RELIABILITY ENGINEERING – I SEM 2019-20

BITS Pilani Dr. ARUN MAITY

Pilani Campus
 BITS Pilani
Pilani Campus

MODULE 1: OVERVIEW OF RELIABILITY ENGINEERING

Lecture No. 1
COURSE CONTENT

No Course objectives
CO1 To study the various failure distribution methods and learning
about how to implement these methods for failure rate
modeling.
CO2 To learn about how to determine the reliability of various
system.
CO3 To learn about how to design for reliability, maintainability
and availability
CO4 To study of various empirical methods for data collection and
their application for Reliability estimation

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TEXTBOOK

T1 Charles E. Ebeling: An introduction to Reliability and maintainability

engineering, edition 2000, Fourteen reprint 2011, TMH, New Delhi

R1 A.K.Gupta, Reliability, Maintenance and Safety Engineering, First edition

2009, Reprint 2013, University Science Press, New Delhi
R2 E. Balagurusamy, Reliability Engineering, TMH, New Delhi

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COURSE CONTENT

• Study of Failure distribution and failure rate models

– Study of Reliability and Maintainability, Concepts
– Reliability function
– Mean time to failure
– The two - parameter exponential distribution
– Redundancy and the CFR Model
– Failure distribution models
• Determination of Reliability of different systems
– Different system configuration
– Load sharing system
– Standby system

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• Design for Reliability, Maintainability and Availability
– Dynamic Models, Physics of failure models
– Static models
– Reliability allocation
– Design methods
– Repair time distribution
– Maintenance Requirements
– Availability
 
• Different empirical methods for data collection and Reliability estimation

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EVALUATION COMPONENTS

• EC1 : QUIZ – 1, 2 : 15 marks

• EC2 : MID-SEMESTER TEST – CLOSED BOOK : 35 marks

• EC3 : COMPREHENSIVE EXAM – OPEN BOOK : 50 marks

• Grading will be on statistical basis

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HISTORY

• 1816 : The word “reliability” was first coined by poet Samuel Taylor Coleridge
• In statistics, reliability is the consistency of a set of measurements or
measuring instrument, often used to describe a test.
• A test is considered reliable if we get the same result repeatedly.
• Before World War II, reliability as a word came to mean dependability or
repeatability.
• 1940 : The modern use was redefined by the U.S. military.
• It initially came to mean that a product that would operate when expected.
The current meaning connotes a number of additional attributes that span
products, service applications, software packages or human activity

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Growth of Reliability Engineering

• Increased Complexity
• Sophistication of systems
• Obsession for Quality Products
• New Laws and Regulations
• Government contractual requirements
• Profit considerations due to
• High cost of failures
• Repair cost
• Warranty programs

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Utility

• Engineering Design Process

• Life-cycle costing
• Cost-Benefit Analysis
• Operational Capability Studies
• Repair and Facility resourcing
• Inventory and Spare Parts requirement
• Replacement Decisions, Make and Buy Decisions
• Preventive Maintenance Programs

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Product Quality

• Performance
• Lasts for long time
• Service
• Easily repaired
• Warranty
• Easy to use
• Appearance
• Brand Name
• Packaging
• Latest Model

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Need

• To improve the reliability and availability of product

• High Failure rate components: Redundancy/duplication/standby
• Designing for excess strength, selection of right material can reduce failures
• Derating of equipment can achieve desired reliability
• Reducing the number of components will reduce failure rate
• Reducing downtime through good maintainability design: Maintainability at
the design stage

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Initiatives for Improved Reliability

• Reliability Growth program

• Quality Control program
• Reducing variability
• Inspection and Sampling Plans
• Preventive Maintenance program
• Engineering Modifications
• Improved maintainability using test equipment, skilled technicians

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DEFINITION

• Reliability Engineering is engineering that emphasizes dependability in the

life-cycle management of a product
• Reliability is defined as the ability of a product or system to perform its
required functions without failure for a specified time period and when used
under specified conditions
• Engineering and analysis techniques are used to improve the reliability or
dependability of a product or system.
• Reliability engineering falls within the maintenance phase of the software
development life cycle (SDLC). The overall aim of the SDLC is to make
software and products more reliable.

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OBJECTIVES

• To apply engineering knowledge and specialist techniques to prevent or to

reduce the likelihood or frequency of failures
• To identify and correct the causes of failures that occur despite the efforts to
prevent them
• To determine ways of coping with failures that occur, if their causes have not
been fixed
• To apply methods for estimating the likely reliability of new software and for
analyzing reliability data

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SPECIFICATION

• Reliability can be difficult to specify, since it is defined in qualitative terms.

• Reliability metrics are stated as probability statements that are measurable
by testing.

Examples of reliability requirements specifications are as follows:

1. A patient monitoring system can fail less than 1 hour per year.
2. The software shall have no more than x number of bugs per 1000 lines of
code.

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IMPLEMENTATION

• Testing: Testing combined with the data it generates, product reliability

predictions can be done

• Measure of reliability is determined based on the trade-off between increased

levels of reliability and increased levels of testing

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ROLE OF RELIABILITY ENGINEER

• To identify and manage asset reliability risks that could adversely affect plant
or business operations

• Loss Elimination, Risk Management and Life Cycle Asset Management

• Loss Elimination: To track the production losses and abnormally high

maintenance cost assets, then find  ways to reduce those losses or high
costs. The Reliability Engineer and team develops a plan to eliminate or
reduce the losses through root cause analysis, obtains approval of the plan
and facilitates the implementation.

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RISK MANAGEMENT

• To manage risk to the achievement of an organization’s strategic objectives

in the areas of environmental health and safety, asset capability, quality and
production.
• TOOLS:
HAZAN / HAZOP STUDIES
FMEA - Failure modes and effects analysis
CA - Criticality analysis
MI - Maintainability information
FTA - Fault tree analysis
ETA - Event tree analysis

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LIFE CYCLE ASSET MANAGEMENT

• Studies show that as much as 95% of Life Cycle Cost (LCC) of an asset is
determined before it is put into use.

• This reveals the need for the Reliability Engineer to be involved in the design
and installation stages of projects for new assets and modification of existing
assets.

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RESPONSIBILITIES AND DUTIES

• Works with Project Engineering to ensure the reliability and maintainability of

new and modified installations. The Reliability Engineer is responsible for
adhering to the Life Cycle Asset Management (LCAM) process throughout the
entire life cycle of new assets.
• Participates in the development of design and installation specifications along
with commissioning plans. Participates in the development of criteria for and
evaluation of equipment and technical MRO (Maintenance, repair and
operation) suppliers and technical maintenance service providers. Develops
acceptance tests and inspection criteria.
• Participates in the final check out of new installations. This includes factory and
site acceptance testing that will assure adherence to functional specifications.

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• Guides efforts to ensure reliability and maintainability of equipment,
processes, utilities, facilities, controls, and safety/security systems.
• Defines, designs, develops, monitors and refines an Asset Maintenance
Plan that includes:
– Value-added preventive maintenance tasks
– Effective utilization of predictive and other non-destructive testing
methodologies designed to identify and isolate inherent reliability problems
• Provides input to a Risk Management Plan that will anticipate reliability-
related, and non-reliability-related risks that could adversely impact plant
operation.

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• Develops engineering solutions to repetitive failures and all other problems that
adversely affect plant operations. These problems include capacity, quality,
cost or regulatory compliance issues.
•  
Data analysis techniques that can include:
– Statistical Process Control
– Reliability modelling and prediction
– Fault Tree Analysis
– Weibull Tree Analysis
– Six Sigma (6σ) Methodology
• Root-cause and Root-Cause Failure Analysis (RCA, RCFA)
• Failure Reporting, Analysis and Corrective Action System (FRACAS)

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• Works with Production to perform  analyses of assets including:
– Asset Utilization
– Overall Equipment Effectiveness
– Remaining useful life
– Other parameters that define operating condition, reliability and costs of assets
• Provides technical support to production, maintenance management and
technical personnel.
• Applies value analysis to repair/replace, repair/redesign and make/buy
decisions.

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Failure Distribution

• Reliability Function : R(t)

• Cumulative Distribution Function: F(t)

• Probability Density Function: f(t)

• Design Life (t R)

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Reliability Function: R(t)

• Reliability is defined as the probability of a system / component /part that will

function adequately for the period intended under the given operating and
environmental conditions

• We define the continuous variable T to be the time to failure of the system

and T ≥ 0; then R(t) = Pr (T ≥ t)

• At t = 0 R(t) = 1 and at t = ∞ R(t) = 0 therefore 0 ≤ R(t) ≤ 1

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Cumulative Distribution Function: F(t)

• Cumulative Distribution Function F (t) is the probability that a failure occurs

before time t

• F(0) = 0 F(∞) = 1

• F(t) = 1 – R (t)

• Failure Distribution Function F (t) is the unreliability function

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Probability Density Function : f(t)

•  Probability Density Function is the first derivative of the Failure Density

Function and given by f(t)

• F(t) = 1 – R(t)

• f(t) =

• f(t) ≥ 0 and

• F(t) = and R(t) =

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Design Life

 • A design life is defined to be the time to failure t R that corresponds to a

specified / desired reliability R.

• R (t R) = R

• Failure occurring within some interval of time [a, b] = F(b) – F(a)

= R(a) – R(b)
=

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Mean Time to Failure (MTTF)

 MTTF is the first moment of probability density function f(t)

MTTF =

= -
Integrating by parts, we get

MTTF =

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Median Time to Failure (t med)

•  Median Time to Failure is the time with 50% of the failure occurring before
the median time to failure and 50% occurring after the median

• R (t med) = 0.5

• MODE Time to Failure

• F (t mode) = Max f(t) where 0 ≤ t ≤ ∞

• VARIANCE = =

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BITS Pilani, Pilani Campus
Hazard Rate Function
•  Hazard Rate Function is defined as the limit of the failure rate as the interval approaches zero.

• The hazard function is the instantaneous failure rate

• ƛ (t) = Lim △t⤑0

ƛ (t) = - x

ƛ (t) =

ƛ (t) dt = - Integrating both sides then = - ln R(t)

R(t) = exp [ -

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CFR and AFR

•  Cumulative Failure Rate (CFR) over a period of time t is defined by

L(t) =
• Average Failure Rate (AFR) between two time periods t1 and t2 is defined by
AFR (t1,t2) = =

If t1 = 0 and t 2 = t then AFR = = =

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Bath Tub

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SOLUTION 2.1 PAGE 38

 Given R(t) = t≥0

Find

R(100) = = = 0.9091

R(1000) = = = 0.5

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 b. = - ln R(t)

= - =

It is an increasing function as the value is positive.

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Solution 2.2 Page 39

 = 0.4 t where t is in years

a. R(t) = exp [ - = exp [ -

Hence when t = 1/12 year = 1 month R(t) = 0.9986

b. R (tr) = R = 0.95

exp -0.2 td2 = 0.95 td = 0.5064 years = 6 months

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Solution 2.3 Page 39

 Given f(t) = 0.01 where 0 ≤ t ≤ 100 days

a. R(t) =

b. ƛ (t) = =

c. MTTF = dt = 50 days

d. Variance = = 833.33 STD DEV = 28.87

e. R(t) = 1 – 0.01t = 0.5 tmed = 50 days

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SOLUTION 2.4 PAGE 39

 
Given f(t) = 0 ≤ t ≤ 1000 hrs.
a. Probability of failure within 100 hr warranty period

F(t) = = = 0.001
b. MTTF = dt = 750 hrs.

c. R(tr) = 0.99 = dt = 215.44 hrs.

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THANK YOU

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