PowerPoint presentation to accompany Besterfield Quality Control, 8e
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D Fundamental Aspects D Additional Statistical Aspects D Life and Reliability Testing Plans D Availability and Maintainability
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Learning Objectives
When you have completed this chapter you should be able to:
D Know the definition of reliability and the factors associated with it.
D Know the various techniques to obtain reliability. D Understand the probability distributions, failure curves, and reliability curves as a factor of time.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Learning Objectives contd.
When you have completed this chapter you should be able to:
D Calculate the failure rate under different conditions.
D Construct the life history curve and describe its three phases.
D Calculate the normal, exponential, and Weibull failure rate.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Learning Objectives contd.
When you have completed this chapter you should be able to: D Construct the OC Curve
D Determine life and reliability test curves
D Calculate the normal, exponential, and Weibull failure rate
D Understand the different types of test design
D Understand the concepts of availability and maintainability
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Reliability
D Generally defined as the ability of a product to perform as expected over time.
D Formally defined as the probability that a product, piece of equipment, or system will perform its intended function for a stated period of time under specified operating conditions.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Reliability
D Means quality over the long run. D A product that works for a long period of time is a reliable one.
D Since all units of a product will fail at different times, reliability is a probability.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Reliability
There are four factors associated with Reliability: 1. Numerical Value. D The numerical value is the probability that the product will function satisfactorily during a particular time.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Reliability
There are four factors associated with Reliability: 2. Intended Function. D Product are designed for particular applications and are expected to be able to perform those applications.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Reliability
There are four factors associated with Reliability: 3. Life. D How long the product is expected to last. Product life is specified as a function of usage, time, or both.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Reliability
There are four factors associated with Reliability: 4. Environmental Conditions D Indoors. D Outdoors. D Storage. D Transportation.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Achieving Reliability
Emphasis: 1. The Consumer Protection Act of 1972. 2. Products are more complicated. 3. Automation.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved System Reliability
D As products become more complex (have more components), the chance that they will not function increases.
D The method of arranging the components affects the reliability of the entire system.
D Components can be arranged in series, parallel, or a combination.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Series System
D For a series systems, the reliability is the product of the individual components.
1 2 n
R S = R 1 R 2 ... R n
D As components are added to the series, the system reliability decreases.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Parallel System
1
2
n R s = 1 - (1 - R 1 ) (1 - R 2 )... (1 - R n )
D When a component does not function, the product continues to function, using another component, until all parallel components do not function.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved R Series-Parallel System
C R A R B R D
C A B D C
R C
D Convert to equivalent series system
R A R B R D
A B C D
R C = 1 (1-R C )(1-R C )
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Design
D The most important aspect of reliability is the design.
D It should be as simple as possible. D The fewer the number of components, the greater the reliability.
D Another way of achieving reliability is to have a backup or redundant component (parallel component).
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Design
D Reliability can be achieved by overdesign. D The use of large factors of safety can increase the reliability of a product.
D When an unreliable product can lead to a fatality or substantial financial loss, a fail-safe type of device should be used.
D The maintenance of the system is an important factor in reliability.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Production
D The second most important aspect of reliability is the production process.
D Emphasis should be placed on those components which are least reliable.
D Production personnel.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Transportation
D The third most important aspect of reliability is the transportation.
D Packaging D Shipment D Performance of the product by the customer is the final evaluation.
D Good packaging techniques and shipment evaluation are essential.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Additional Statistical Aspects
Distributions Applicable to Reliability: D Exponential distribution. D Normal distribution. D Weibull distribution. Reliability Curves: D The curves as a function of time.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Additional Statistical Aspects
Reliability Curves: D The reliability curves for the exponential, normal and Weibull distributions as a function of time are given in Figure 11-2(b) .
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Additional Statistical Aspects
Failure-Rate Curve: D It is important in describing the life-history curve of a product.
D See Figure 11-2.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Life History Curve
D The curve, sometimes referred to as the bathtub curve, is a comparison of failure rate with time.
D It has three distinct phases: D The debugging phase. D The chance failure phase. D The wear-out phase.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Life History Curve
Infant mortality period
Debugging Phase
Chance Failure Phase Wear Out Phase
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Life History Curve
1. The debugging phase: It is characterized by marginal and short-life parts that cause a rapid decrease in the failure rate.
It may be part of the testing activity prior to shipment for some products.
The Weibull distribution <1 is used to describe the occurrence of failures.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Life History Curve
2. The chance failure phase: Failures occur in a random manner due to the constant failure rate. The Exponential and the Weibull distributions = 1 are best suited to describe this phase.
3. The wear-out phase: Is depicted by a sharp raise in failure rates. The Normal distribution and the Weibull distribution >1 are used to describe this phase.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Normal Failure Analysis
D The Weibull distribution is usually uses. D The Normal distribution.
R(t): Reliability at time t P(t): Probability of failure or area of the normal curve to the left of time t. Table A.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Exponential Failure Analysis
Exponential distribution:
Rt = e t/
Where: t: Time or cycles. : Mean life.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Weibull Failure Analysis
D Can be used for the debugging phase (<1) and the chance failure phase (=1).
D By setting = 1, the Weibull equals the exponential.
D By setting =3.4, the Weibull approximates the Normal.
Rt = e (t/)
Where is the Weibull slope.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved OC Curve Construction
Steps: 1. Assume values for the mean life .
2. These values are converted to the failure rate, l =1/ .
3. Calculate the expected average number of failures nTl.
4. From Table C of the Appendix using nTl and c value, get Pa.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Life and Reliability Testing Plans
Type of Tests: D Failure-Terminated: These life-test sample plans are terminated when a preassigned number of failures occurs to the sample.
D Time-Terminated: This life-test sampling plan is terminated when the sample obtains a predetermined test time.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Life and Reliability Testing Plans
Type of Tests contd.: D Sequential: A third type of life-testing plan is a sequential life-test sampling plan whereby neither the number of failures nor the time required to reach a decision are fixed in advance.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Life and Reliability Testing Plans
Tests are based on one or more of the following characteristics:
D Mean life: the average life of the product. D Failure rate: the percentage of failures per unit time or number of cycles.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Life and Reliability Testing Plans
Test are based on one or more of the following characteristics contd.:
D Hazard rate: the instantaneous failure rate at a specified time.
D Reliable life: the life beyond which some specified portion of the items in the lot will survive.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Handbook H108
D Quality Control Reliability Handbook H108 gives sampling procedures and tables for life and reliability testing.
D Sampling plans in the handbook are based on the exponential distribution.
D Provides for the three different types of test: failure-terminated, time-terminated, and sequential.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Handbook H108
D The handbook is over 70 pages long. D The time-terminated plan: 1. Stipulated producers risk, consumers risk, and sample size.
2. Stipulated producers risk, rejection number, and sample size.
3. Stipulated producers risk, consumers risk, and test time.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Reliability Management
D Define customer performance requirements. D Determine important economic factors and relationship with reliability requirements.
D Define the environment and conditions of product use.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Reliability Management
D Select components, designs, and vendors that meet reliability and cost criteria.
D Determine reliability requirements for machines and equipments.
D Analyze field reliability for improvement.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Availability and Maintainability
For long-lasting products and services such as refrigerators, electric power lines, and front-line services, the time-related factors of availability, reliability, and maintainability are interrelated.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Availability
D It is a time-related factor that measures the ability of a product or service to perform its designated function.
D The product or service is available when it is in the operational state, which includes active and standby use.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Availability
Where:
MTBM = mean time between maintenance
MDT = mean down time
MTBF = mean time between failures MTTR = mean time to repair
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Maintainability
Maintainability is the probability that a system or product can be retained in, or one that has failed can be restored to, operating condition in a specified amount of time.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved Maintainability
D Maintainability is the totality of design factors that allows maintenance to be accomplished easily.
D Preventive maintenance reduces the risk of failure.
D Corrective maintenance is the response to failures.
Besterfield: Quality Control, 8 th ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458. All rights reserved