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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

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