Beruflich Dokumente
Kultur Dokumente
RELIABILITY
CIELO
GRAGG
MAIGUE
REYES
SILVESTRE
WHAT IS RELIABILITY?
Elimination/avoidance of failure modes/mistakes
The probability that a product will perform its intended
function:
Under customer operating conditions
For a specified life
In a manner that meets or exceeds customer
expectations
MAJOR PHASES OF A
TYPICAL DFR PROGRAM
Define
Identify
Analyze and Assess
Quantify and Improve
Validate
Monitor and Control
DEFINE
The purpose of this stage is to clearly and quantitatively
define the reliability requirements and goals for a product as
well as the end-user product environmental/usage conditions.
These can be at the system level, assembly level, component
level or even down to the failure mode level.
TOOLS:
Goal Setting; Develop Metrics; Benchmarking; Gap Analysis;
Reliability Program Plan Writing; Quality Function Deployment
(QFD)
IDENTIFY
In this stage, a clearer picture about what the product
is supposed to do starts developing.
TOOLS:
Reliability Prediction (compare design alternatives,
identify preferred components and suppliers); Cost
Trade-offs; Tolerance evaluation; Better understanding
of customer specifications; Failure Modes and Effects
Analysis (FMEA); Fault Tree Analysis (FTA)
TOOLS:
Finite Element Analysis (FEA); Physics of Failure (PoF);
Reliability Prediction; Reliability Block Diagram (RBD);
Engineering judgment, expert opinions, existing data;
Warranty Analysis of the existing products; Design
Review by Failure Mode (DRBFM); Stress-Strength
Analysis; FMEA updated
QUANTIFY AND
IMPROVE
In this stage, quantifying all of the previous work based
on test results will commence. By this stage,
prototypes should be ready for testing and more
detailed analysis. This involves an iterative process
where different types of tests are performed, the
results are analyzed, design changes are made, and
tests are repeated.
TOOLS:
Highly Accelerated Life Testing (HALT); Accelerated Life
Testing (ALT); Test to failure (Life data analysis);
Degradation analysis; Reliability Growth Process (if
enough data is available); Design Review Based on Test
Results (DRBTR); Design of Experiments (DOE); System
VALIDATE
In the Validate stage, a Demonstration Test can be used
to make sure that the product is ready for high volume
production.
TOOLS:
Design Validation (Including ALT and Reliability
Demonstration); Process Validation; Demonstration Test
MONITOR AND
CONTROL
Assure that the process remains unchanged and the
variations remain within the tolerances.
TOOLS:
Control Charts and Process Capability Studies (Cpk,
Ppk, etc.); Human Reliability; Continuous Compliance;
Field return analysis (warranty) and forecasting;
Ongoing reliability testing (ORT); Audits