Reliability

MANAGEMENT
By
Lt Col (Retd) Navneet Sood
B.Tech, M.Tech, PGDBA, PMP, CRE, CMQ/OE
Why R&M ?
- Reduced Design Cycle Time
- Optimal Design
- Survivability in Manufacturing
- Survivability in Actual Usage
- Cost Reduction
- Customer Satisfaction
- Competitive in Business

The aim of this session is to
give you an overview about the
Reliability Management and its
relevance for a BEL design
engineer.
aIM
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
Reliability
Terminology
Phase-I
What is Reliability ?
O Fitness for Use
O Probability of Survival
O Probability of Satisfactory
Operation of an Equipment for
a Specified period of Time t
under Intended /actual
Operating Conditions.
Reliability: Definition
-The duration or probability of
failure free performance under
stated conditions.
-The Probability that an item
will perform a required
function without failure under
stated conditions for a stated
period of Time.
Types of Systems
There are 2 basic types of systems
Non - Repairable Repairable
TERMINOLOGY
1. 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)




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:
R
s
= R
1*
R
2 *
R
3************
R
n

R
s
= e
-s t

R
s
= e
(1 + 2+.+ n)

t

Additive term

NOTE: THESE CONCEPTS WERE ACCEPTED IN EARLY 1950S
AND HAVE BEEN APPLIED EVER SINCE.
GENERAL CONCEPTS
MTBF Exercise
E Given R= 0.95, t = 50 hrs, What
is the MTBF goal ?
O What is the goal if R=0.99?
E What is the Reliability if the
mission time is as large as the
MTBF ?
974 Hrs
0.368
4974Hrs
What is the Mission Time?
Comsat
Mazda
Endeavor
Cruise
Reliability Vs Mission Time
Desirable that MTBF >> Mission 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
Reliability Vs Mission Time
Interrelationship
of Safety, Quality
& Reliability
Phase-II
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 consequences
of failure, damage, error, accidents, harm or
any other event which could be considered
non-desirable.
Safety can also be defined to be the control
of recognized hazards to achieve an
acceptable level of risk.
Product Safety
Safety 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 design
reviews, 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 these
tests should be recorded and analyzed.
- When Failures Occur In The Field: The detailed information
should be recorded for each failure occurrence (Date and
Time, Operation and Environmental conditions, FMs, Actions
to repairs Active op time, operator and his skill level, cause,
failure analysis, Recommended corrective action, CA
implementation/ effective)

Meaning of Quality
Websters Dictionary
degree of excellence of a
thing
American Society for Quality
totality of features and
characteristics that satisfy
needs
Consumers and Producers
Perspective
Meaning of Quality:
Consumers Perspective
Fitness for use
how well product or
service does what it
is supposed to
Quality of design
designing quality
characteristics into a
product or service
A Mercedes and a
Ford are equally fit
for use, but with
different design
dimensions

Meaning of Quality:
Producers Perspective
Quality of Conformance
Making sure a product or service is
produced according to design
if new tires do not conform to
specifications, they wobble
if a hotel room is not clean when a
guest checks in, the hotel is not
functioning according to
specifications of its design
Meaning of Quality:
A Final Perspective
Consumers and producers
perspectives depend on each
other
Consumers perspective: PRICE
Producers perspective: COST
Consumers view must
dominate
Fitness for
Consumer Use
Producers Perspective Consumers Perspective
Quality of Conformance





Conformance to
specifications
Cost
Quality of Design





Quality characteristics
Price
Marketing Production
Meaning of Quality
Meaning of Quality
Quality: Definition
Quality is the totality of features and
characteristics of a product or service that
bear on its ability to satisfy stated or implied
needs.
Some goals of quality programs include:
Fitness for Use. (Is the product or service capable
of being used?)
Fitness for Purpose. (Does the product or service
meet its intended purpose?)
Customer Satisfaction. (Does the product or
service meet the customer's expectations?)
Conformance to the Requirements. (Does the
product or service conform to the requirements?)

Management
Quality

Safety
Reliability

Interrelationship
Definition
Reliability is defined as the
probability that an item will
perform a required function
without failure under stated
conditions for a specified
period of time.
Quality is a snapshot at the
start of life and reliability is a
motion picture of the day-by-
day operation.
Safety, Quality& Reliability
Quality and Reliability Engineers
provide different inputs into the design
process.
Quality Engineers suggest changes that
permit the item to be produced within
tolerance at a reasonable cost.
Reliability Engineers make
recommendations that permit the item
to function correctly for a longer period
of time.
Safety, Quality& Reliability
Sometimes equipment failure can
have a major impact on human safety
and / or health. From the point of
view of assessing product reliability,
we treat these kinds of catastrophic
failures no differently from the failure
that occurs when a key parameter
measured on a manufacturing tool
drifts slightly out of specification,
calling for an unscheduled
maintenance action.
Safety, Quality& Reliability
It is up to the Reliability Engineer
(and the relevant customer) to
define what constitutes a failure in
any reliability study.
More resource (test time and test
units) should be planned for when
an incorrect reliability assessment
could negatively impact safety
and/or health.

Reliability Engrs Perspective
Reliability Engineers often refer to
the nines metric.
R=0.999999 would be referred to
as Six Nines reliability.
Unreliability is simply U=1-R
Simplistically, Reliability may be
thought of as a measurement of
design quality (Material , Margin of
Safety, etc.) over some time period.

Reliability & Unreliability
Benefits of
Reliability
Engineering
Phase-III
Why Reliability Engineering?
Reliability, Availability, Maintainability, Safety and Quality are what
the Customer says they are, not what the Engineers or the Designers
say they are.
Companies who control the Reliability of their products can only
survive in the business in future as todays consumer is more
intelligent and 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 a
product he might tell 8 other people, whereas dissatisfied customer
will tell 22 people. It would be interesting to repeat this today.
Reliability is Money!
Why Reliability Engineering?
Why Reliability Engineering?
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


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 incorrect
specifications.
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).
Failures
As Reliability Engineering is concerned
with analyzing failures and providing feedback
to design and production to prevent future
failures, it is only natural that a rigorous
classification of failure types must be agreed
upon.

Reliability engineers speak of:
Failures Causes (External to the system)
Failure Modes
Failure Mechanisms (Internal to system)

Failures
FAILURE CAUSE: Circumstances during design,
production or use, that eventually results in a failure
of 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 a
failure.

Failures in Time
O Early Failures
O Chance Failures
O Wear out Failures
Equipment Life Curve


Time
Infant
Active
Wearout

What walks on four in the morning
two at noon and three in the evening ?
= Failure rate
Equipment Life Curve
Infant: Failures are due to
problems in workmanship,
process and parts

Active: Failures are caused by
extrinsic factors

Wear out: Failures are caused by
intrinsic factors
Bath Tub Curve
Bath Tub Curve
Phase Failure
Rate
Possible Causes Improvement
Actions
Burn-in Decreasing
(DFR)
Manufacturing Defects:
Welding, soldering,
assembly errors, part
defects, poor QC, Poor
workmanship
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.
Reasons for Poor Reliability
E Poor Design
E Wrong Manufacturing Techniques
E Product Complexity
E Poor Maintenance
E Organizational Rigidity
E Human Errors
How do we Eliminate Failures?
- Meticulous R&M Planning

- Rigorous Application of
R&M Techniques

- Effective R&M Reviews
F
a
i
l
u
r
e
s

Time
Without 6s, DFSS or DFRM
DFSS + 6s
DFRM + DFSS and 6s
Six Sigma & DFRM
Reliability Engg: Objectives
- To prevent or to reduce the likelihood or
frequency of failures.
- To identify & correct the causes of failures
that do occur, despite the efforts to
prevent them.
- To determine ways of coping with
failures 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.
Reliability Engg: Benefits
-Matching the capabilities of Product
Design to meet Customer Expectations.
-Avoiding Wasted Time due to
unanticipated failures in
Products/Services.
-Applying predictive & preventive
Maintenance Programs the reduce
downtime.
-Optimizing Product Burn-in times &
Conditions.
Reliability Engg: Benefits
-Minimizing Distribution Systems Costs.
-Optimizing Warranty Costs.
-Reducing injuries & loss of life related
to Product failure/liability.
-Reducing the loss of property due to
equipment failure.
-Staffing the team with qualified
professionals (reducing redesign &
rework cost).
Reliability in
Product/Process
Development
Phase-IV
Reliability-Product/Process Devp
Reliability of products is a result of various key functions
working together during development of new products and
processes.

Various activities to assure reliable products include
activities such as: Capturing voice of customer, Design
Reviews, Design Failure Modes and Effects Analysis
(DFMEA), Design Analysis, Simulation Studies, Optimization
of product and process parameters to deliver consistent
products, Reliability Testing and Validation, Reliability
Growth Studies, Process Capability Evaluation.

Performing these activities require teamwork of many
organizational functions such as marketing, design,
development, suppliers, manufacturing, service and quality.
Product
Manager
QA
Manager
Procedure
& Audit
QC Data
Analysis
Marketing
Manager
Engineering
Manager
Design
Reliability
Engineering
Parts Evaluation
& Failure Analysis
Statistical
Engineering
Environmental
Test
Design
Assurance
Development
Other
Managers
Production
Manager
Production
Test &
Inspection
Engineering Based
Reliability Organization
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 to
the Design & Development Planning in all
the four types of projects (BEL R&D Manual)
R&M Planning
4 Integral Part of Design Planning
-Identification of R&M Tasks
-Responsibility Allocation
-Documenting the R&M Plan
4 Is Product Specific
Design Life Cycle Phases
Conceptual Phase
Design Phase
Engineering Phase
Manufacturing Phase
Deployment Phase
Conceptual Phase
Quality Function Deployment (QFD)
Setting R&M Goals
Preparation of R&M Plan
Trade off analysis
Review
Design Phase
Part Control
Derating / Thermal Design
EMI/ESD Control
Reliability Prediction
FMECA
Designing for Manufacture
Software Quality Planning
Review
Engineering Phase
Derating Verification
Reliability Prediction
Maintainability Prediction
Spare Part Prediction
EMC/ESD Evaluation
Environmental Stress Testing
ESS Plan
Software Evaluation
Review
Manufacturing Phase
ESD Control
ESS
DOE
SPC
Corrective Action
Review
Deployment Phase
QFD Review
Analysis of field failure data
Corrective Action
Updating FMECA and
Spares Prediction
Final R&M Report
Review
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
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
Conceptualize
Design
Engineer
Freeze
Product /System Realisation
Project Management Design Phases
Production Information
/ Documentation Phase
Evaluation Phase
Design Realisation
Phase
Product / System
Design 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
ASPECTS 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,
Reliability / Durability/ Safety
DESIGN
Create (Product, Processes)
Analyse (Performance,
Reliability)
Refine / Improve
QFD
Specification Review
DEVELOPMENT
TEST PLAN
Create
Design Review
RELIABILITY/
DURABILITY
TESTS
PERFORMANCE
CONFORMITY
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, Taguchi
Standard Methods, FRACAS,
Data Analysis, Maintenance,
RCM
Final Design
Production
Design Reviews
Design reviews are regularly scheduled meetings led
by the design function. It must include other
affected areas
Design reviews is an effective method to prevent
problems and misunderstandings.
Design reviews are series of verification and design
evaluation activities that are more than an
engineering inspection
Design reviews must include:
Design / Functional requirement considerations
Formal reliability and confidence goals
Component sub-system duty cycles
Computer simulation and bench test results
Design Review Committee
Member Role
Chairperson (sometimes
design 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 heat
treatment), 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
Product & Process Devp
Mean time between failure (MTBF)
values for existing products can be
determined and reasonable goals
established.
MTBF values for components and
purchased parts can be determined.
Failure types and times of
occurrence can be anticipated.

Product & Process Devp
Optimal break-in/burn-in times
can be determined.
Recommendations for warranty
times can be established.
The impact of age and operating
conditions on the life of the
product can be studied.
The effects of parallel or redundant
design features can be determined.

Product & Process Devp
Accelerated 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 of
product development by scheduling
design tasks in parallel rather than
sequentially.
Product & Process Devp
Reliability engineering can provide
information to individual teams about
failure rates of their proposed
components.
Cost accounting estimates can be
improved through the use of lifecycle
cost analysis using reliability data.
When management employs FMEA
techniques, reliability engineering
provides essential input.
Liability &
Warranty
Management
Phase-V
A liability can mean something that is a
hindrance or puts an individual or group at a
disadvantage, or something that someone is
responsible for, or something that increases
the chance of something occurring (i.e. it is a
cause). Liability may refer in specific to:

1. Negligence-Legal
2. Strict Liability-Legal
3. Breach of WarrantyLegal
4. Defects
5. Failure to Warn
Product Liability
Negligence
1. Product manufacturers owe a
duty of care to Customer.
2. The standards for that care have
been breached.
3. As a result a compensable injury
results.
4. There are damages or injury to
the plaintiff.
Ex: Sharp edges, Screws protruded out,
open manholes without any sign board
Warranties are violated when the promise
is broken or the goods are not as
expected. The seller may honor the
warranty 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 faulty
hoses, gas pedal,
foot mat etc.
Breach of Warranty
1. Implied Merchantability
2. Implied Warranty for particular
purpose (pacemaker, lawnmower
may be excluded by seller)

3. Breach of express warranty
(written or oral contract:
cures 100%)
Strict Liability
1. Actual Defect (sharp edges,)
2. Consumer Expectations/Seller
Knowledge.
3. Risk / Benefit
4. Defective Warnings
5. Inadequate Guarding
Defect
You have a duty to warn. If you do not
warn that coffee is hot, you are likely
to get in trouble
Failure to Warn
Often users seek liability damages
because a product creates a risk that the
company could not predict during the
design and manufacturing efforts.
Product traceability helps a company to
locate products in the hands of the user.
Often, a company finds that they have a
need to provide additional user hazard
information, modify or recall products
for newly uncovered user hazards.
Liability Management
Warranty is a statement of assurance or
undertaking issued by the manufacturer
of a product w.r.t. the performance of
the product and parts supplied for a
certain period of time as stated in the
warranty card.
It means replacement or repair of the
defective product/part in the stated time
period by the supplier/ manufacturer.
Warranty
The basic customer requirements
for a product Warranty are:
The warranty is Full or
Limited.
The information is simple, clear
and easy to understand.
The warranty is available to the
customer before purchase.
Product Warranty
Implied Warranty: Product will perform
upon sale.
Express Warranty: Created by the
words/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
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 in
Warranty Mgt.
Latest View: Warranty Management is
considered as a Separate Revenue
Stream. It can provide a competitive
edge. (Tools: ALT, FMEA to build high
Reliability in Design of products)
Customer Needs
& Supplier
Reliability
Phase-VI
CUSTOMER
There is only one BOSS-The Customer.
He can FIRE everybody in the Company
From the CHAIRMAN.on down-
Simply by-
SPENDING HIS MONEY SOMEWHERE ELSE.
-Sam Walton

Customer Expectations


OHigh Reliability
OLow Life Cycle Cost
OReliability Linked Warranty
OReliability Centered Maintenance
OReliability Demonstration
OLogistic Support Analysis
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 process
and after fielding the device.
- Reliability requirements may be specified by
the customer or generated by the design
team.
Customer Needs Assessment
Three methods of determining customer
requirements include:
1. Marketing surveys
2. 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 customers
desires.
Customer Requirements
Process Benchmarking: It focuses on discrete
work processes and operating systems.

Performance Benchmarking: It focuses on
elements 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, and
controlling projects.
Benchmarking
Prototyping
Prototyping is a process that enables the developer to create a design
in an evolutionary manner. The sequence of events would be:-
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 audience
outside of the programming team.
The software is released to groups of
people so that further testing can ensure
the product has few faults or bugs.
Sometimes, beta versions are made
available to the open public to increase the
feedback field to a maximal number of
future users.
QFD
QFD is a system/tool for translating
customer requirements into appropriate
company requirements at each stage from
Research and Product development to
Engineering and Manufacturing to
Marketing/Sales and distribution.
- Methodology having high customer focus
- Assists in the planning processes for
products/services.
- The voice of the customer is the driver for
the development of requirements (for the
new or revised product or service).


Objective Statement
Customer Needs
requirement of
WHATS ?
I
m
p
o
r
t
a
n
c
e

r
a
t
i
n
g

o
f

W
H
A
T
S

Relation ship
Matrix between
HOWs? WHATs?
Technical Competitive
Assessment of HOWs or How
Much?
Target Goals of HOWS ?
Correlation Matrix of HOWS?
Technical descriptors of HOWS ?
C
u
s
t
o
m
e
r

a
s
s
e
s
s
m
e
n
t

o
f

c
o
m
p
e
t
i
t
o
r
s

House of
Quality
1
2
3
4
5
6
7
6
QFD
QFD - Benefits
` Fewer & Earlier Changes
` Shorter Development Time
` Fewer Start-up Problems
` Lower Start-up Costs
` Warranty Reduction
` Customer Satisfaction
` Knowledge Transfer
Supplier Reliability


An effective Supplier Reliability
Process is important to the procurement
of 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 key
steps are:-
Supplier Reliability


Step-1: Generate a document that
describes basic supplier Product
requirements.
Step-2: Perform an analysis of potential
supplier capabilities.
Step-3: Review the suppliers proposal
& examine the details of how they plan
to conform to the requirements.
Step-4: Supplier selection should be
based upon a no of factors. (Best & LCC)
Supplier Reliability


Step-5: Finalize procurement criteria by
working with the selected supplier.
Step-6: Manage the manufacturing
process by having the supplier use tools
like SPC, FRACAS & config control.
Step-7: Validate the suppliers
processes by evaluating Mfg stability &
process control over multiple runs.
Step-8: Perform a Rel Demonstration
Test that covers both process & product.
Supplier Reliability


Step-9: Provide component suppliers
feedback and focus on Quality,
conformance & Life Cycle Costs.
Step-10: Run an internal FRACAS &
document failure modes down to root
causes for all significant failures.
Step-11: Tie sch Prog/Project Design
Reviews together & work more closely.
Step-12: Near Completion; Long term
durability / Demo / Rel Growth / abuse
Tests (if indicated). Share the Results.
Product Life
Cycle & System
Engineering
Phase-VII
Life Cycle Cost Planning


Costs, that should be considered in the context of product
reliability, may be viewed from the perspective of the product
life cycle model. Major life cycle stages are:
Concept / Planning
Design / Development
Production / Manufacturing
Operation / Repair
Wear out / Disposal

C(LCC) = C(ACQ) + C(OM)

C(LCC) = Change in total life cycle cost over the total product life
cycle due to changes in the product MTBF.
C(ACQ)=Changes in the acquisition cost of the program due to
changes in the product MTBF.
C(OM) = Changes in the operation and maintenance (O and M)
costs of the program due to changes in the product MTBF.
Life Cycle Cost
Cost-Reliability Relationship
Product Life Cycle Engg
The definition given in MIL-STD-721C for reliability
growth is : The improvement in a reliability parameter
caused by the successful correction of deficiencies in
item design of manufacture.

There are techniques by which one may assess the
growth of reliability. MIL-HDBK-189 identifies detailed
program management and mathematical models that
may be applied to asses the demonstrated reliability
compared to planned reliability progress over time.

The two predominant models that are applied by
reliability professionals are :
1. Duane model (developed by James T. Duane)
2. US Army Material Systems Analysis Activity
(AMSAA) model.
Reliability Growth
MIL-HDBK-781A: In order to avoid duplication of test
effort and to ensure that deficiencies are not
overlooked, the integrated reliability test planning
should define procedures which ensure that reliability
data is derived from all other tests. Integrated test
planning should consider a description of the test plans
selected for use, the decision risks, and the
environmental test conditions, and should be keyed to
the program life-cycle phases.

The Sequential Test Plan will result in the most rapid
determination of product reliability at acceptable risk
levels. Product development or program schedules
should also be integrated with the reliability plan and
activity schedule.
Reliability Plans &
Integrated Schedules
Six issues which should be considered
for the design of an effective reliability
Program are:
1. Definition of Reliability Program.
2. Developing the Reliability Goals and
requirements.
3. Design for Reliability.
4. Assessing Reliability Progress.
5. Measuring Reliability.
6. Ensuring Reliable Performance.
Reliability Program
Design Evaluation
The design process should include periodic evaluations
to assure that the design goals and requirements are
being met. Design Process Steps are:



During the design input and design output cycle ,the
following phases are generally followed :
Phase I: Marketing Research
Phase II: Concepts
Phase III: Design
Preliminary Design
Detailed Design
Phase IV: Manufacturing Engineering
Phase V: Finalized Design
Design and
Development
Planning
Design
Input
Design
Output
Design
Verification
Design Tools
The 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
Requirements Management
IEEE standard 1220 defines a requirement as:
A statement that identifies a product or process
operational, functional, or design characteristics or
constraint, which is unambiguous, testable or measurable,
and necessary for product or process acceptability ( by
consumers or internal quality assurance guidelines ).
Requirements management is used to help prioritize
design and development activities. A requirements
specification typically contains text which provides
background information necessary for understanding the
proposed product and explains and justifies the need for
various product attributes.
The product requirements statement should be
unambiguous, correct and objectively verifiable. Taken in
their entirety the whole set of requirements for a particular
product should be consistent and complete.
Managing Changing
Requirements
Requirements 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 documents
and tests.
Implementing the scheduled changes.
Systems Engineering
It is top down approach defining a logical
sequence of activities and decisions
transforming an operational need into a
description of System performance parameters
and a preferred system configuration. It
includes the following:-
Mission Requirements Analysis.
Functional Analysis.
Reliability Allocation.
Synthesis.
Logistic Engineering.
Project Development Elements
The product development process may be viewed as a
trade off between a no of competing project
requirements as shown below.
Time To
Develop
Development
Cost
Product
Performance
Warranty
Costs (or)
Support
Reliability
Goals
Maintenance
& Spares
Cost
Benchmarks of Reliability Practice
1. Completely analyze all failures to identify the root
cause of failure and determine the necessary corrective
action, including redesign and revision of analytical tools.
2. Avoid dedicated reliability demonstration testing. Focus
on new components or the integration of old items in a
new way. Emphasize engineering development testing to
understand and validate the design process and models.
Accelerated testing should be used to age high reliability
items and to identify their failure mechanisms.
3. Assign responsibility for reliability to a product
development team with the authority to determine the
reliability requirements and to select the design, analysis,
test, and manufacturing activities needed to achieve that
reliability.
Human Factors Analysis
It may be referred to as Human Engineering, ergonomics or
user-friendly designs. Human factors analysis focuses on the
man-machine interface. When designing man-machine
interfaces, it is best to take advantage of the users
expectations. General rules and conventions establish user
expectations.
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 as
abnormal.
Audio alarms signal an abnormal operation.
In software, users expect the same conventions from all
manufacturers.
YOU WILL GET WHAT
YOU HAVE BEEN
GETTING.