Reliability

What is Reliability?
Probability that a system or product will perform in a satisfactory manner for a given period of time when used under specified operating condition
Reliability is an integral part of how the company develops products and production systems Plan for it - Design for it - Do it (and verify) - Learn from it (and get even better)

Reliability Definition vs. the Real World

Reliability

is the probability that an item can perform its intended function for a specified interval under stated conditions following prescribed procedures. are Real World conflicts with this textbook definition that we need to keep in mind
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There

Reliability Definition vs. the Real World

Probability Customers expect a probability of 1, It Works Intended Function The product may be used in unintended ways and still be expected to work Under Stated Conditions The product may be operated outside of the stated conditions and still be expected to work Prescribed Procedures Customers may not have the required tools or skill level and may not follow procedures and still expect the product to work
Customers

are looking for Quality over Time

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Reliability vs. Quality

(Glesner, Kececioglu, et al.)

Reliability Assurance is the ability of a system or component to perform its required functions under stated conditions, for a specified period of time. Quality Assurance is a set of activities whose purpose is to demonstrate that a product meets all quality requirements.

Reliability - 4 main elements

1.

2.

Probability numerical representation - number of times that an event occurs (success) divided by total number trials Satisfactory performance criteria established which describe what is considered to be satisfactory system operation

Reliability - 4 main elements

3.

4.

Specified time measure against which degree of system performance can be related - used to predict probability of an item surviving without failure for a designated period of time Specified operating conditions expect a system to function - environmental factors, humidity, vibration, shock, temperature cycle, operational profile, etc.

Managing Reliability

Reliability Engineering A systems approach to planning for, designing in, verifying, and tracking the reliability of products throughout their life to achieve reliability goals.
Bathtub Curve

Early Life

Useful Life

Wearout
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Reliability Tools
Quality Function Deployment Life Cycle Cost

Corrective and Preventive Action

Awareness of Reliability Prediction, Maintainability Analysis, FMEA, DOE, Reliability Testing, Field Data Collection and Analysis
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Basic Reliability Terms

Failure - A failure is an event when an item is not available to perform its function at specified conditions when scheduled or is not capable of performing functions to specification. Failure Rate - The number of failures per unit of gross operating period in terms of time, events, cycles.

MTBF - Mean Time Between Failures - The average time between failure occurrences. The number of items and their operating time divided by the total number of failures. For Repairable Items
MTTF - Mean Time To Failure - The average time to failure occurrence. The number of items and their operating time divided by the total number of failures. For Non-repairable Items

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Basic Reliability Terms

Maintainability - A characteristic of design, installation and operation, usually expressed as the probability that an item can be retained in, or restored to, specified operable condition within a specified interval of time when maintenance is performed in accordance with prescribed procedures. MTTR - Mean Time To Repair - The average time to restore the item to specified conditions. Maintenance Load - The repair time per operating time for an item.

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Basic Reliability Terms

Overall Equipment Effectiveness - A measure of a production systems ability to meet requirements for availability, efficiency, and yield. This represents the systems ability to operate, at specified production rate, to specified quality standards, when needed. Availability - A measure of the time that a system is actually operating versus the time that the system was planned to operate. Efficiency - A measure of the actual production rate that a system produces product versus the specified production rate of the system. Yield - A measure of the portion of product that meets defined product quality specifications versus the total amount of product produced.

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Overall Equipment Effectiveness

Overall Equipment Effectiveness is a measurement of a production systems ability to meet requirements for availability, throughput, and quality. It is a percentage calculation that represents the portion of the time that the system is operating, at specified production rate, to specified quality standards versus the time that the system was planned to operate. OEE = Availability x Efficiency x Yield
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Overall Equipment Effectiveness

OEE = Availability x Efficiency x Yield

How is the Production System performing? Is it running?

Availability = Uptime / (Uptime + Downtime)

Efficiency = Design Cycle Time / Actual Cycle Time

At design rate? Are the parts good?

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Yield = Good Parts / Total Parts

What Would You Try To Improve?

System OEE Effectiveness 85% = 70% = 66% = 64% = Availability 90% Efficiency 95% Yield 98%

75%
90% 90%

95%
75% 95%

98%
98% 75%
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Basic Calculations
Suppose n0 identical units are subjected to a test. During the interval (t, t+t), we observed nf(t) failed components. Let ns(t) be the surviving components at time t, then the MTTF, failure density, hazard rate, and reliability at time t are:
MTTF

t
i 1

n0

n0

(t ) n f (t ) f n0 t (t ) P (T t ) ns (t ) R r n0

(t ) n f (t ) , ns (t )t

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Basic Definitions Contd

The unreliability F(t) is

F( )t 1 ( R t )
Example: 200 light bulbs were tested and the failures in 1000-hour intervals are

Time Interval (Hours) 0-1000 1001-2000 2001-3000 3001-4000 4001-5000 5001-6000 6001-7000 Total

Failures in the interval 100 40 20 15 10 8 7 200

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Calculations
Time Interval
Time Interval (Hours) 0-1000 1001-2000 2001-3000 3001-4000 4001-5000 5001-6000 6001-7000 Failures in the interval 100 40 20 15 10 8 7

Failure Density Hazard rate f (t ) x 104 h(t ) x 104

100 5.0 200 103 100 5.0 200 103

0-1000

1001-2000 2001-3000 6001-7000

40 2.0 200 103

40 4.0 100 103 20 3.33 60 103

20 1.0 200 103

..
7 0.35 200 103

7 10 7 103
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Total

200

Failure Density vs. Time

10-4

x 103

Time in hours
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Hazard Rate vs. Time

10-4

103

Time in Hours
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Calculations
Time Interval (Hours) 0-1000 1001-2000 2001-3000 3001-4000 4001-5000 5001-6000 6001-7000 Total Failures in the interval 100 40 20 15 10 8 7 200
6001-7000 7/200=0.035

Time Interval 0-1000 1001-2000 2001-3000

Reliability R(t ) 200/200=1.0 100/200=0.5 60/200=0.33

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Reliability vs. Time

7 x 10 3

Time in hours
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Exponential Model Contd

Statistical Properties

MTTF

1
1

5 106

Failures/hr

MTTF=200,000 hrs or 20 years

Variance

2
1
Median life =138,626 hrs or 14 years
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Median life (ln ) 2

Reliability Function
1.2

Reliability0.8
0.6

0.4

0.2

0 0 200 400 600 800 1000 1200

Time

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