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Reliability
MANAGEMENT
By
Lt Col (Retd) Navneet Sood
B.Tech, M.Tech, PGDBA, PMP, CRE, CMQ/OE
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Why R&M ? Reduced Design Cycle Time
Optimal Design
Survivability in Manufacturing Survivability in Actual Usage
Cost Reduction
Customer Satisfaction
Competitive in Business
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The aim of this session is to
give you an overview about theReliabilityManagementand its
relevance for a BEL design
engineer.
aIM
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Phase-I : Reliability Terminology
Phase-II : Interrelationship of Safety-Quality-Rel
Phase-III : Benefits of Reliability Engineering
Phase-IV : Rel in Product/Process Development
Phase-V : Liability & Warranty Management
Phase-VI : Customer Needs & Supplier Reliability
Phase-VII: Product Life Cycle & Systems Engg
PReVIEW
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Reliability
Terminology
Phase-I
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What is Reliability ?
Fitness for Use
Probability of Survival
Probability of SatisfactoryOperation of an Equipment for
a Specified period of Time tunder Intended /actualOperating Conditions.
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Reliability: Definition
The duration or probability offailure free performance under
stated conditions.The Probability that an item
will perform a required
function without failure understated conditions for a stated
period of Time.
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Types of SystemsThere are 2 basic types of systems
Non - Repairable Repairable
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TERMINOLOGY1. Failure Rate () :No. of failures per hour, per cycle, per mile, etc.
2. MTBF (1/) :Mean Time Between Failures (Repairable Items) is
equal to the reciprocal of failure rate.
3. MTTF :Mean Time to Failure (Non-Repairable Items)
4. Maintainability : The Probability that an item will be retained in
or restored to a specified condition within
a given period of time, when the maintenance
is performed in accordance with prescribed
procedures and resources.
5. Availability : Normally defined in connection with repairable
systems as the time fraction where the system is
functioning or can be made to function.
Availability= MTBF / (MTBF + MTTR)
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Reliability is described by means of the single parameter
Exponential Distribution: R(t)=e-t
Where:
= Failure rate
t = Mission time
M = MTBF = 1/
Reliability of a System:
Rs = R1*R2 *R3************Rn
Rs = e-st
Rs = e(1 + 2+.+ n)
tAdditive term
NOTE: THESE CONCEPTS WERE ACCEPTED IN EARLY 1950SAND HAVE BEEN APPLIED EVER SINCE.
GENERAL CONCEPTS
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MTBF Exercise
Given R= 0.95, t = 50 hrs, Whatis the MTBF goal ?
What is the goal if R=0.99?
What is the Reliability if themission time is as large as theMTBF ?
974 Hrs
0.368
4974Hrs
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What is the Mission Time?
Comsat
Mazda
Endeavor
Cruise
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Reliability Vs Mission Time
Desirable that MTBF >> Miss ion Time
Mission Time (t) Reliability (R)
t = MTBF 0.368
t = MTBF/2 0.606538
t = MTBF/4 0.77880091
t = MTBF/10 0.904837
t = MTBF/100 0.9900498
t = MTBF/1000 0.999000505
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Reliability Vs Mission Time
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Interrelationship
of Safety, Quality
& Reliability
Phase-II
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Safety: Definition Safety is the state of being safe, the
condition of being protected against physical,social, spiritual, financial, political,emotional, occupational, psychological,
educational or other types or consequencesof failure, damage, error, accidents, harm orany other event which could be considerednon-desirable.
Safety can also be defined to be the controlof recognized hazards to achieve anacceptable level of risk.
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Product SafetySafety Related Data Issues: w.r.t. feedback, Customer
feedback, design data and field data can be collected,Analyzed and used to improve the safety of a product.
During Design Phase: It is important to doc all designreviews, FMECAS, FTAs, trade off Studies, etc. Results should
be compared to contractual requests. In The Production Phase: All the screening and functional
testing should be performed to prescribed. Results of thesetests should be recorded and analyzed.
When Failures Occur In The Field: The detailed informationshould be recorded for each failure occurrence (Date andTime, Operation and Environmental conditions, FMs, Actionsto repairs Active op time, operator and his skill level, cause,failure analysis, Recommended corrective action, CAimplementation/ effective)
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Meaning of Quality
Websters Dictionarydegree of excellence of athing
American Society for Qualitytotality of features andcharacteristics that satisfyneeds
Consumers and Producers
Perspective
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Meaning of Quality:
Consumers Perspective Fitness for use how well product or
service does what itis supposed to
Quality of design designing quality
characteristics into aproduct or service
A Mercedes and aFord are equally fitfor use, but withdifferent designdimensions
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Meaning of Quality:
Producers Perspective Quality of ConformanceMaking sure a product or service is
produced according to design
if new tires do not conform tospecifications, they wobble
if a hotel room is not clean when aguest checks in, the hotel is notfunctioning according tospecifications of its design
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Meaning of Quality:
A Final Perspective Consumers and producers
perspectives depend on each
other Consumers perspective: PRICE
Producers perspective: COST
Consumers view mustdominate
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Fitness forConsumer Use
Producers Perspective Consumers Perspective
Quality of Conformance
Conformance to
specifications Cost
Quality of Design
Quality characteristics Price
MarketingProduction
Meaning of Quality
Meaning of Quality
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Quality: Definition
Quality is the totality of features andcharacteristics of a product or service thatbear on its ability to satisfy stated or impliedneeds.
Some goals of quality programs include:
Fitness for Use. (Is the product or service capableof being used?)
Fitness for Purpose. (Does the product or servicemeet its intended purpose?)
Customer Satisfaction. (Does the product orservice meet the customer's expectations?)
Conformance to the Requirements. (Does theproduct or service conform to the requirements?)
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Management
Quality
Safety
Reliability
Interrelationship
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Definition
Reliabilityis defined as theprobability that an item willperform a required function
without failure under statedconditions for a specifiedperiod of time.
Qualityis a snapshot at thestart of life and reliabilityis amotion picture of the day-by-day operation.
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Safety, Quality& Reliability
Quality and Reliability Engineersprovide different inputs into the designprocess.
Quality Engineerssuggest changes thatpermit the item to be produced withintolerance at a reasonable cost.
Reliability Engineersmakerecommendations that permit the itemto function correctly for a longer period
of time.
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Safety, Quality& ReliabilitySometimes equipment failure can
have a major impact on human safetyand / or health. From the point ofview of assessing product reliability,
we treat these kinds of catastrophicfailuresno differently from the failurethat occurs when a key parameter
measured on a manufacturing tooldrifts slightly out of specification,calling for an unscheduled
maintenance action.
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Safety, Quality& Reliability
It is up to the Reliability Engineer(and the relevant customer) todefine what constitutes a failure in
any reliability study. More resource (test time and test
units) should be planned for when
an incorrect reliability assessmentcould negatively impact safetyand/or health.
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Reliability EngrsPerspective
Reliability Engineers often refer tothe nines metric.
R=0.999999 would be referred to
as Six Nines reliability.
Unreliability is simply U=1-R
Simplistically, Reliability may bethought of as a measurement ofdesign quality (Material , Margin of
Safety, etc.) over some time period.
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Reliability & Unreliability
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Benefits ofReliability
Engineering
Phase-III
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Why Reliability Engineering? Reliability, Availability, Maintainability, Safety and Quality are what
the Customer says they are, not what the Engineers or the Designerssay they are.
Companies who control the Reliability of their products can only
survive in the business in future as todays consumer is more
intelligentand product aware.
Liability for unreliable products can be very high.
Complexity of products is ever increasing and thus challenge to
Reliability Engineering is also increasing.
Products are advertised by their Reliability Ratings.
A study, in the 80s, showed that when a customer is satisfied with aproduct he might tell 8 other people, whereas dissatisfied customerwill tell 22 people. It would be interesting to repeat this today.
Reliability is Money!
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Why Reliability Engineering?
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Why Reliability Engineering?
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Why do Engg Items Fail?
Designed to Fail Manufactured to Fail
Assembled to Fail Screened to Fail
Stored to Fail
Transported to Fail
Operated to Fail
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Why do Engg Items Fail? The design might be inherently incapable.
The item might be overstressed in some way. Failures might be caused by Variation.
Failures can be caused by wear out.
Failures can be caused by other time dependent
mechanisms (Battery run down, high temp & stress). Failures can be caused by sneaks.
Failures can be caused by errors , such as incorrectspecifications.
There are many other causes of failures:-Gears might be noisy.Oil seals might leak.Display screens might flicker.Operating instructions might be wrong or ambiguous.
Effect of Electromagnetic Interference (EMI).
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FailuresAs Reliability Engineering is concerned
with analyzing failures and providing feedbackto design and production to prevent futurefailures, it is only natural that a rigorousclassification of failure types must be agreedupon.
Reliability engineers speak of:
Failures Causes (External to the system)Failure Modes
Failure Mechanisms (Internal to system)
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Failures FAILURE CAUSE: Circumstances during design,
production or use, that eventually results in a failureof the item.
FAILURE MODE: It is the observed result of a failure.For electrical and electronic components the
following failures modes will be typical. Open Circuits
Short Circuits
Parameter Degradation
Excessive Noise
FAILURE MECHANISM: It is the physical, chemical,metallurgical or other process which results in afailure.
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Failures in Time
Early Failures Chance Failures
Wear out Failures
E i t Lif C
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Equipment Life Curve
Time
Infant
Active
Wearout
What walks on four in the morningtwo at noon and three in the evening ?
= Failure rate
E i t Lif C
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Equipment Life Curve
Infant: Failures are due toproblems in workmanship,process and parts
Active: Failures are caused byextrinsic factors
Wear out: Failures are caused byintrinsic factors
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Bath Tub Curve
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Bath Tub CurvePhase Failure
Rate
Possible Causes Improvement
Actions
Burn-in Decreasing
(DFR)
Manufacturing Defects:
Welding, soldering,
assembly errors, part
defects, poor QC, Poorworkmanship
Better QC,
Acceptance testing,
Burn-in testing,
screening, Highly
Accelerated Stress
Screening
Useful
Life
Constant
(CFR)
Environment, random
loads, Human errors,
Acts of God, chance
events
Excess strength,
redundancy, robust
design
Wear Out Increasing
(IFR)
Fatigue, Corrosion,
Aging, Friction
Derating, preventive
maintenance, parts
replacement, better
material, improved
designs, technology.
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Reasons for Poor Reliability
Poor Design Wrong Manufacturing Techniques
Product Complexity
Poor Maintenance
Organizational Rigidity
Human Errors
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How do we Eliminate Failures?
Meticulous R&M Planning
Rigorous Application ofR&M Techniques
Effective R&M Reviews
Si Si & DFRM
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Failures
Time
Without 6s, DFSS or DFRM
DFSS + 6s
DFRM + DFSS and 6s
Six Sigma & DFRM
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Reliability Engg: Objectives To prevent or to reduce the likelihood or
frequency of failures.
To identify & correct the causes of failuresthat do occur, despite the efforts to
prevent them.
To determine ways of coping withfailures that do occur, if their causes
have not been corrected. To apply methods for estimating the
likely reliability of new designs, and for
analysing reliability data.
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Reliability Engg: BenefitsMatching the capabilities of Product
Design to meet Customer Expectations.
Avoiding Wasted Time due tounanticipated failures inProducts/Services.
Applying predictive & preventive
Maintenance Programs the reducedowntime.
Optimizing Product Burn-in times &
Conditions.
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Reliability Engg: BenefitsMinimizing Distribution Systems Costs.
Optimizing Warranty Costs.
Reducing injuries & loss of life related
to Product failure/liability.
Reducing the loss of property due toequipment failure.
Staffing the team with qualifiedprofessionals (reducing redesign &rework cost).
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Reliability inProduct/Process
Development
Phase-IV
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Reliability-Product/Process Devp Reliability of products is a result of various key functions
working together during development of new products andprocesses.
Various activities to assure reliable products includeactivities such as: Capturing voice of customer, Design
Reviews, Design Failure Modes and Effects Analysis(DFMEA),Design Analysis, Simulation Studies, Optimizationof product and process parameters to deliver consistentproducts, Reliability Testing and Validation, ReliabilityGrowth Studies,Process Capability Evaluation.
Performing these activities require teamwork of manyorganizational functions such as marketing, design,development, suppliers, manufacturing, service and quality.
Engineering Based
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ProductManager
QAManager
Procedure& Audit
QC DataAnalysis
MarketingManager
EngineeringManager
DesignReliability
Engineering
Parts Evaluation& Failure Analysis
StatisticalEngineering
EnvironmentalTest
Design
Assurance
Development
OtherManagers
Production
Manager
ProductionTest &
Inspection
Engineering BasedReliability Organization
T f P j t i BEL
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Types of Projects in BEL
In House Development Projects Joint Development Projects
with DRDO & other National
Labs TOT Projects Design Outsourcing
NOTE: R&M Requirements are an input totheDesign & Development Planning in allthe four types of projects (BEL R&D Manual)
R&M Planning
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R&M Planning
Integral Part of Design Planning
Identification of R&M Tasks
Responsibility Allocation
Documenting the R&M Plan Is Product Specific
i if l h
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Design Life Cycle Phases
Conceptual Phase
Design Phase
Engineering Phase
Manufacturing Phase
Deployment Phase
Conceptual Phase
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Conceptual Phase
Quality Function Deployment (QFD) Setting R&M Goals
Preparation of R&M Plan Trade off analysis
Review
Design Phase
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Design Phase Part Control
Derating / Thermal Design
EMI/ESD Control
Reliability Prediction
FMECA
Designing for Manufacture
Software Quality Planning
Review
Engineering Phase
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Engineering Phase
Derating Verification
Reliability Prediction
Maintainability Prediction
Spare Part Prediction EMC/ESD Evaluation
Environmental Stress Testing
ESS Plan
Software Evaluation
Review
Manufacturing Phase
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Manufacturing Phase
ESD Control ESS DOE SPC Corrective Action
Review
Deployment Phase
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Deployment Phase
QFD Review Analysis of field failure data Corrective Action
Updating FMECA andSpares Prediction
Final R&M Report Review
R&M Plan
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R&M Plan Brief Description of the Product
Functional Block Diagram Design Approach Application Environment
Market Potential Customer R&M Goals
R&M Phases R&M Tasks/Responsibilities Data Collection System (FRACAS) Preparation of R&M Report
R&M Techniques
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R&M Techniques Quality Function Deployment
Part Control & Derating Thermal Design and Analysis Redundancy
EMI / ESD Control DFMM Reliability Prediction Maintainability Prediction Spare Part Prediction FMEA and FMECA ESS, HALT & HASS
Corrective Action
DFRM Road Map
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DFRM Road Map
ConceptualizeDesign
Engineer
Freeze
Product /System Realisation
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Product /System RealisationProject Management Design Phases
Production Information/ Documentation Phase
Evaluation Phase
Design RealisationPhase
Product / SystemDesign Phase
Conceptual Phase
Project Planning,
Execution Tracking,Progress Reviews,
Resource Monitoring,
Communications,
Risk Management,
Procurement Tracking,
Amendment Sanction
Project Initiation, Planning,Proposal & Sanction
Project Closure
Reliability Program Flow
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Reliability Program FlowASPECTS TO CONSIDER TASKS METHODS
Project / Contract Requirements,
Markets,
Competition,
Technology Knowledge
Risks, Costs
Project / Contract Requirements,
Environments, Stresses
Variation,
Tools, Methods,Skills, Training,
Suppliers,
Value / Cost
Project / Contract Requirements,
Environments, Stresses
Variation,Methods,
Test Items, Numbers Levels
Manufacturing,
Facilities,
Suppliers,
SPECIFICATION
Performance, Cost,Reli abil ity / Dur abil ity/ Safety
DESIGNCreate (Product, Processes)
Analyse (Performance,
Reliability)Refine / Improve
QFD
SpecificationReview
DEVELOPMENTTEST PLAN
Create
Design Review
RELIABILITY/DURABILITY
TESTS
PERFORMANCECONFORMITY
TESTS
Synthesis, Models CAD/CAE/EDA
FEA, CFD Simulation
(EDA, Monte Carlo)
FMEA, FTA, etc.DOE, Taguchi
Maintenance, RCM
Design Review
Performance, Conformity
HALT, DOE, TaguchiStandard M ethods, FRACAS,
Data Analysis, Main tenance,
RCM
Final Design
Production
Design Reviews
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DesignReviews Design reviews are regularly scheduled meetings led
by the design function. It must include otheraffected areas
Design reviews is an effective method to preventproblems and misunderstandings.
Design reviews are series of verification and designevaluation activities that are more than anengineering inspection
Design reviews must include:
Design / Functional requirement considerationsFormal reliability and confidence goals
Component sub-system duty cycles
Computer simulation and bench test results
Design Review Committee
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Design Review CommitteeMember Role
Chairperson (sometimesdesign leader) Chair the meeting and ensure compliance to agenda, time management
Design leader
(usually chairperson)
Presents the design concept, features and details
Quality Engineer Represents the customer and provides input on design
Materials Engineer Reviews selection of material, process requirements ( such as heattreatment), comments on availability of standard materials ( such as
alloy steel)
Manufacturing Engineer
( if applicable)
Considers current process capabilities and provides input on feasibility
Supplier ( if applicable) Considers current process capabilities and provides input on feasibility
CAD / Applied
Mechanics Analysis
Plans for appropriate analysis and later shares analysis results and
gives recommendation for changes if any
Reliability Engineer Evaluates the designs, interprets the test and analysis reports with
reference to reliability goals
Safety Engineer Reviews and ensures that safety requirements are addressed
P d t & P D
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Product & Process Devp
Mean time between failure (MTBF)values for existing products can bedetermined and reasonable goals
established.MTBF values for components and
purchased parts can be determined.
Failure types and times ofoccurrence can be anticipated.
P d t & P D
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Product & Process Devp
Optimal break-in/burn-in timescan be determined.
Recommendations for warranty
times can be established.
The impact of age and operatingconditions on the life of theproduct can be studied.
The effects of parallel or redundant
design features can be determined.
P d t & P D
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Product & Process DevpAccelerated life testing can be used
to provide failure data.
Field failure data can be analyzed to
help evaluate product performance.Concurrent engineering can improve
the efficiency & effectiveness ofproduct development by schedulingdesign tasks in parallel rather thansequentially.
P d t & P D
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Product & Process DevpReliability engineering can provide
information to individual teams aboutfailure rates of their proposedcomponents.
Cost accounting estimates can beimproved through the use of lifecycle
cost analysis using reliability data.When management employs FMEA
techniques, reliability engineering
provides essential input.
V
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Liability &
Warranty
Management
Phase-V
Product Liability
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A liability can mean something that is a
hindrance or puts an individual or group at adisadvantage, or something that someone isresponsible for, or something that increasesthe chance of something occurring (i.e. it is acause). Liability may refer in specific to:
1. Negligence-Legal
2. Strict Liability-Legal3. Breach of WarrantyLegal4. Defects5. Failure to Warn
Product Liability
Negligence
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Negligence1. Product manufacturers owe a
duty of care to Customer.2. The standards for that care havebeen breached.
3. As a result a compensable injuryresults.4. There are damages or injury to
the plaintiff.
Ex: Sharp edges, Screws protruded out,open manholes without any sign board
Breach of Warranty
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Warranties are violated when the promise
is broken or the goods are not asexpected. The seller may honor thewarranty by making a refund or a
replacement.1. The product is defective or dangerous.2. Risk is too high (risk/benefit higher
than competition, etc.)Ex: Honda Cars with faultyhoses, gas pedal,foot mat etc.
Breach of Warranty
Strict Liability
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1. Implied Merchantability2. Implied Warranty for particularpurpose (pacemaker, lawnmower
may be excluded by seller)
3. Breach of express warranty
(written or oral contract:cures 100%)
Strict Liability
Defect
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1. Actual Defect (sharp edges,)
2. Consumer Expectations/Seller
Knowledge.
3. Risk / Benefit
4. Defective Warnings5. Inadequate Guarding
Defect
Failure to Warn
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You have a duty to warn. If you do notwarn that coffee is hot, you are likelyto get in trouble
Failure to Warn
Liability Management
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Often users seek liability damages
because a product creates a risk that thecompany could not predict during thedesign and manufacturing efforts.
Product traceability helps a company tolocate products in the hands of the user.
Often, a company finds that they have a
need to provide additional user hazardinformation, modify or recall productsfor newly uncovered user hazards.
Liability Management
Warranty
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Warranty is a statement of assurance or
undertaking issued by the manufacturerof a product w.r.t. the performance ofthe product and parts supplied for a
certain period of time as stated in thewarranty card.
It means replacement or repair of the
defective product/part in the stated timeperiod by the supplier/ manufacturer.
Warranty
Product Warranty
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The basic customer requirementsfor a product Warranty are:
The warranty is Full or
Limited. The information is simple, clear
and easy to understand.
The warranty is available to thecustomer before purchase.
Product Warranty
Warranty Types
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Implied Warranty: Product will perform
upon sale.
Express Warranty: Created by thewords/actions of the seller.
Full Warranty: Full service warranty.
Extended Warranty:Add on (sold along).
Deceptive Warranty: False Promise.As-is Warranty: Sold with faults
(What you see, is what you get)
Warranty Types
Warranty Management
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Warranty Management Traditional View:Considered as Cost of
providing Customer Satisfaction. 4-5%of total sales revenue per annum.
Modern View: Many realized the
potential of underlying value inWarranty Mgt.
Latest View: Warranty Management is
considered as a Separate RevenueStream. It can provide a competitiveedge. (Tools: ALT, FMEA to build high
Reliability in Design of products)
Phase VI
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Customer Needs
& Supplier
Reliability
Phase-VI
CUSTOMER
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CUSTOMER
There is only one BOSS-The Customer.He can FIREeverybody in the Company
From the CHAIRMAN.on down-Simply by-
SPENDING HIS MONEY SOMEWHERE ELSE.
-Sam Walton
Customer Expectations
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Customer Expectations
High Reliability
Low Life Cycle Cost
Reliability Linked WarrantyReliability Centered Maintenance
Reliability DemonstrationLogistic Support Analysis
Customer Needs Assessment
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Reliability Requirements: These requirements
must have the following attributes: Measurable Attainable
Keyed to customer desires Requirements must be measurable so that
they can be verified during the design processand after fielding the device.
Reliability requirements may be specified bythe customer or generated by the designteam.
Customer Needs Assessment
Customer Requirements
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Three methods of determining customerrequirements include:
1. Marketing surveys2. Benchmarking and
3. Prototyping with beta testing.4. Quality Function Deployment (QFD).
Customer surveys are used to determine
what customers want by asking them. Surveys should be designed to obtain the
maximum information about the customersdesires.
Customer Requirements
Benchmarking
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Process Benchmarking: It focuses on discrete
work processes and operating systems.
Performance Benchmarking: It focuses onelements of price, technical quality, features,speed, reliability, etc.
Project Benchmarking: Project constraint factors
are time, cost, resources& performance. Project bench marking is used to select new
techniques for planning, scheduling, andcontrolling projects.
Benchmarking
Prototyping
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yp gPrototyping is a process that enables the developer to create a designin an evolutionary manner. The sequence of events would be:-
Beta Testing
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Beta Testing Beta testing can be considered a form of
external user acceptance testing. Versions of the software, known as beta
versions, are released to a limited audienceoutside of the programming team.
The software is released to groups ofpeople so that further testing can ensurethe product has few faults or bugs.
Sometimes, beta versions are madeavailable to the open public to increase thefeedback field to a maximal number offuture users.
QFD
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QFDQFD is a system/tool for translating
customer requirements into appropriatecompany requirements at each stage fromResearch and Product development to
Engineering and Manufacturing toMarketing/Sales and distribution.
Methodology having high customer focus
Assists in the planning processes forproducts/services. The voice of the customer is the driver for
the development of requirements (for the
new or revised product or service).
House of 7
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Objective Statement
Customer Needsrequirement of
WHATS ?
ImportanceratingofWHATS
Relation shipMatrix between
HOWs? WHATs?
Technical Competitive
Assessment of HOWs or How
Much?
Target Goals of HOWS ?
Correlation Matrixof HOWS?
Technical descriptors of HOWS ?
Cu
stomerassessmentof
competitors
Quality
1 2
3
45
6
6
QFD
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Q
QFD - Benefits
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Q Fewer & Earlier Changes
Shorter Development Time
Fewer Start-up Problems
Lower Start-up Costs
Warranty Reduction
Customer Satisfaction
Knowledge Transfer
Supplier Reliability
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Supplier Reliability
An effective Supplier ReliabilityProcess is important to the procurementof key/ critical components, material,
assemblies and sub systems.It overlaps Procurement Quality &also addresses the specific preparations& monitoring necessary for durable &reliable products. The suggested 12 keysteps are:-
Supplier Reliability
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Supplier Reliability
Step-1: Generate a document thatdescribes basic supplier Productrequirements.
Step-2: Perform an analysis of potentialsupplier capabilities.Step-3: Review the suppliersproposal& examine the details of how they planto conform to the requirements.Step-4: Supplier selection should bebased upon a no of factors. (Best & LCC)
Supplier Reliability
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Supplier Reliability
Step-5:Finalize procurement criteria byworking with the selected supplier.Step-6: Manage the manufacturing
process by having the supplier use toolslike SPC, FRACAS & config control.Step-7: Validate the suppliersprocesses by evaluating Mfg stability &process control over multiple runs.Step-8: Perform a Rel DemonstrationTest that covers both process & product.
Supplier Reliability
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pp yStep-9: Provide component suppliers
feedback and focus on Quality,conformance & Life Cycle Costs.Step-10: Run an internal FRACAS &
document failure modes down to rootcauses for all significant failures.Step-11: Tie sch Prog/Project Design
Reviews together & work more closely.Step-12: Near Completion; Long termdurability / Demo / Rel Growth / abuse
Tests (if indicated). Share the Results.
Phase VII
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Product Life
Cycle & System
Engineering
Phase-VII
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Life Cycle Cost
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e Cyc e Cost
Cost-Reliability Relationship
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Cost Reliability Relationship
Product Life Cycle Engg
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Reliability Growth
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The definition given in MIL-STD-721C for reliabilitygrowth is : The improvement in a reliability parameter
caused by the successful correction of deficiencies initem design of manufacture.
There are techniques by which one may assess thegrowth of reliability. MIL-HDBK-189 identifies detailed
program management and mathematical models thatmay be applied to asses the demonstrated reliabilitycompared to planned reliability progress over time.
The two predominant models that are applied byreliability professionals are :
1. Duane model (developed by James T. Duane)2. US Army Material Systems Analysis Activity(AMSAA) model.
Reliability Plans &
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MIL-HDBK-781A:In order to avoid duplication of testeffort and to ensure that deficiencies are notoverlooked, the integrated reliability test planningshould define procedures which ensure that reliabilitydata is derived from all other tests. Integrated testplanning should consider a description of the test plansselected for use, the decision risks, and theenvironmental test conditions, and should be keyed tothe program life-cycle phases.
The Sequential Test Plan will result in the most rapiddetermination of product reliability at acceptable risklevels. Product development or program schedulesshould also be integrated with the reliability plan and
activit schedule.
Integrated Schedules
Reliability Program
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Six issues which should be considered
for the design of an effective reliabilityProgram are:
1. Definition of Reliability Program.
2. Developing the Reliability Goals andrequirements.
3. Design for Reliability.4. Assessing Reliability Progress.
5. Measuring Reliability.
6 Ensuring Reliable Performance
y g
Design Evaluation
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gThe design process should include periodic evaluationsto assure that the design goals and requirements arebeing met. Design Process Steps are:
During the design input and design output cycle ,thefollowing phases are generally followed :
Phase I: Marketing ResearchPhase II: Concepts
Phase III: DesignPreliminary DesignDetailed Design
Phase IV: Manufacturing EngineeringPhase V: Finalized Design
Design and
Development
Planning
Design
Input
Design
Output
DesignVerification
Design Tools
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gThe design Tools used in the design planning are:
Geometric Dimensioning & Tolerancing (GD&T)Design for Manufacturing / Design for Assembly
Value Engineering
Design of Experiments (DoEs)
FMEA / FMECA
Finite Element Analysis (FEA)
Solid Modeling
Simulation Techniques
Computer Aided Design (CAD)
Computer Aided Engineering (CAE)
Reliability Engineering Plans
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Managing Changing
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RequirementsRequirements may change during specification,design, development, and testing proceeds.Below are the procedures for managing
changing requirements. Submitting requirements change request.
Evaluating requirements change request.
Reviewing requirements change request.
Scheduling changes to product documentsand tests.
Implementing the scheduled changes.
Systems Engineering
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y g gIt is top down approach defining a logical
sequence of activities and decisionstransforming an operational need into adescription of System performance parametersand a preferred system configuration. It
includes the following:-
Mission Requirements Analysis.
Functional Analysis.
Reliability Allocation.
Synthesis.
Logistic Engineering.
Project Development Elements
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j pThe product development process may be viewed as a
trade off between a no of competing projectrequirements as shown below.
Time To
Develop
Development
Cost
Product
Performance
WarrantyCosts (or)Support
ReliabilityGoals
Maintenance& Spares
Cost
Benchmarks of Reliability Practice
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y1. Completely analyze all failures to identify the root
cause of failure and determine the necessary correctiveaction, including redesign and revision of analytical tools.
2. Avoid dedicated reliability demonstration testing. Focuson new components or the integration of old items in a
new way. Emphasize engineering development testing tounderstand and validate the design process and models.Accelerated testing should be used to age high reliabilityitems and to identify their failure mechanisms.
3. Assign responsibility for reliability to a productdevelopment team with the authority to determine thereliability requirements and to select the design, analysis,test, and manufacturing activities needed to achieve thatreliability.
Human Factors AnalysisIt b f d t H E i i i
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It may be referred to as Human Engineering, ergonomics oruser-friendly designs. Human factors analysis focuses on the
man-machine interface. When designing man-machineinterfaces, it is best to take advantage of the usersexpectations. General rules and conventions establish userexpectations.Toggle switches should move up for on and down for off.
Rotating knobs for liquids turn counter-clockwise for on,and clockwise for off.
Electrical equipment is the opposite for liquids, counter-clockwise turns off while clockwise turns on.
Use green as a normal operating indicator, and red asabnormal.
Audio alarms signal an abnormal operation.
In software, users expect the same conventions from allmanufacturers.
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Conclusion
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REMEMBERIF YOU DO WHAT YOUHAVE BEEN DOINGYOU WILL GET WHAT
YOU HAVE BEEN
GETTING.
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AnyDoubtsOR
Questions?
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