRITERIA ........................... Vl-27
TESTING ENVIRONMENT ...................... Vl-29
II. RELIABILITY FUNDAMENTALS ................ 11-1 REFERENCES ............................... Vl-32
LEADERSHIP FOUNDATIONS ............... 11-2
BENEFITS OF RELIABILITY ............... 11-2 VII. TESTING & MODELING ......................... Vll-1
INTERRELATIONSHIPS .................. 11-5 TESTING ..................................... Vll-2
LEADERSHIP RESPONSIBILITIES ......... 11-8 ACCELERATED LIFE TESTS .................. Vll-2
ROLES AND RESPONSIBILITIES ......... 11-11 STRESS SCREENING ....................... Vll-12
FUNCTION OF RELIABILITY ENGR ........ 11-12 QUALIFICATION TESTING ................... Vll-22
ETHICS IN RELIABILITY ENGR ........... 11-15 DEGRADATION TESTING .................... Vll-40
SUPPLIER ASSESSMENTS .............. 11-19 SOFTWARE TESTING ....................... Vll-44
PERFORMANCE MONITORING ........... 11-22 MODELING .................................. Vll-54
RELIABILITY FOUNDATIONS ............... 11-24 BLOCK DIAGRAMS ......................... Vll-54
RELIABILITY TERMINOLOGY ............ 11-24 PHYSICS OF FAILURE ...................... Vll-81
DRIVERS OF RELIABILITY ............... 11-39 FAILURE MODELS ......................... Vll-87
CAPA ................................ 11-44 PREDICTION METHODS ..................... Vll-91
ROOT CAUSE ANALYSIS ................ 11-47 DESIGN PROTOTYPING ....................Vll-107
LIFECYCLE STAGES ................... 11-54 REFERENCES .............................. Vll-108
COST OF POOR RELIABILITY ............ 11-59
MAINTAINABILITY/AVAILABILITY ECON.... 11-60 VIII. RELIABILITY DESIGNS ........................ Vlll-1
QUALITY TRIANGLE .................... 11-68 EVALUATION TECHNIQUES .................... Vlll-2
SIX SIGMA METHODOLOGIES ........... 11-70 STRESS-STRENGTH ANALYSIS . ............... Vlll-8
SYSTEMS ENGINEERING ............... 11-82 DESIGN OF EXPERIMENTS ................... Vlll-10
REFERENCES ........................... 11-86 RELIABILITY OPTIMIZATION .................. Vlll-57
HUMAN FACTORS ........................... Vlll-60
111. RISK MANAGEMENT ....... ................. 111-1 DESIGN FOR X .............................. Vlll-64
IDENTIFICATION ........................... 111-2 DESIGN FOR RELIABILITY .................... Vlll-72
RISK MGMT TECHNIQUES ...... .... ... .... 111-2 PARTS & SYSTEMS DEVELOPMENT ........... Vlll-77
TYPES OF RISK ..... .... ............. .... 111-5 SELECTION TECHNIQUES .................. Vlll-77
ANALYSIS ................ ...... ... .... .... 111-7 PARTS STANDARDIZATION ................. Vlll-82
FAULT TREE ANALYSIS ................... 111-7
FMEA/FMECA ............... ........... 111-13
REFERENCES .............................. Vlll-89
V
COMMON MODE ANALYSIS ............... 111-21 IX. MAINTAINABILITY ............................. IX-1
HAZARD ANALYSIS . ......... ........ ... 111-23 MAINTENANCE STRATEGIES ................... IX-2
RISK MATRIX ........................... 111-35 PREVENTIVE MAINTENANCE ANALYSIS ........ . IX-32
SYSTEM SAFETY ... ..... ............... 111-40 CORRECTIVE MAINTENANCE ANALYSIS ......... IX-36
MITIGATION .............................. 111-54 REFERENCES ............................... IX-39
REFERENCES ... .................. ....... 111-58
X. APPENDIX .................................... X-1
IV. STATISTICAL CONCEPTS ................... IV-1 TABLES .................................... X-2
BASIC STATISTICS ......................... IV-2 SUPPLEMENT ..............................X-16
PROBABILITY CONCEPTS ................. IV-11 CALCULUS REVIEW ......................... X-18
PROBABILITY DISTRIBUTIONS .............. IV-19 AUTHOR/NAME INDEX ....................... X-27
PROBABILITY FUNCTIONS ................. IV-50 FORMULAS INDEX ..........................X-28
RELIABILITY SAMPLING PLANS ............. IV-60 SUBJECT INDEX ............................ X-30
SPC & PROCESS CAPABILITY ............... IV-63 QUESTION ANSWERS ....................... X-41
CONFIDENCE INTERVALS .................. IV-90
REFERENCES ........................... IV-100

V. DATA MANAGEMENT ........................ V-1

SOURCES OF RELIABILITY DATA .............. V-2
TYPES OF DATA ...........................V-11
DATA COLLECTION METHODS ............... V-16
DATA SUMMARY & REPORTING .............. V-20
FAILURE ANALYSIS METHODS ............... V-28
FRACAS .................................. V-31
REFERENCES ............................. V-35

CRE 2018 INTR0-8 © QUALITY COUNCIL OF INDIANA

I. CERTIFICATION OVERVIEW

Certified Reliability Engineer Exam {Continued)

Duration

The written test lasts 4 hours and will begin at an advised time (typically 8 A.M.).
The Prometric exam lasts 4.5 hours

Other Details

Can be obtained by calling ASQ headquarters at 1-800-248-1946 or on the internet

at http://www.asq.org. They will send a CRE brochure free of charge.

Bibliography Sources

The reference sources recommended in the ASQ brochure should be consulted.

Those recommended by the authors include:

Dodson, 8., & Nolan, D. (2002). Reliability Engineering Handbook. Tucson: QA

Publishing, LLC.

Ireson, W. G., Coombs, C. F., & Moss, R. Y., (Eds.). (1996). Handbook of Reliability
Engineering and Management, 2nd ed. New York: McGraw-Hill.

Kapur, K. C. & Lamberson, L. R. (1977). Reliability in Engineering Design. New York:

John Wiley and Sons, Inc. (out of print)

Locks, M. 0. (1995). Reliability, Maintainability, and Availability Assessment, 2nd ed.

Milwaukee: ASQ Quality Press. (out of print)

O'Connor, P. D. T. (2002). Practical Reliability Engineering, 4th ed. New York: John
Wiley and Sons, LTD (latest reprint September 2008)

Omdahl, T. P. (2015). RAM Dictionary, available from QCI (800) 660-4215.

Reliability Toolkit: Commercial Practices Edition. (1993). Rome, New York: Reliability
Analysis Center.

CRE 2018 I -4 © QUALITY COUNCIL OF INDIANA

I. CERTIFICATION OVERVIEW

CRE BOK {Continued)

2. Basic probability concepts (Analyze)
Use basic probability concepts (e.g., independence, mutually exclusive,
conditional probability), and compute and interpret the expected values.

3. Probability distributions (Analyze)

Compare and contrast various distributions (e.g., binomial, Poisson,
exponential, Weibull, normal, and log-normal), and recognize their
associated probability plots.

4. Probability functions (Apply)

Compare and contrast various probability functions (e.g., cumulative
distribution functions (CDFs), probability density functions (PDFs), and
hazard functions), and recognize their application in various situations.

5. Sampling plans for statistics and reliability testing (Apply)

Use various theories, tables, and formulas to determine appropriate
sample sizes or testing time for statistical and reliability testing.

6. Statistical process control (SPC) and process capability studies (Cp, Cpk)
(Understand)
Define and describe SPC and process capability studies (Cp, Cpk • etc.),
control charts, and how each is related to reliability.

7. Confidence and tolerance intervals (Evaluate)

Compute confidence intervals and tolerance intervals, draw conclusions
from the results, and describe how point estimates are used to determine
the interval.

8. Data Management

1. Sources and uses of reliability data (Analyze)

Describe sources of reliability data (prototype, development, test, field,
warranty, published, etc.), their advantages and limitations, and how the
data can be used to measure and enhance product reliability.

2. Types of data (Evaluate)

Identify and distinguish between various types of data (e.g., attributes vs.
variable, discrete vs. continuous, censored vs. complete, and univariate
vs. multivariate). Select appropriate analysis tools based on the data type.

CRE 2018 I -10 © QUALITY COUNCIL OF INDIANA

I. CERTIFICATION OVERVIEW

CRE BOK (Continued)

4. Failure criteria (Understand)
Define and describe failure criteria based on system requirements and
warranty terms and conditions.

5. Test environment (Evaluate)

Appraise the environment in terms of system location and operational
conditions, and designate the environment in the test plan to ensure an
appropriate test strategy is implemented.

B. Testing (Evaluate)
Describe the purpose, advantages, and limitations of each of the following
types of tests, and use common models to develop test plans, evaluate risks,
and interpret test results.

1. Accelerated life tests (single-stress, multiple-stress, sequential stress,

step-stress, HALT, margin tests)

2. Stress screening (ESS, HASS, burn-in tests)

3. Qualification/demonstration testing (sequential tests, fixed-length tests)

4. Degradation (wear-to-failure) testing

5. Software Testing (white-box, black-box, operational profile, and

fault-injection)

C. Modeling

1. Reliability block diagrams and models (Evaluate)

Generate and analyze various types of block diagrams and models,
including series, parallel, partial redundancy, and time-dependent.

2. Physics of failure and failure mechanisms (Apply)

Identify various potential failure mechanisms (e.g., fracture, corrosion,
memory corruption) and describe the physical process of these failures.

3. Failure models (Analyze)

Select appropriate theoretical models (e.g., Arrhenius, S-N curve) to
assess or predict failure rates.

CRE 2018 I -12 © QUALITY COUNCIL OF IN DIANA