reliability through design

Similarity analyses have been reported to have a high degree of accuracy in commercial avionics (see Boydston and Lewis, 2009). In active redundancy, all of a system’s parts are energized during the. They demonstrate that all manufacturing and assembly processes are capable of producing the system within the statistical process window required by the design. MyNAP members SAVE 10% off online. Reliability: The measure of a product’s ability to . During each phase of its life cycle, a system will experience various environmental and usage stresses. Fault trees can also assist with root-cause analyses. Increasing the Reliability of Valves Through Design. For overstress mechanisms, failure susceptibility is evaluated by conducting a stress analysis under the given environmental and operating conditions. Assessment of the reliability potential of a system design is the determination of the reliability of a system consistent with good practice and conditional on a use profile. RAM Analysis. The basic elements of a fault tree diagram are events that correspond to improper functioning of components and subcomponents, and gates that represent and/or conditions. In order to increase performance, manufacturers may adopt features for products that make them less reliable. Different categories of failures may require different root-cause analysis approaches and tools. Fault tree analysis is a systematic method for defining and analyzing system failures as a function of the failures of various combinations of components and subsystems. So, let’s take a look at DfR fundamentals and how companies employ it to their best advantage. They ensure that the supply-chain participants have the capability to produce the parts (materials) and services necessary to meet the final reliability objectives and that those participants are following through. Failure mechanisms are the processes by which specific combinations of physical, electrical, chemical, and mechanical stresses induce failure. Design for Reliability is a very hot topic these days, and it can be a challenge to find a good starting point that will give you the foundation you need to start sifting through and exploring all of the available options. Yang said that at Ford they start with the design for a new system, which is expressed using a system boundary diagram along with an interface analysis. Afterwards, the calculated correlation is run through the Spearman Brown formula. Ideally, such data should be obtained and processed during actual application. (This assumes that all unmanaged risks are producer risks.). Virtual qualification can be used to accelerate the qualification process of a part for its life-cycle environment. If this is a page you have "bookmarked" or added to your "favorites", please be sure to update the link accordingly. One estimate of reliability is test-retest reliability. Equipment manufacturers who use such parts need to adapt their design so that the part does not experience conditions beyond its ratings. These factors include the type or technology of the part under consideration, the quantity and type of manufacturer’s data available for the part, the quality and reliability monitors employed by the part manufacturer, and the comprehensiveness of production screening at the assembly level. It should contain information and data to the level of detail necessary to identify design or process deficiencies that should be eliminated. A manufacturer’s ability to produce parts with consistent quality is evaluated; the distributor assessment evaluates the distributor’s ability to provide parts without affecting the initial quality and reliability; and the parts selection and management team defines the minimum acceptability criteria based on a system’s requirements. Knowledge of the likely failure mechanisms is essential for developing designs for reliable systems. the full process or specific aspects of this technique (see, e.g., Foucher et al., 2002). A high percentage of defense systems fail to meet their reliability requirements. With the goal of simultaneous design optimization, the typical engineering silos are counterproductive. If the integrity test data are insufficient to validate part reliability in the application, then virtual qualification should be considered. An important tool in failure analysis is known as FRACAS or failure reporting, analysis and corrective action system. The process for assessing the risks associated with accepting a part for use in a specific application involves a multistep process: A product’s health is the extent of degradation or deviation from its “normal” operating state. throughout the life of the product with low overall life-cycle costs. Low temperature: In mechanical and electromechanical systems, low temperatures can cause plastics and rubber to lose flexibility and become brittle, cause ice to form, increase viscosity of lubricants and gels, and cause structural damage due to physical contraction. Improve customer experience through design for reliability “Proactive experience reliability and innovation” — which is another way of discussing design for reliability — is one of my five customer experience competencies , which I’ve developed over 30+ years of doing this customer-driven work with companies of all sizes. Determine the impact of unmanaged risk: Combine the likelihood of risk occurrence with the consequences of occurrence to predict the resources associated with risks that the product development team chooses not to manage proactively. Mechanical shock can lead to overstressing of mechanical structures causing weakening, collapse, or mechanical malfunction. There are three methods used to estimate system life-cycle loads relevant to defense systems: similarity analysis, field trial and service records, and in-situ monitoring: 1 This is one of the limitations of prediction that is diminishing over time, given that many systems are being outfitted with sensors and communications technology that provide comprehensive information about the factors that will affect reliability. “Risk” is defined as a measure of the priority assessed for the occurrence of an unfavorable event. Over the past 20 years, manufacturers of many commercial products have learned that to expedite system development and to contain costs (both development costs and life-cycle or warranty costs) while still meeting or exceeding reliability requirements, it is essential to use modern design-for-reliability tools as part of a program to achieve reliability requirements. Destructive techniques include cross-sectioning of samples and de-capsulation. Ready to take your reading offline? The effects of manufacturing variability can be assessed by simulation as part of the virtual qualification process. The approach is based on the identification of potential failure modes, failure mechanisms, and failure sites for the system as a function of its life-cycle loading conditions. Thus, components can be modeled to have decreasing, constant, or increasing failure rates. The importance that engineering design plays in the reduction of maintenance costs is well known. Cost control: 70% of a project’s budget is allocated to design. Failure tracking activities are used to collect test- and field-failed components and related failure information. It supports physics-. However, changes between the older and newer product do occur, and can involve. Failure susceptibility is evaluated using the previously identified failure models when they are available. Sign up for email notifications and we'll let you know about new publications in your areas of interest when they're released. In this article, we will give an example using DOE++ to improve product reliability, and at the same time make sure the product meets its functional requirement. This process combines the strengths of the physics-of-failure approach with live monitoring of the environment and operational loading conditions. These best practices also guide the process along. However, the operational profile of each computer may be completely different depending on user behavior. All the lessons learned from failure analysis reports can be included in a corrective actions database for future reference. ... Certain players have a knack for coming through in key situations no matter how late in the season or how worn down they are. Those systems are not only less likely to successfully carry out their intended missions, but they also could endanger the lives of the operators. While traditional reliability assessment techniques heavily penalize systems making use of new materials, structures, and technologies because of a lack of sufficient field failure data, the physics-of-failure approach is based on generic failure models that are as effective for new materials and structures as they are for existing designs. It’s important to consider reliability and validity when you are creating your research design, planning your methods, and writing up your results, especially in quantitative research. Ideally, a virtual qualification process will identify quality suppliers and quality parts through use of physics-of-failure modeling and a risk assessment and mitigation program. While an invaluable and essential part of board design, vias introduce weaknesses and affect solderability. Information on life-cycle conditions can be used for eliminating failure modes that may not occur under the given application conditions. High temperature: High-temperature tests assess failure mechanisms that are thermally activated. Nondestructive techniques include visual observation and observations under optical microscope, x-ray, and acoustic microscopy. Reliability block diagrams model the functioning of a complex system through use of a series of “blocks,” in which each block represents the working of a system component or subsystem. Keep in mind, it’s less expensive to design for reliability than to test for reliability. Recorded data from the life-cycle stages for the same or similar products can serve as input for a failure modes, mechanisms, and effects analysis. Failure susceptibility is evaluated by assessing the time to failure or likelihood of a failure for a given geometry, material construction, or environmental and operational condition. Reliability is the extent to which an instrument would give the same results if the measurement were to be taken again under the same conditions: its consistency. As a consequence, erroneous reliability predictions can result in serious problems during development and after a system is fielded. The page you have attempted to reach is no longer available. This approach is inaccurate for predicting actual field failures and provides highly misleading predictions, which can result in poor designs and logistics decisions. If no failure models are available, then the evaluation is based on past experience, manufacturer data, or handbooks. The data are a function of the lengths and conditions of the trials and can be extrapolated to estimate actual user conditions. Improvement The following formula is for calculating the probability of failure. Several techniques for design for reliability are discussed in the rest of this section: defining and characterizing life-cycle loads to improve design parameters; proper selection of parts and materials; and analysis of failure modes, mechanisms, and effects. Register for a free account to start saving and receiving special member only perks. Understanding the Elements of Operational Reliability: A Key for Achieving High Reliability This viewgraph presentation reviews operational reliability and its role in achieving high reliability through design and process reliability. The application areas of this approach include civil and mechanical structures, machine-tools, vehicles, space applications, electronics, computers, and even human health. Additional insights into the criticality of a failure mechanism can be obtained by examining past repair and maintenance actions, the reliability capabilities of suppliers, and results observed in the initial development tests. Finally, systems that fail to meet their reliability requirements are much more likely to need additional scheduled and unscheduled maintenance and to need more spare parts and possibly replacement systems, all of which can substantially increase the life-cycle costs of a system. Design for Reliability. Some users may shut down the computer every time they log off; others may shut down only once at the end of the day; still others may keep their computers on all the time. This change was noted in the 2011 Annual Report to Congress of the Director of Operational Test and Evaluation (U.S. Department of Defense, 2011b, p. v): [I]ndustry continues to follow the 785B methodology, which unfortunately takes a more reactive than proactive approach to achieving reliability goals.

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