Quality Engineering: "Reliability"

QUALITY ENGINEERING
Lecture 9
“Reliability”
Presented by:
Dr. Mahendran Samykano
Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc

Dale H. Besterfield Upper Saddle River, New Jersey 07458 • All Rights Reserved
OUTLINE
 FUNDAMENTAL ASPECTS
 ADDITIONAL STATISTICAL ASPECTS
 LIFE AND RELIABILITY TESTING PLANS
 TEST DESIGN
 AVAILABILITY AND MAINTAINABILITY
Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc2

LEARNING OBJECTIVES
WHEN YOU HAVE COMPLETED THIS CHAPTER YOU SHOULD BE

ABLE TO:
 KNOW THE DEFINITION OF RELIABILITY AND THE FACTORS
ASSOCIATED WITH IT.
 KNOW THE VARIOUS TECHNIQUES TO OBTAIN RELIABILITY.
 UNDERSTAND THE PROBABILITY DISTRIBUTIONS, FAILURE CURVES,

AND RELIABILITY CURVES AS A FACTOR OF TIME.

LEARNING OBJECTIVES
WHEN YOU HAVE COMPLETED THIS CHAPTER YOU SHOULD

BE ABLE TO:
 CALCULATE THE FAILURE RATE UNDER DIFFERENT CONDITIONS.
 CONSTRUCT THE LIFE HISTORY CURVE AND DESCRIBE ITS THREE

PHASES.
 CALCULATE THE NORMAL, EXPONENTIAL, AND WEIBULL FAILURE

RATE.

LEARNING OBJECTIVES
WHEN YOU HAVE COMPLETED THIS CHAPTER YOU SHOULD BE

ABLE TO:
 CONSTRUCT THE OC CURVE
 DETERMINE LIFE AND RELIABILITY TEST CURVES
 CALCULATE THE NORMAL, EXPONENTIAL, AND WEIBULL FAILURE RATE
 UNDERSTAND THE DIFFERENT TYPES OF TEST DESIGN
 UNDERSTAND THE CONCEPTS OF AVAILABILITY AND MAINTAINABILITY

RELIABILITY
 GENERALLY DEFINED AS THE ABILITY OF A PRODUCT TO PERFORM

AS EXPECTED OVER TIME.
 FORMALLY DEFINED AS THE PROBABILITY THAT A PRODUCT, PIECE

OF EQUIPMENT, OR SYSTEM WILL PERFORM ITS INTENDED FUNCTION
FOR A PRESCRIBED LIFE UNDER STATED ENVIRONMENTAL
CONDITIONS

RELIABILITY
 MEANS QUALITY OVER THE LONG RUN.
 A PRODUCT THAT “WORKS” FOR A LONG PERIOD OF

TIME IS A RELIABLE ONE.
 SINCE ALL UNITS OF A PRODUCT WILL FAIL AT DIFFERENT

TIMES, RELIABILITY IS A PROBABILITY.

RELIABILITY
THERE ARE FOUR FACTORS ASSOCIATED WITH RELIABILITY:

1. NUMERICAL VALUE.
 THE NUMERICAL VALUE IS THE PROBABILITY THAT THE PRODUCT
WILL FUNCTION SATISFACTORILY DURING A PARTICULAR TIME.
2. INTENDED FUNCTION.
 PRODUCT ARE DESIGNED FOR PARTICULAR APPLICATIONS AND
ARE EXPECTED TO BE ABLE TO PERFORM THOSE APPLICATIONS.

RELIABILITY
THERE ARE FOUR FACTORS ASSOCIATED WITH RELIABILITY:
3. LIFE.
 HOW LONG THE PRODUCT IS EXPECTED TO LAST. PRODUCT LIFE IS
SPECIFIED AS A FUNCTION OF USAGE, TIME, OR BOTH.
4. ENVIRONMENTAL CONDITIONS
 INDOORS.
 OUTDOORS.
 STORAGE.
 TRANSPORTATION.

ACHIEVING RELIABILITY
EMPHASIS:
1. THE CONSUMER PROTECTION ACT OF 1972.
2. PRODUCTS ARE MORE COMPLICATED.
3. AUTOMATION.

SYSTEM RELIABILITY
 AS PRODUCTS BECOME MORE COMPLEX (HAVE MORE COMPONENTS),

THE CHANCE THAT THEY WILL NOT FUNCTION INCREASES.
 THE METHOD OF ARRANGING THE COMPONENTS AFFECTS THE

RELIABILITY OF THE ENTIRE SYSTEM.
 COMPONENTS CAN BE ARRANGED IN SERIES, PARALLEL, OR A

COMBINATION.

SERIES SYSTEM
 For a series systems, the reliability is the product of the individual
components.
1 2 n
RS = R1 R2 ... Rn
 As components are added to the series, the system reliability

decreases.

PARALLEL SYSTEM
1
2
n Rs = 1 - (1 - R1) (1 - R2)... (1 - Rn)

 When a component does not function, the product continues to function,
using another component, until all parallel components do not function.

SERIES-PARALLEL SYSTEM
C
RA RB RC RD
A B D
C
RC
 CONVERT TO EQUIVALENT SERIES SYSTEM
RA RB RD
A B C’ D
RC’ = 1 – (1-RC)(1-RC)
DESIGN
 THE MOST IMPORTANT ASPECT OF RELIABILITY IS THE DESIGN.
 IT SHOULD BE AS SIMPLE AS POSSIBLE.
 THE FEWER THE NUMBER OF COMPONENTS, THE GREATER THE

RELIABILITY.
 ANOTHER WAY OF ACHIEVING RELIABILITY IS TO HAVE A BACKUP

OR REDUNDANT COMPONENT (PARALLEL COMPONENT).

DESIGN
 RELIABILITY CAN BE ACHIEVED BY OVERDESIGN.
 THE USE OF LARGE FACTORS OF SAFETY CAN INCREASE THE

RELIABILITY OF A PRODUCT.
 WHEN AN UNRELIABLE PRODUCT CAN LEAD TO A FATALITY OR

SUBSTANTIAL FINANCIAL LOSS, A FAIL-SAFE TYPE OF DEVICE SHOULD
BE USED.

PRODUCTION
 THE SECOND MOST IMPORTANT ASPECT OF RELIABILITY IS THE

PRODUCTION PROCESS.
 EMPHASIS SHOULD BE PLACED ON THOSE COMPONENTS WHICH

ARE LEAST RELIABLE.
 PRODUCTION PERSONNEL.

TRANSPORTATION
 THE THIRD MOST IMPORTANT ASPECT OF RELIABILITY IS THE

TRANSPORTATION.
 PACKAGING
 SHIPMENT
 PERFORMANCE OF THE PRODUCT BY THE CUSTOMER IS THE FINAL

EVALUATION.
 GOOD PACKAGING TECHNIQUES AND SHIPMENT EVALUATION

ARE ESSENTIAL.

MAINTENANCE
 ELIMINATE NEED
 WARNINGS, SUCH AS AUDIBLE OR VISUAL SIGNALS
 SIMPLE AND EASY TO PERFORM

ADDITIONAL STATISTICAL ASPECTS
DISTRIBUTIONS APPLICABLE TO RELIABILITY:
 EXPONENTIAL DISTRIBUTION.
 NORMAL DISTRIBUTION.
 WEIBULL DISTRIBUTION.
RELIABILITY CURVES:
 THE CURVES AS A FUNCTION OF TIME.

RELIABILITY CURVES:
 THE RELIABILITY CURVES FOR THE EXPONENTIAL, NORMAL

AND WEIBULL DISTRIBUTIONS AS A FUNCTION OF TIME ARE
GIVEN IN FIGURE 11-2(B) .

FAILURE-RATE CURVE:
 IT IS IMPORTANT IN DESCRIBING THE LIFE-HISTORY CURVE OF A
PRODUCT.
 SEE FIGURE 11-2C.
number of test failures r

λest = =
sum of test times  t +(n - r)T
EXPONENTIAL NORMAL WEIBULL

LIFE HISTORY CURVE
 The curve, sometimes referred to as the “bathtub”
curve, is a comparison of failure rate with time.
 It has three distinct phases:
 The debugging phase.
 The chance failure phase.
 The wear-out phase.

LIFE HISTORY CURVE
Wear Out
Chance Failure Phase
“Infant Debugging
Phase
Phase
mortality
period”

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 ß<1 is used to describe the occurrence of

failures.

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 β= 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 ß >1 are used to describe this phase.

NORMAL FAILURE ANALYSIS
 THE WEIBULL DISTRIBUTION IS USUALLY USES.
 THE NORMAL DISTRIBUTION.
t
R(t) = 1.0 -  f(t)dt
0
R(t) = 1.0 - P(t)

 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.

EXPONENTIAL FAILURE ANALYSIS
EXPONENTIAL DISTRIBUTION:
RT = E –T/Ө
WHERE:
T: TIME OR CYCLES.
Ө: MEAN LIFE.

WEIBULL FAILURE ANALYSIS
 CAN BE USED FOR THE DEBUGGING PHASE (ß<1) AND THE

CHANCE FAILURE PHASE (ß=1).
 BY SETTING = 1, THE WEIBULL EQUALS THE EXPONENTIAL.
 BY SETTING ß=3.4, THE WEIBULL APPROXIMATES THE NORMAL.
RT = E –(T/Ө)ß
WHERE ß IS THE WEIBULL SLOPE.

OC CURVE CONSTRUCTION
STEPS:
1. ASSUME VALUES FOR THE MEAN LIFE Ө.
2. THESE VALUES ARE CONVERTED TO THE FAILURE RATE, Λ =1/Ө.
3. CALCULATE THE EXPECTED AVERAGE NUMBER OF FAILURES NTΛ.
4. FROM TABLE C OF THE APPENDIX USING NTΛ AND C VALUE, GET

PA.
5. SEE TABLE 11-1

OC Curve for the Sampling Plan, n = 16, T = 600 h, c = 2, and r = 3

LIFE AND RELIABILITY TESTING PLANS
TYPE OF TESTS:
 FAILURE-TERMINATED: THESE LIFE-TEST SAMPLE PLANS ARE
TERMINATED WHEN A PREASSIGNED NUMBER OF FAILURES
OCCURS TO THE SAMPLE.
 TIME-TERMINATED: THIS LIFE-TEST SAMPLING PLAN IS

TERMINATED WHEN THE SAMPLE OBTAINS A PREDETERMINED
TEST TIME.

TYPE OF TESTS CONT’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.

TESTS ARE BASED ON ONE OR MORE OF THE FOLLOWING
CHARACTERISTICS:
 MEAN LIFE: THE AVERAGE LIFE OF THE PRODUCT.
 FAILURE RATE: THE PERCENTAGE OF FAILURES PER UNIT TIME OR

NUMBER OF CYCLES.
 HAZARD RATE: THE INSTANTANEOUS FAILURE RATE AT A SPECIFIED

TIME.
 RELIABLE LIFE: THE LIFE BEYOND WHICH SOME SPECIFIED PORTION OF

THE ITEMS IN THE LOT WILL SURVIVE.

TEST ARE BASED ON ONE OR MORE OF THE FOLLOWING

CHARACTERISTICS CONT’D.:
 HAZARD RATE: THE INSTANTANEOUS FAILURE RATE AT A
SPECIFIED TIME.
 RELIABLE LIFE: THE LIFE BEYOND WHICH SOME SPECIFIED

PORTION OF THE ITEMS IN THE LOT WILL SURVIVE.

THANK YOU
38
Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc


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QUALITY ENGINEERING

Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc

 ADDITIONAL STATISTICAL ASPECTS

 LIFE AND RELIABILITY TESTING PLANS

 AVAILABILITY AND MAINTAINABILITY

Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc2

WHEN YOU HAVE COMPLETED THIS CHAPTER YOU SHOULD BE

 KNOW THE VARIOUS TECHNIQUES TO OBTAIN RELIABILITY.

 UNDERSTAND THE PROBABILITY DISTRIBUTIONS, FAILURE CURVES,

Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc3

WHEN YOU HAVE COMPLETED THIS CHAPTER YOU SHOULD

 CONSTRUCT THE LIFE HISTORY CURVE AND DESCRIBE ITS THREE

 CALCULATE THE NORMAL, EXPONENTIAL, AND WEIBULL FAILURE

Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc4

WHEN YOU HAVE COMPLETED THIS CHAPTER YOU SHOULD BE

 DETERMINE LIFE AND RELIABILITY TEST CURVES

 CALCULATE THE NORMAL, EXPONENTIAL, AND WEIBULL FAILURE RATE

 UNDERSTAND THE DIFFERENT TYPES OF TEST DESIGN

 UNDERSTAND THE CONCEPTS OF AVAILABILITY AND MAINTAINABILITY

Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc5

 GENERALLY DEFINED AS THE ABILITY OF A PRODUCT TO PERFORM

 FORMALLY DEFINED AS THE PROBABILITY THAT A PRODUCT, PIECE

Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc6

 MEANS QUALITY OVER THE LONG RUN.

 A PRODUCT THAT “WORKS” FOR A LONG PERIOD OF

 SINCE ALL UNITS OF A PRODUCT WILL FAIL AT DIFFERENT

Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc7

THERE ARE FOUR FACTORS ASSOCIATED WITH RELIABILITY:

 THE NUMERICAL VALUE IS THE PROBABILITY THAT THE PRODUCT

WILL FUNCTION SATISFACTORILY DURING A PARTICULAR TIME.

 PRODUCT ARE DESIGNED FOR PARTICULAR APPLICATIONS AND

ARE EXPECTED TO BE ABLE TO PERFORM THOSE APPLICATIONS.

Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc8

 HOW LONG THE PRODUCT IS EXPECTED TO LAST. PRODUCT LIFE IS

SPECIFIED AS A FUNCTION OF USAGE, TIME, OR BOTH.

Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc9

2. PRODUCTS ARE MORE COMPLICATED.

Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc10

 AS PRODUCTS BECOME MORE COMPLEX (HAVE MORE COMPONENTS),

 THE METHOD OF ARRANGING THE COMPONENTS AFFECTS THE

 COMPONENTS CAN BE ARRANGED IN SERIES, PARALLEL, OR A

Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc11

 For a series systems, the reliability is the product of the individual

 As components are added to the series, the system reliability

Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc12

n Rs = 1 - (1 - R1) (1 - R2)... (1 - Rn)

using another component, until all parallel components do not function.

Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc13

 THE MOST IMPORTANT ASPECT OF RELIABILITY IS THE DESIGN.

 IT SHOULD BE AS SIMPLE AS POSSIBLE.

 THE FEWER THE NUMBER OF COMPONENTS, THE GREATER THE

 ANOTHER WAY OF ACHIEVING RELIABILITY IS TO HAVE A BACKUP

Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc15

 RELIABILITY CAN BE ACHIEVED BY OVERDESIGN.

 THE USE OF LARGE FACTORS OF SAFETY CAN INCREASE THE

 WHEN AN UNRELIABLE PRODUCT CAN LEAD TO A FATALITY OR

Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc16

 THE SECOND MOST IMPORTANT ASPECT OF RELIABILITY IS THE

 EMPHASIS SHOULD BE PLACED ON THOSE COMPONENTS WHICH

Quality Improvement, 9e © 2013, 2008 by Pearson Higher Education, Inc17

 THE THIRD MOST IMPORTANT ASPECT OF RELIABILITY IS THE

 PERFORMANCE OF THE PRODUCT BY THE CUSTOMER IS THE FINAL

 GOOD PACKAGING TECHNIQUES AND SHIPMENT EVALUATION