Reliability

VIT – HCL 2019
SMART Engineering Team-HCL Technologies Ltd
Copyright © 2018 HCL Technologies Limited | www.hcltech.com

Agenda
 Introduction of HCL and SMART Team 3 Mins
 Introduction to Reliability 5 Mins
 Industrial Expectations for Reliability Engineers 3 Mins
 Benefits of using Reliability Engineering in Industry 2 Mins
 Growth Pattern for Reliability Engineers 2 Mins
 Case Study :
 Case Study 1: Reliability Engineering in Mechanical Domain 20 Mins
 Case Study 2: Reliability Engineering in Hardware Domain 20 Mins
 Case Study 3: Reliability in Wind Energy 20 Mins
 Q&A 15 Mins
2 Copyright © 2018 HCL Technologies Limited | www.hcltech.com

SMART ENGINEERING SERVICES Overview
$7.6 BILLION
32 COUNTRIES
119,000 P E O P L E
 Access to one of
Best Reliability
Team in the
Industry
 Strong experience
from different
domain brings in
knowledge base of
Do and Don’ts
 Methodologies,
processes and best
practices leverage
 Experience on
reliability tools /
Engineering TEAM software
What is Reliability?
• “The Probability (%) that a system will perform its

intended function (Customer/System requirement) for a
given period of time
(Hours/Cycles/Mileage/Counts/Operations) under
specified operating conditions”.
• Simply, a system working for long time without any problem is

considered as reliable product whereas if it frequently fails to meet the
requirement it is considered as unreliable product

Reliability Terminologies
Failure Rate
Reliability % PPM
Mean Time Between Failure

B10
(MTBF)
Warranty Maintainability
Availability
Why we should do Reliability?
• To determine the that to what extent the system/component can endure before
failing.
• To know the design weaknesses in the system/component and take corrective

steps.
• To uncover all potential failures which could be available in the field and to
reduce the surprise of failures in the field.
• A system/component is said to have a high reliability if it produces similar results

under consistent conditions.
• To determine the Failure rate , Maintenance Period and other parameters related
to the system/component.
6 | Copyright © 2019 HCL Technologies Limited | www.hcltech.com
Cost of Unreliability
COST OF FAILURE Before we go deeper, lets refresh again to know WHY should I learn Reliability?
• Unreliable System fails very often.
• The costs of this unreliability is very high
• Major affect on the company’s reputation and brand name.
• Reliability Engineering analysis helps to minimize not just cost of failure, but entire life cycle cost.
•Warranty Costs
• Field Repair Costs
• Product Service Indirect Costs

• Inventory Costs for Spares
• Customer Visit T&L

• Root Cause Investigation Costs
• Engineering Support Costs • Lost Sales w/ impacted Customers
• Concession Costs • Impact of Failures on Customers
• Product Recall Costs • Lower Margins on new Jobs
WHAT RELIABILITY CAN DO FOR ME?
• Systematic approach for addressing the following:
• What is the expected life of the product in field?
• What are the hard and soft failure modes?
• How do I design in a longer life (robustness, redundancy, etc.)?
• What will be my warranty and life cycle cost?
• What are the potential Safety Issues in the product design?
• How do I test the product more efficiently?
• What supplier metrics should I have (parts and equipment)?
• How do I maintain the product (preventive, corrective etc.)?

Industrial Expectations for Reliability Engineers and Growth Pattern
 Strong with engineering fundamentals
 Enthusiastic to learn new concepts
 Analytical thinking to quickly solve customer problem
 Communicate the problem statement and solution effectively
 Cross-Collaboration with multiple stakeholders and complete the

project effectively
 Upgrade to New Technologies

Services in Medical Devices
• Bottom to Top Approach • Risk Management Plan
Cognition Cockpit • Boundary Diagram • Product Risk Threshold
• Parameter Diagram • Risk Assessment
Weibull++ • Material & Non-Material Transformation • Risk Estimation
ALTA • Failure Modes & Effects Analysis • Risk Evaluation
• Risk Control
• Overall Residual Risk Evaluation
Risk • Risk Benefit Analysis
• Top to Bottom Approach Management • Post-Production Control
D/P/A
• Fault Tree of Top un-desired FMEA • Risk Management Report
Event
• Logic Gates (Boolean Algebra)
• Probability Estimation Fault Tree
Analysis
Tools
Minitab Reliability
MED 7 • Test Objective Testing
• Test Plan
• Test Protocol
Statistical Analysis Software • Test Execution Post-Market
• Test Data Analysis & Inference Surveillance Compliance
• Test Report
PQDR
• Complaints Data Collection • FDA

• Data Cleaning, Grouping & • EU MDR
Categorization • Complaints Trends
• 510K PMS
• Hazard, Haz-Sit and Harm • Performance Dashboard
Identification • Dynamic Reporting
• Probability Estimation • Process Improvement
• Risk Calibration • Complaint Board Meeting
Services in Aerospace
Reliability Across Lifecycle Services
• Reliability Plan & Approach
• PSSA & SSA
• Reliability Prediction (Parts count /Parts
In- Stress)
Service
Production • Fault Tree Analysis (FTA)
Development • FMEA / FMECA (LRU & System level)
Design
• Design FMEA HCL Reliability Team
Feasibility
• Functional FMEA /FMES consists of Engineers
• Process FMEA from Mechanical,
• Common Mode Analysis Hardware and Software
Reliability Analysis
• Functional Failure Path Analysis (FFPA) background
• Intrinsic & Environmental Condition HA
 Biggest and best skilled pool of RMS Engineers in • BIT / testability Analysis
various disciplines across
 Design Certification requirement meeting FAR & ARP • Logistic Support Analysis (LSA) – GSE, M&O  Reliability COE consists of 60+ Engineers
4761 • Warranty & Reliability Analysis with Failure in various disciplines
 Supporting Design Studies Data
 Differentiator for HCL
 20 Engineers working in Aero projects
• Maintainability Analysis
 Successful onsite deployment with happy customers
 Representation of Customer at his customer for critical • Reliability Test Plan (HALT/RGT/ALT)
skill presentations • Functional Hazard Analysis (FHA)

Service in Automobile and Industrial Domain
Reliability
Reliability Weibull
Goal Warranty Nevada
Allocation Analysis
Setting Forecast Chart
Warranty
Functional
Reliability Reliability Analysis Warranty
Block
Prediction Testing Cost
Diagram
Baseline
Study
Design For SMART FMEA

Reliability
Services
DFMEA AIAG STD

VDA STD
PRAT
Reliability AFMEA PFMEA

Testing
RDT RGT

Functional Safety Services across domains
Provide End to End Certification Support Applicable to all
Electronic industries
Functional Automobile
Hazard
Safety Life
cycle Analysis IEC 61508
ISO 26262
SIL/ASIL Risk De-Rating
Allocation Analysis Analysis
ʎ
Process
FTA Systematic
Capability IEC 61511
FMEDA SPFM
EN 50129 Off-Road
Reliability SAFETY Vehicles
LPFM Railway
Prediction LIFECYCLE
SUPPORT

Business Intelligence - Data Analytics
 Data Mining
 SAS Base
 R
 Python
 BI / Visualization
 SAS
 Tableau
 QlikView
 Power BI
 MS Excel
 Data Processing
 SAS
 SAP
 Minitab
 Data Storage
 MS Access
 MySQL

Recent Researches-Replication of Field Scenario in Testing
Challenges Faced:
• Customer was denied new business
by an major truck manufacturer in
North America owing to their poor
warranty, poor reliability and the
Defining operating Identified Failure modes
complication in the new NPD conditions and functional from warranty analysis and
requirements FMEA
• The OEM demanded higher
reliability demonstration from the
customer to award the business
• The system is more complicated
than the existing HVAC unit Calculate Sample size and test
duration
Accelerated Test Profile
Conventional Vibration testing Measure and Record
• Based on any international standard • Measure actual vibration
• Use a PSD vs HZ, with break point from the field or test track
table • Record the vibration data
• Most of the time have higher
excitation energy level Analyze, edit and combine
• Remove dead space,
Disadvantage: unwanted recordings
• Do not represent actual field condition • Combine multiple waveforms
• Total fatigue damage in the test is not
equivalent to field condition
• Low shock levels
Dead Space
• Do not uncover field failures

Frequency Range and filtering Compute Fatigue Damage Spectrum
• Determine test frequency range • Understand the damage to be incurred in the system
• What frequency will affect the product? using available data
• High frequencies will increase peaks and
RMS
• Low frequencies will increase overall
displacement
Save the waveform
• After select the low frequency and high
frequency ranges, save the wave form
Draft Test plan

• Calculate the life or test duration to be tested
• Compute the fatigue damage spectrum for the required
duration that create damage equivalent to the
measured data
• Convert the FDS to equivalent PSD vs Hz and break
point table
Recent Researches
Field Replication- Fatigue Damage Spectrum
Measure & Analyze, Edit & Fatigue Damage Spectrum Test Profile
Record Combine
Condition Based Monitoring
Physics of Failure approach for Electronics
Design import & Life Profile modelling 3D distribution of Time to Failure plots
PCB modelling & Meshing stress

Challenges Faced
Domain: Automobile
Product: Blower Speed Controller
Description
• An speed controller used in automotive HVAC blower
• The failure rate of the blower controller is high in the winter
and less in the field
• The root cause of the failure was analyzed and an corrective
action is in Place
• The controller is in the path of the airflow, hence hot air
heats the controller and eventually fails Other Challenges:
Requirement • Text mining to build a dynamic warranty
• More than 3K parts are in field database
• Need to estimate the warranty returns of the parts • Estimation of Solar panel life mounted
to prepare for the replacement on the top of the truck
Challenges:
Different heat exposures makes the conventional reliability
model no feasible for this product

Reliability Prediction - Methodology
Models such as Telcordia,

217 Plus, Prism exists
Model Parameters include, but not limited to the
following:
1. Application Environment – Ground / Air /
Automotive etc
2. Operating Temperature & Temp Rise over
Ambient
3. Part Quality
4. Electrical Stress Levels

Sample Schematic & Bill of Material
Item Qty Component Description Manufacturer P/N Designator

1 1 Res, 75 K Resistor Generic R1
2 1 Res, 4.7 M Resistor Generic R2
5 1 Pot, 500 K Potentiameter CTS Electrocomponents 448XD2504BDN R5
7 2 74HCT74 Frequency Comparator NXP Semiconductors 74HCT74 A,B
8 3 ZVNL110 MOSFET Diodes Incorporated ZVNL110A Q1, Q2, Q3
9 1 Cap, 10 uF, Tant. Tantalum Capacitor Generic C1
10 2 Cap, .01 uF, Tant. Tantalum Capacitor Generic C2, C4
11 1 Cap, .001 uF, Tant. Tantalum Capacitor Generic C3, C7
12 2 Cap, 47 pF, Tant. Tantalum Capacitor Generic C5, C6
13 1 1.5 V Battery Lithion Ion Battery Generic Bat 1
14 1 Motor Brushless DC-Servomotor Faulhaber 1628T M
15 1 12 V Battery 12 Battery Generic Bat 2
16 2 Housing Housing Wise Plastics TBD -

De-rating Analysis
• Identify the over-stressed components

− Both Thermal & Electrical
• Electrical Overstress
− Based on Voltage / Current / Power rating – Rated Vs. Actual
• Thermal Overstress
− Calculation of Junction Temperature based on Power Dissipated and actual Ambient Temperatures
− IR Imaging to assess the Hot Spots
• Generate Reliability Critical Item List
• Identify Alternate parts for improved margin.

De-rating Analysis
Electrical De-rating
Thermal De-rating

Prediction Model Data
Other Assumptions used for Calculations

1. Quality Level I
2. 15 Deg C Temperature Rise
3. Electrical Stress Levels – 50% for all components where we have models request that info –
Res, Cap, MOSFET etc
4. GB Env considered

PoF Based Models
• Science based Approach
• Analyses Loads and Stress during application
• Verifies it against the ability of materials to endure them

− From Strength &
− Mechanics of Material point of view
• Primarily used for Mechanical components
• Due to advancement in computing power of PCs, it is now possible to extend this to Electronic CCAs.

PoF Models for CCAs – What it can predict
Start
• Plated through hole (PTH) lifetime
Collect Inputs
• Solder Joint Lifetime Import Inputs –

Profile, PCB & Part
− Under thermal cycling Properties
− Under Vibration Analyse CCA for Vibration,
Shock , Thermal , CAF &
Failure Rate Estimates
• Interconnect failures during mechanical shock
Import Inputs –
Profile, PCB & Part
• MTBF Calculation - Properties
Summarize & Report

• Estimate the risk of Conductive anodic filament (CAF) the findings
formation
End
Inputs
• Inputs
− ODB++ file of CCA
− Operational Profile
▫ Thermal – Cycles
▫ Mechanical Shock Profile
▫ Harmonic Levels
− Part Details
− PCB – Stackup & Layer info

Analyses
Analyse the CCA for

 Vibration – Harmonic &
Random
 Shock
 Solder Fatigue
 Thermal De-rating
 ICT
 Failure Rate
 CAF

Outputs
Provides the detailed report on

the following.
 Reliability Curve
 Top 10 Lowest Time To Fail
(TTF) components
 Vibration & Shock
distribution pattern
 Thermal Analysis results

Summary
• Prediction can be based on either

− Handbook Based
− Physics of Failure
− Field Data
• Effective during early Design Stages (Even before first Prototype)

− Identifies the design Weakness
− Compare designs / products
− Basis for Test Planning

HALT Objective
• To uncover design and/or process weaknesses
• To uncover latent defects in product design, component selection and / or manufacturing process that would not
otherwise be found through conventional qualification methods.
• To assess design robustness and
• To determine design margin.

HALT Process
Product Understand tailoring

Understand Health
Understanding – required in
Monitoring Mechanical Fixturing
Modes of Operation, SW/Firmware for
Requirements
Inputs, Outputs etc., Test
Determine the Stress

Profiles Test Plan Dry Run Test Execution
Failure Analysis Data Analysis Final Report

HALT – Stress Profiles

Test Set-up – Data Monitoring
Thermal & Vibration Monitoring Unit Health Monitoring

HALT Test Report - Contents

FRACAS

Case Study: Effect of Reliability Engineering in Wind Turbine

Making Reliable Wind Turbine ?
https://www.cbc.ca/news/canada/windsor/faulty-blade-that- https://www.rechargenews.com/wind/1711006/ge-turbine- https://www.windpowermonthly.com/article/1347145/an

caused-wind-turbine-collapse-cost-company-6m-1.4647617 collapses-at-nexteras-latest-us-wind-farm nual-blade-failures-estimated-around-3800

Customer Problem Statement

The Wind Turbines are already existing in the field. Need to increase the profitability of the business with increased reliability for our products in the field.
Can we reduce the cost spent by the company for the products which is already existing in the field ?
Your Views ?
Yes we can reduce the cost !!!!

Field Data Collecting Data from Database Scrubbing and Filtering

HCL Solution  Identify Potential Failure Modes

Field Data Analysis in the product
Analysis of Field Data with identification of key failure components/ sub-system
in the field  Optimize the design with
Failure Pattern
recommendations or solutions
Perform Weibull Analysis and identify Failure Pattern in the field and
identification of Reliability over a period of time. Provide recommendations  Suggest Maintenance Strategy
with extensive RCA. & Effective Availability of the
Wind turbine in the field
Reliability Block Diagram
Identification of Weak elements in the design which are contributing to
overall system Un-Reliability
 Cost optimization with
suggestions or identify focus
area.
Maintenance Strategy & Cost Optimization Maintenance & Cost
Suggest Optimal replacement strategy and identify potential cost RBD
incurring sub-system and provide recommendations to design team
Failure Pattern
FDA

 Perform Analysis using R-Studio to calculate the Time to failure
Field Data Analysis - R Studio
 Using Minitab / R Software calculate the Eta and Beta for each failed
components/sub-system
 Update the eta and beta value to Block Sim (Simulation based Reliability Software)
 Perform Maintenance & Cost Optimization using Excel
 Add-on:
 We can provide Predictive Modelling (Machine Learning) for Maintenance
 Create a tool based to perform the analysis repetitive for all sub-systems
 Provide the inputs of failures to design team for re-design of the system
Failure Pattern - Minitab Maintenance & Cost Optimization - Excel

Reliability Block Diagram - Blocksim

Data Gathering, Filtering, and Scrubbing
 Gather the data from SQL Via R- Programming. Perform Filtering, Scrubbing of unwanted data from the data table and have a much better quality output.
 You can also use Python as an alternative / any other language to do it.
 You can perform the same in SQL as well, the reason to do this is to visualize the raw data and understand how the population is working in the field.
 Calculation of Time to Failure is happening and output is tabulated separately.

Weibull Analysis of Failure Data
 With the output data of time to failure from R-Studio, we can plot the Weibull graph to get the eta and beta values.
 This shows how the failures are distributed in the field for the deployed products
 You can perform the analysis either using Minitab software or dedicated software's like Weibull++.
 Output of Parameters are taken from this analysis

Reliability Simulations
 With the output data of reliability parameters, reliability block diagram is performed and given as input
 This diagram represents the system level simulation of reliability and all the input from each components from previous step are given as input into each block.
 You can perform the analysis using BlockSim which are block based design based on either the components are connected in series and parallel.
 System Level Output for reliability is calculated.

Maintenance and Cost Optimization
 From the above analysis Maintenance Strategy and Cost Optimization is done for the system and sub-system.
 The time to replace the components are identified from this analysis, which gives maximum availability of the system and on the meantime also increases the
reliability.

$7.6 BILLION ENTERPRISE | 119,000 IDEAPRENEURS | 32 COUNTRIES

Reliability

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VIT – HCL 2019

SMART Engineering Team-HCL Technologies Ltd

Copyright © 2018 HCL Technologies Limited | www.hcltech.com

 Introduction to Reliability 5 Mins

 Industrial Expectations for Reliability Engineers 3 Mins

 Benefits of using Reliability Engineering in Industry 2 Mins

 Growth Pattern for Reliability Engineers 2 Mins

2 Copyright © 2018 HCL Technologies Limited | www.hcltech.com

• “The Probability (%) that a system will perform its

• Simply, a system working for long time without any problem is

4 Copyright © 2018 HCL Technologies Limited | www.hcltech.com

Mean Time Between Failure

• To know the design weaknesses in the system/component and take corrective

• A system/component is said to have a high reliability if it produces similar results

• Product Service Indirect Costs

• Customer Visit T&L

8 | Copyright © 2019 HCL Technologies Limited | www.hcltech.com

 Strong with engineering fundamentals

 Enthusiastic to learn new concepts

 Analytical thinking to quickly solve customer problem

 Communicate the problem statement and solution effectively

 Cross-Collaboration with multiple stakeholders and complete the

 Upgrade to New Technologies

• Complaints Data Collection • FDA

11 Copyright © 2018 HCL Technologies Limited | www.hcltech.com

Design For SMART FMEA

DFMEA AIAG STD

Reliability AFMEA PFMEA

12 Copyright © 2018 HCL Technologies Limited | www.hcltech.com

13 Copyright © 2018 HCL Technologies Limited | www.hcltech.com

14 Copyright © 2018 HCL Technologies Limited | www.hcltech.com

16 Copyright © 2018 HCL Technologies Limited | www.hcltech.com

Draft Test plan

Condition Based Monitoring

Physics of Failure approach for Electronics

18 Copyright © 2018 HCL Technologies Limited | www.hcltech.com

19 Copyright © 2018 HCL Technologies Limited | www.hcltech.com

Models such as Telcordia,

20 | Copyright © 2019 HCL Technologies Limited | www.hcltech.com

Item Qty Component Description Manufacturer P/N Designator

21 | Copyright © 2019 HCL Technologies Limited | www.hcltech.com

• Identify the over-stressed components

• Generate Reliability Critical Item List

• Identify Alternate parts for improved margin.

22 | Copyright © 2019 HCL Technologies Limited | www.hcltech.com

23 | Copyright © 2019 HCL Technologies Limited | www.hcltech.com

Other Assumptions used for Calculations

24 | Copyright © 2019 HCL Technologies Limited | www.hcltech.com

• Science based Approach

• Analyses Loads and Stress during application

• Verifies it against the ability of materials to endure them

• Primarily used for Mechanical components

25 | Copyright © 2019 HCL Technologies Limited | www.hcltech.com

• Solder Joint Lifetime Import Inputs –

Summarize & Report

27 | Copyright © 2019 HCL Technologies Limited | www.hcltech.com

Analyse the CCA for

28 | Copyright © 2019 HCL Technologies Limited | www.hcltech.com

Provides the detailed report on

29 | Copyright © 2019 HCL Technologies Limited | www.hcltech.com

• Prediction can be based on either

• Effective during early Design Stages (Even before first Prototype)

30 | Copyright © 2019 HCL Technologies Limited | www.hcltech.com

• To uncover design and/or process weaknesses