DESIGN FOR
RELIABILITY
CASTANEDA | CASTILLO | CASTRO | CATANGHAL | OBCENA | RESURRECCION | SURESCA
OBJECTIVES
Define and explain reliability and reliability
concepts;
Identify measures of reliability; and
Use reliability tools
OUTLINE
1. Introduction
a.
b.
What is reliability
Reliability concepts
2. Measures of
Reliability
a.
b.
c.
Failure Rate
MTTF
MTBF
3. Steps in Designing
for Reliability
4. Reliability Tools
a.
b.
c.
d.
e.
f.
Block Diagram
P-diagram
QFD
FMEA
Design Verification
Plan
Reliability
Demonstration Matrix
DESIGN FOR RELIABILITY
Developed by MPD Cohort Team
(team members: Julie Earle, Dave
Herczeg, and Jim Van Glider)
Developed in 2002
DESIGN FOR RELIABILITY
Why design for reliability?
it can make or break the long-term success
of a product:
o
o
too high reliability = too expensive product
too low reliability = high warranty and repair costs
(market share will be lost)
aka design durability, design for robustness,
design for useful life
RELIABILITY
General Definition
the ability of a product to perform as
expected over time
Formal Definition
the probability that a product, piece of
equipment, or system performs its
intended function for a stated period of
time under specified operating
conditions.
RELIABILITY
Further Definitions
elimination or avoidance of failure modes
the probability that a product will perform its
intended function:
o
under customer operating conditions
for a specified life
in a manner that meets or exceeds customer
expectations
a reliable product is robust and mistake-free
RELIABILITY
TYPES OF FAILURES
1. Functional failure
o failure that occurs at the start of product
life due to manufacturing or material
detects
2. Reliability failure
o failure after some period of use
RELIABILITY
TYPES OF RELIABILITY
1. Inherent reliability
o predicted by product design.
2. Achieved reliability
o observed during use.
RELIABILITY
Reliability Failure Modes
Two Types of Failure Mode
1. hard (when something breaks)
2. soft (when the performance degrades)
. Two Root Causes
1. lack of robustness
2. mistakes
MEASURES OF RELIABILITY
Failure Rate ()
number of failures per unit time
Infant mortality period
MEASURES OF RELIABILITY
Mean Time To Failure (MTTF)
average time of operation to first failure
Mean Time Between Failures (MTBF)
average time between product failures
STEPS IN DFR
1.Develop a Reliability Plan
2.Analyze Noise Factors
3.Tests for Reliability
4.Track Failures and Determine Corrective Actions
STEPS IN DFR
1.Develop a Reliability Plan
A reliability plan helps ensure that
product reliability is optimized within the
cost and performance constraints of a
program and customer requirements.
STEPS IN DFR
2. Analyze Noise Factors
a.Change the design concept
b.Make basic current design assumptions insensitive to
the noises design out failure
c.Insert a compensation device
d.Disguise the effect - Send the error state/noise
where it will do less harm
STEPS IN DFR
3. Test for Reliability
How robust are the products?
Test to Bogey: assessing performance at a predetermined time,
cycle or number of miles. It estimates the proportion of failures at a
particular time. pass/fail
Test to Failure: shows when a component or system can no
longer perform at a specified level
Degradation Testing: focuses on the key stresses associated
with real world uses for example - increasing the tire load to
create a tire failure
How can you shorten the reliability test time for new
designs?
Key Life Test/Accelerated Test
STEPS IN DFR
4.Track Failures and Determine Corrective Actions
This process involves:
Data collection and selection
Set up databases for tracking failures
Warranty, Early Warranty, Things Gone Wrong
Analyzing trends
Performing closed loop analysis/corrective action
Calculating observed reliability parameters
Assessing reliability growth.
RELIABILITY TOOLS
Block Diagram
Three Categories:
1. Series
1
RS = R1 R2 ... Rn
RELIABILITY TOOLS
Block Diagram
Three Categories:
2. Parallel
redundant
RS = 1 - (1 - R1) (1 - R2)... (1 - Rn)
RELIABILITY TOOLS
Block Diagram
Three Categories:
3. Complex
o
combination of series and parallel
Example of a complex block diagram:
RELIABILITY TOOLS
Example:
C
RA
RB
RC
RD
D
C
RC
Convert to equivalent series system
RA
RB
RD
C
RC = 1 (1-RC)(1-RC)
RELIABILITY TOOLS
Exponential Distribution Model
Note that the mean time between failure
(MTBF) in the infant mortality phase can
be modeled by a negative exponential
distribution.
The exponential distribution therefore can be used to
determine various probabilities of interest specially on the
analysis of equipment failures as well as product failures
since they usually occur in this pattern.
RELIABILITY TOOLS
Let T represent length of service, the
probability (P) that failure will not occur
before time T is given by
P (failure before T) = 1 eT/MTBF
Where e = 2.7183
T = Length of service before failure
MTBF = Mean time between failures
The probability (P) that failure will occur
before time T is given by
P (failure before T) = 1 eT/MTBF
RELIABILITY TOOLS
Normal Distribution Model
Product failure due to wear-out can
sometimes be modeled by normal
distribution
z =
T Mean wear-out time
Standard Dev of wear-out time
RELIABILITY TOOLS
P-Diagram
RELIABILITY TOOLS
QFD
RELIABILITY TOOLS
Failure
Mode and
Effects
Analysis
(FMEA)
RELIABILITY TOOLS
Design Verification Plan
RELIABILITY TOOLS
Design Verification Plan
Key Life Testing
Accelerated test designed to detect a major
component failure mode
Used to improve quality by designing reliability into
the product
Weibull Testing
Used to estimate the life of all products in the
population by fitting a statistical distribution to life
date from a representative sample of units
RELIABILITY TOOLS
Reliability Demonstration Matrix
Demonstrates whether a product has met
a certain reliability requirement with a
specific confidence
Usually performed at the system level and
is typical set up as a pass/fail system
RELIABILITY TOOLS
Reliability Demonstration Matrix
Demonstrates whether a product has met
a certain reliability requirement with a
specific confidence
Usually performed at the system level and
is typical set up as a pass/fail system
END
