7-Reliability Fundamentals - Session-1-17-Jul-2019Material II 17-Jul-2019 RELIABILITY FUNDAMENTALS Session 1

Reliability Fundamentals
Session - 1
Copyright © 2018 HCL Technologies Limited | www.hcltech.com

Agenda
 Introduction
 Basics of Reliability Engineering

 Need
 Terms / Terminology
 Roles & Responsibilities of a Reliability Engineer
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
Why Reliability? Who needs Reliability?
• Consumer and Customer demands Warranty
• Demands Life of the product
• Market competition
• Manufacturer Liability
• Competitive advantage
• Diverse market needs

Reliability – Why?
Perhaps most important, X Company’s reputation has been damaged.
Lost business opportunities partially due to poor reliability. Some customer

is also expressing disappointment.

Reliability – Why?
Three important statements summarize the best practice reliability
philosophy of successful companies:
1) Reliability must be designed into products and processes

using the best available science-based methods.
2) Knowing how to calculate reliability is important but, perhaps even more

is knowing how to achieve reliability.
3) Reliability practices must begin early in the design process and

must be well integrated into the overall product development cycle.
One more: Flow down of reliability requirements to component

suppliers is critical to system reliability.
OEM & Supplier needed as strong partner!

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
Life of the product
Statistics Physics – Load (Stress)
7
Reliability is Quality over Time! Copyright © 2018 HCL Technologies Limited | www.hcltech.com
Role of Reliability Engineer
Key Role: Reliability
Plan
 Involve from the beginning of Statistical

Analysis
Criticality
Analysis
project
 Coordinate with all stakeholders New
Reliability Equipment
in project…Design team, Quality Reporting specificatio
n
team, Testing team, Supply Reliability
chain management team, Engineer
Manufacturing team etc.. Reliability Perform

Test Plan FMEA/RCM
 Active participating in Root

cause analysis, FMEA and other
Asset Root Cause
activities Manageme
nt Strategy
Failure
Analysis
Measure
 Ensure Reliability Met Key Metrics

Responsibility of Reliability Engineer
Key Responsibility:
Ensure
Reliability
 Bring and Maintain the
Reliability culture with in the Reliability
Reporting
Reliability
Culture
team and Organization level

 Ensure active participation from
Bridge
all stakeholders for FMEA and Asset Reliability between
Management Project team
Engineer
RCA Strategy and
Management
 Update the status to

Management
Team Active
Monitor Key
participation
Metrics
– RCA, FMEA
Reliability Test
Execution

Ethics of Reliability Engineer
 Being sensitive to changes in the attitudes of others
 Accepting responsibility for personal mistakes
 Exhibiting a positive outlook and seeking value in

achievement
 Protecting the employer’s confidential information

Benefits of Reliability
 Avoid over Engineering
 Increase Availability
 Increase Throughput
 Reduce Inventory
 Reduce Injuries and Loss of properties
 Focus on New Product Development

Introduction to Reliability
Early Life Useful Life Wearout Life

Instantaneous Failure Rate
Unanticipated variation in: Degradation

Poor Mfg
Environment Fatigue
Poor Inspection
Application Corrosion
Poor QC
Materials (failure rate increases w/ time)
(failure rate decreases w/ time)
(failure rate approx constant)
External
Production
Stress Failures
& Design Defects

Introduction to Reliability
Reliability Engineering is a combination of Physics, Statistics and Engineering
into one discipline.
Statistics Physics
• Quantifying • Physics of
Reliability failure
• Sample size • Failure modes
estimation
Engineering
• Robust Design
• Usage profile study
• Engineering Analysis

Reliability Metrics
Failure Rate λ
% of Reliability % of Confidence Level
B10 Life PDF & CDF
Mean Time Between Failure

Maintenance
(MTBF) & MTTF
Safety PPM
Availability
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 Design for Reliability (DFR) 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.)?

Generic DFR Process
1 Reliability Goal Setting
2 Reliability Plan Development
3 Identify Critical sub systems and components
4 Construct Functional Block Diagram
5 Allocate Reliability Target
6 Generate Life / Reliability Predictions
7 Develop P-Diagrams
8 Develop FMEA
9 Define and Execute Reliability Test Strategy
10 Track Field / Lab Failures
Is Field / Lab
Improve the No Reliability meets Yes Sustain to reproduce same
Engineering Design desired allocated Reliability over time
reliability
Important to Know
• Failure and Failure Rate
• Hazard/Instantaneous failure rate
• Data
• Type of Data
• MTBF
•MTTF
•Availability & Maintainability

RAMS
• 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”.
Availability – as ability to keep a functioning state in the given

environment.
Maintainability – as ability to be timely and easily maintained

(including servicing, inspection and check, repair and/or
modification).
Safety – as ability not to harm people, the environment, or any

19
assets during a whole life cycle Copyright © 2018 HCL Technologies Limited | www.hcltech.com
Failure and Failure Rate
Failure - when an System can no longer perform its required function as specified
Failure Rate (, FR)

The ratio of the number of failures within a sample to the cumulative operating time.
Example:
Two motors fail from a sample of 1000 after all were used constantly for a week.
What is the Failure Rate?
2 failures 2
Failure Rate   failures / hour
1000 * 24 * 7 hours 168,000
= 1.19E-5 failures/hr
Hazard/Instantaneous failure rate
Hazard Rate [h(t)]
The "instantaneous" probability of failure of an item given that it has survived up
until that time. Sometimes called the instantaneous failure rate.
• Hazard measures the conditional probability of a failure given the system is
currently working
• The failure density (PDF) measures the overall speed of failures
• The Hazard/Instantaneous Failure Rate measures the dynamic (instantaneous)
speed of failures
• To understand the hazard function we need to review conditional probability and
conditional density functions (very similar concepts)
Example:
Two motors fails each year from an initial population of 100.
What is the hazard rate at the end of 5 years?
8 motors have already failed leaving 92 operating;
So, the fifth cumulative failure is two failure out of 92 surviving
Hazard rate (in year 5) = (2 failure/year) / 92 Units surviving = 0.0217 failures / yr.
Failure Rate vs. Hazard Rate
Failure Rate Hazard Rate
- Constant with respect to time - A function of time
- An “average” - “Instantaneous”
“Instantaneous”
0 .0 0010 0
Hazard Rate
Probability of Failure
“Average”
Failure Rate
0 .0 0009 5
0 .0 0009 0
0 1000 0 2 0000 30 000 400 00 5000 0
Time
What is Data?
Data is a collection of facts, such as numbers, words, measurements, observations or even just descriptions of things.
Complete Data Censored Data-Right Censored Data
Types of Data
 Complete Data
 Interval Data
 Censor Data
 Right
 Left
Censored Data-Left Censored Data Censored Data-Interval Censored Data

Mean Time Between Failures (MTBF)
Mean Time Between Failures [MTBF]
For a repairable item, the ratio of the cumulative operating time to the
number of failures for that item.
(also called Mean Cycles Between Failures, MCBF, etc.)
Example
A motor is repaired and returned to service six times during its life and
provides 45,000 hours of service. What is the motor’s MTBF?
Total operating time 45,000

MTBF    7,500 hours
# of failures 6
MTBF or MTTF is a useful metric if the rate of failure is constant.

Mean Time To Failure (MTTF)
Mean Time To Failure [MTTF]
For non-repairable items, the ratio of the cumulative operating time to the
number of failures for a group of items.
(also called Mean Cycles To Failure, MCTF, etc.)
Example
1000 motors are operated for one week.
During that time, two failures occur.
Total operating time 1000 * 7 * 24
MTTF    84,000 hours
# of failures 2
For any given period,

Maintainability
Maintainability:
Measure of the ability of an item to retained or restored to a specific condition when maintenance is
performed by personnel having specified skill levels, using prescribed procedures and resources, at
each prescribed level of maintenance and repair.
The probability that the product will perform its intended function at any time, when used under
stated operating conditions (uptime).
Mean time to Repair (MTTR)
where:
MTBF = Mean Time Between Failure
MTTR = Mean Time To Repair an item (total time to restore service)
Availability requirements dictate spares & maintenance cycles.

Availability
Mean Availability
The probability that the product will perform its intended function at any
time, when used under stated operating conditions (uptime).
MTBF
Mean Availability (uptime / total time) =
MTBF + MTTR
where:
MTBF = Mean Time Between Failure
MTTR = Mean Time To Repair an item (total time to restore service)
Availability requirements dictate spares & maintenance cycles.

Availability Example 1
Switchgear
A switchgear lineup consists of a number of breakers. The system fails at
a rate of 0.000115 failures/hr. When a failure occurs, it takes 4 weeks to
change out the faulty breaker (delivery & installation).
What is the mean availability of the system?
1
MTBF = = (1.15E-4)-1 = 8696 hours
l
MTBF 8696
Availability = =
MTBF + MTTR 8696 + 4(7 week
days
)(24 )
hours
day
Availability = 92.83%

Reliability – Product Life Cycle Engineering

Abbreviation
ALT Accelerated Life Test
CDF Cumulative Density Function
CFD Computational Fluid Dynamics
CTQ Critical To Quality
DFR Design For Reliability
DFSS Design For Six Sigma
DOE Design Of Experiments
FBD Functional Block Diagram
FEA Finite Element Analysis
FIT Failure In Time
FMEA Failure Modes and Effects Analysis
FRACAS Failure Reporting Analysis and Corrective Action System
FTA Fault Tree Analysis
HALT Highly Accelerated Life Test
KCP Key Control Parameter
KNP Key Noise Parameter
MCTL Mean Cycles To Failure
MLPL Mechanical Life Prediction Library
MTBF Mean Time Between Failures
MTTF Mean Time To Failures
MTTR Mean Time To Repair
PDF Probability Density Function
P-Dig Parameter diagram
PDM Product Development and Management
POF Physics Of Failure
QFD Quality Function Deployment
RBD Reliability Block Diagram
RPN Risk Priority Number
SCR Service Call Rate
$7.6 BILLION ENTERPRISE | 119,000 IDEAPRENEURS | 32 COUNTRIES

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Reliability Fundamentals

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

 Basics of Reliability Engineering

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

• Demands Life of the product

• Diverse market needs

Perhaps most important, X Company’s reputation has been damaged.

Lost business opportunities partially due to poor reliability. Some customer

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

1) Reliability must be designed into products and processes

2) Knowing how to calculate reliability is important but, perhaps even more

3) Reliability practices must begin early in the design process and

One more: Flow down of reliability requirements to component

OEM & Supplier needed as strong partner!

 Involve from the beginning of Statistical

Manufacturing team etc.. Reliability Perform

 Active participating in Root

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

team and Organization level

 Update the status to

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

 Being sensitive to changes in the attitudes of others

 Accepting responsibility for personal mistakes

 Exhibiting a positive outlook and seeking value in

 Protecting the employer’s confidential information

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

 Reduce Injuries and Loss of properties

 Focus on New Product Development

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

Early Life Useful Life Wearout Life

Unanticipated variation in: Degradation

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

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

% of Reliability % of Confidence Level

B10 Life PDF & CDF

Mean Time Between Failure

• Product Service Indirect Costs

• Customer Visit T&L

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

2 Reliability Plan Development

3 Identify Critical sub systems and components

4 Construct Functional Block Diagram

5 Allocate Reliability Target

6 Generate Life / Reliability Predictions

9 Define and Execute Reliability Test Strategy

10 Track Field / Lab Failures

• Hazard/Instantaneous failure rate

•Availability & Maintainability

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

Availability – as ability to keep a functioning state in the given

Maintainability – as ability to be timely and easily maintained

Safety – as ability not to harm people, the environment, or any

Failure Rate (, FR)

0 1000 0 2 0000 30 000 400 00 5000 0

Censored Data-Left Censored Data Censored Data-Interval Censored Data

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

Total operating time 45,000

MTBF or MTTF is a useful metric if the rate of failure is constant.

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

For any given period,

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

Mean time to Repair (MTTR)

Availability requirements dictate spares & maintenance cycles.

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