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Product/service
designed for particular applications.
expected to perform it task.
What is the intended life of the
product/service?
Complex product/service
many different components
a system
chances of components not working is increased.
Therefore, the method of arranging the components
affects the entire system reliability.
Series, parallel, or combination.
(2) System Reliability
(Components in Series arrangement)
Component I
RI=0.750
Component J
RJ=0.840
One component fails, the whole system still able to work;
until all parallel components do not function.
Rs = 1 – (Probability of component I fail)(Probability of
component J fail)
RS = 1 – (1-RI)(1-RJ)=1-(1-0.750)(1-0.840)=0.960
(2) System Reliability
(Components in Parallel arrangement)
Component I
RA=0.955 RC=0.999
Component J
RJ=0.840
Component I Component K
RJ=0.840 RL=0.840
Component M
RM=0.999
RS = (RA)(RI,J )(RC)(RK,L,M )
= (RA)[1-(1-RI)(1-RJ)](RC)[1-(1-RK)(1-RL)(1-RM)
(3) Design
Other techniques:
Having a backup or redundant component (in parallel
arrangement; cheaper redundant component)
see next slide
Over-design.
Having a fail-safe type of device (safety concern)
Maintenance.
Protection for certain environment.
Investment in reliability (RM) reliability
Up to certain level.
(3) Design
(redundancy)
Redundancy (Kelebihan) is the duplication of parts or
features in such a way that the duplicate can take over
the function of another part in the event of failure.
Eg: In a two-engine aircraft, the second aircraft engine
will propel the aircraft if one engine fails.
The addition of redundant parts to a product can
improve the reliability of a system enormously.
enormously
It is important with safety related products and services.
There are 2 types of redundancy:
redundancy
(3) Design
(Active redundancy)
Active redundancy occurs when all the redundant items
are in operation at the same time.
time
Examples:
All 4 aircraft engines operating at the same time
when only 1 engine is enough at cruising altitude
(one engine is not enough for take off).
Both hydraulic brake circuits in your car always
working.Only one circuit is enough to stop the car in
normal driving (but not enough for an emergency
stop).
(3) Design
(Passive redundancy)
Passive redundancy occurs when the redundant items
are available but not put into in use until the active
item fails.
Examples:
The spare tyre in your car can be used in the event
of a puncture.
Spare globe in an overhead projector.
(4) Production
Corrective What customers see CMs are maintenance activities done in a reactive mode and
maintenance (CM) exclude proactive activity such as preventive maintenance.
rate
Part replacement What factory & A part replacement is any part replaced during a CM activity.
(PR) rate logistics
organization see
Failure rate What engineers see A returned part that fails a manufacturing or engineering test.
Any parts that pass all tests are called no trouble found (NTF).
NTFs are important because they indicate a problem with out
test capabilities, diagnostics, or support process.
Each of the stated reliability metrics takes one of three
forms:
CM/PR/failure rate goal based on market demand.
Expected CM/PR/failure rate based on predictions
(Technology/Process Capability)
Actual CM/PR/failure rate based on measurement.
The relationship among the various metrics
Expected
CM/PR/F
R
Actual > Expected Expected > Goal
Potential design or Consider new
process problems technology or
design/mfg/maintenanc
e
Actual Goal
Actual > Goal
CM/PR/F Potential competitive CM/PR/F
R Disadvantage R
Reliability Prediction
Expected
CM/PR/F Reliability
R Model
-baseline
understanding
of product’s
reliability
Actual Goal
CM/PR/F CM/PR/F
R R
Reliability Prediction
Rt = e
( θ)
− t
β
(Failure-Rate Curves)
Failure-rate, , is important in describing the life-
history curve of a product.
Failure-rate probability of a failure during a stated
period of time, cycle, or number of impacts.
Failure rate can be estimated from test data by use of
the formulae:
(1) time terminated without a replacement.
(Failure-Rate Curves)
Q&A
•Determine the failure rate for an item that has the test of
9 items terminated at the end of 22 hours. Four of the
items failed after 4, 12, 15, and 21 h, respectively. Five
items were still operating at the end of 22 h.
r
λest =
∑ t + ( n − r )T
4
λest = = 0.025
(4 + 12 + 15 + 21) + (9 − 4)22
(Failure-Rate Curves)
r
λest =
∑t
Q&A
•Determine the failure rate for 50 items that are tested for
15 h. When failure occurs, the item is replaced with
another unit. At the end of 15 h, 6 of the items had
failed.
r
λest =
∑t
6
λest = = 0.008
50(15)
(Failure-Rate Curves)
Q&A
Determine the failure rate for 6 items that are tested
to failure. Test cycles are 1025, 1550, 2232, 3786,
5608, and 7918.
r
λest =
∑t
6
λest = = 0.00027
1025 + 1550 + 2232 + 3786 + 5608 + 7918
(Failure-Rate Curves)
Exponential :
1
λ=
θ Constant failure rate:
Normal : Exponential distribution and
t −θ
2
Weibull distribution ( =1)
−
e σ 2
λ= 2
∞ 1 x −θ
∫t −
2 σ
Weibull :
β −1
β t
λ =
θ θ
(Failure-Rate Curves)
Exponential Normal Weibull
(Failure-Rate Curves)
MTTF
Availability =
MTTF + mean time to repair
Q&A
•Determine the failure rate and MTBF for 6 items
that are tested to failure. Test cycles are 1025,
1550, 2232, 3786, 5608, and 7918.
r
λest = Time-1
∑t
6
λest = = 0.00027
1025 + 1550 + 2232 + 3786 + 5608 + 7918
1
θ = = 3704 cycle
λ
Q&A
Time (t)
Life-History Curve
(Debugging Phase)
It is also called burn-in or infant-mortality or early failure
phase.
A new machine or service, we often find it fails a few
times before it ‘settle down’ to a reliable state of
performance.
Weibull distribution with < 1 is used to describe the
occurrence of failures in this phase.
Product is under warranty (usually).
It is a significant quality cost.
cost
Life-History Curve
(Chance Failure Phase)
Random or constant failure phase.
Failure rate is constant.
The product or service has ‘settle down’ and is reliable.
Any failures that do occur are random
Exponential and Weibull ( =1) distributions are used to
describe this phase.
Reliability studies and Sampling Plans are concerned
with this phase.
The lower the failure rate, the better the product.
Life-History Curve
(Wear Out Phase)
The product is wearing out or the service support
systems are beginning to fail.
Wear out failures tend to have a sharp rise in failure rate.
Normal distribution is the best to describe this phase.
Weibull distribution ( >1) can be used depending on the
type of wear-out distribution.
(8) Availability and
Maintainability
Time related factors of availability, reliability, and
maintainability are interrelated.
Eg: when a water line breaks (reliability) it is no
longer available to provide water to customers
and must be repaired or maintained.
Availability, A:
A time-related factor.
Measures the ability of a product or service to
perform its designated function.
Product available operation +standby.
Availability and Maintainability
Uptime MTBF
A= =
Uptime + Downtime MTBF + MDT
MTTF
Uptime MTBF
A= =
Uptime + Downtime MTBF + MDT
MTTF
MTBF
MTTF MDT
Time
Maintainability:
Preventive and corrective maintenance on a product
or service can be achieved.
Mean time to repair,mean time to service,repair hours
per number of operating hours, preventive
maintenance cost, and down probability figure of
merit for maintainability.
Keeping maintainability low more cost effective
method of keeping availability high than
concentrating on reliability.