Reliability by DesignMac Klingler

13 August 2013

© M. G. Klingler, Ltd. 20131

Reliability by Design Designed-in Reliability

How do we structure a design program to achieve the best possible outcome?

OEM Issues and Action Field Service Reliability

How should owners analyze data? What should the reliability strategy be?

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Reliability by Design Business Imperative Often Trumps Good

Engineering Judgment Be Careful What You Ask of People

If you ask them to go faster they will If you ask them to do it cheaper they will But….You won’t like the result

Once Built a Prototype Resists Concept Change

Reliability by Necessity takes a back seat to Performance, Life and Cost

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Wind Turbine Evolution Machines increased an ORDER OF

MAGNITUDE in output in about a decade No practical field feedback of RELIABILTIY

or LIFE before the next iteration Obvious Engineering Conclusion?

“We did everything right”

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Definition of ReliabilityBroad Definition of Reliability: Reliability is a science aimed

at predicting, analyzing, preventing, and mitigating failures over time.

Narrow Definition of Reliability: Reliability is the probability that a device will operate successfully for a specified period of time and under specified conditions when used in the manner and for the purpose intended.

Simple Definition of Reliability: Conformance to quality standards over many increments of timeFOUR KEY PARAMETERS THAT GOVERN RELIABILITY:

1. Customer Expectations2. Intended Function3. Specified Life4. Specified Operating Conditions

Bathtub CurveLife Periods

Rate of Occurrence

of Failure

Design LifeGoalFPM LIFE

Goal

% Of MDPGoal

FPM WARGoal

Decompose the Problem

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Component

E-Build Part &Tooling Release

Architecture

Performance

Component

E-Build Part &Tooling Release

Verification General SpecGeneral Spec

Product ProductVerification

Machine Systems Machine systemsVerification

Manufacturing &Durability

Customer useValidationCustomer needs Requirements Capture

Allocation

Reliability by Design Five Basic Design Project Documents

General Specification Defines WHAT the Design Does, not HOW Specific by Function Defines Acceptance Criteria-How do I know

when I’m done Bill of Material-Line by Line Cost Spreadsheet-by increasing detail Weight Spreadsheet-by increasing detail Reliability Spreadsheet-by increasing detail

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Inherent Reliability Planning Tool in Specification Stage Before Design is Finalized Reasonably attained by Mature System The Best a Machine can be under the current

strategy Can the proposed design meet the objectives?

Initial Reliability Predicted/Estimated reliability at the beginning of

System development, prior to hardware testing Where should we apply our efforts? Basis for Test Plan

Reliability Modeling

© M. G. Klingler, Ltd. 2013

© M. G. Klingler, Ltd. 2013

Decompose the Problem

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Component

E-Build Part &Tooling Release

Architecture

Performance

Component

E-Build Part &Tooling Release

Verification General SpecGeneral Spec

Product ProductVerification

Machine Systems Machine systemsVerification

Manufacturing &Durability

Customer useValidationCustomer needs Requirements Capture

Allocation

Reliability by Design FMEA as the Primary Reliability Tool

Teams of Diverse Expertise Most “Experienced” Grey Beards Not too much emotional ownership of the

design These are the people who call the baby ugly

Identify and Rank (RPN’s) not just probable but all POSSIBLE Failure Modes

DO SOMETHING TO RESOLVE EVERY ISSUE Ideas have consequences but only if you do

something about them

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Decompose the Problem

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Component

E-Build Part &Tooling Release

Architecture

Performance

Component

E-Build Part &Tooling Release

Verification General SpecGeneral Spec

Product ProductVerification

Machine Systems Machine systemsVerification

Manufacturing &Durability

Customer useValidationCustomer needs Requirements Capture

Allocation

Reliability by Design Verification “Contract” Document

What Methods Will Be Used to Verify the Acceptance Criteria of the Design ? Modeling & Simulation-Primary Performance

Tool Analysis-Primary Life Tools Component Test-Verification of Modeling Prototype Test-Primarily Performance

Verification and Certification

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Reliability by Design How Will We Validate the Specification ?

Does the Spec meet customer expectations? How will you validate your spec? How will you validate your hardware?

Does IEC Code adequately express customer need?

Does Certification serve the customer?

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Reliability is Part of Design Include time for reliability activities

in the program plan/schedule The sooner they occur, the more benefit

they will haveAddress ALL failures uncovered

during development There are NO fluke failures Never assume they will get fixed later

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Field Service Reliability Keep good records

Discipline field techs to record failed parts Teach Root Cause Analysis

Join Industry Databases Compare to Industry Norms

Are your failures typical Segregate by Make & Model

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Field Service Reliability Address FREQUENCY of FAILURE in

preference to just high cost or high downtime failures

High Frequency Failures effect the most machines and give the biggest payback for your efforts

Try to replace failed parts with BETTER, Longer Life parts

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Conclusions Build a comprehensive General Spec

Function Cost Weight Inherent Reliability Model as a Base

Make RIGOROUS FMEA’s your primary Reliability Tool

Prioritize Field Failures by Frequency-Total Fleet Downtime

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