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Why Design for Reliability?

Reliability can make or break the long-term


success of a product:
Too high reliability will cause the product to be too
expensive
Too low reliability will cause warranty and repair
costs to be high and therefore market share will
be lost

What is Reliability?
Reliability is:
Elimination/avoidance of failure modes/mistakes
The probability that a product will perform its intended
function:
Under customer operating conditions
For a specified life
In a manner that meets or exceeds customer expectations

A reliable product is robust and mistake-free

Common Measures of Unreliability


% Failure - % of failures in a total population
MTTF (Mean Time To Failure) - the average time
of operation to first failure.

MTBF (Mean Time Between Failure) - the


average time between product failures.
Repairs Per Thousand (R/1000)
Bq Life Life at which q% of the population will
fail

When to Use DFR


DFR should be considered throughout the PD cycle:
Early - to develop "product concepts" which are
well suited for production (i.e., conceptual
product design)
Continually - to ensure that the chosen product
concept is implemented through optimal
component design

Steps in Designing for Reliability


1. Develop a Reliability Plan
Determine Which Reliability Tools are
Needed

2. Analyze Noise Factors


3. Tests for Reliability
4. Track Failures and Determine Corrective
Actions

1. Develop a Reliability Plan


Planning for reliability is just as important as
planning for design and manufacturing. Why?
To determine:
useful life of product
what accelerated life testing to be used
where to begin

Reliability must be as close to perfect as


possible for the products useful life.

A Reliability Plan helps ensure that product


reliability is optimized within the cost and
performance constraints of a program and
customer requirements.

How much reliability do you need? Should you


accelerate life testing? Where do you even begin?
Planning for product reliability is just as important as
planning for product design and manufacturing.
The amount of product reliability must be in
proportion to a product's usage and warranty goals.
Too much reliability and the product will be too
expensive. Too little reliability and warranty and repair
costs will be high.
You MUST know where your product's major points of
failure are!

2. Analyze Noise Factors


Inner Noises
Wear-out or fatigue
Piece-to-piece variation
Interfaces with neighboring subsystems

Outer Noises

External Operating Environment (e.g., climate,


road conditions, etc.)
Customer usage / duty cycle

3. Test for Reliability


How robust are the products?
Test to Bogey: assessing performance at a predetermined time,
cycle or number of miles. It estimates the proportion of failures at a
particular time. pass/fail
Test to Failure: shows when a component or system can no longer
perform at a specified level
Degradation Testing: focuses on the key stresses associated with
real world uses for example - increasing the tire load to create a tire
failure

How can you shorten the reliability test time for


new designs?
Key Life Test/Accelerated Test

4. Track Failures and Determine


Corrective Actions

Design for Reliability


Design strategy to ensure reliability can be
Fail-safe approach and
Worst-case approach
fail-safe approach is to identify the weak spots
in a component and provide some way to
monitor that weakness. When the weak link
fails, it is replaced, hence keeping the
component operational

Worst-case approach ,in it the worst


combination of parameters is identified and
the design is based on the premise that all can
go wrong at the same time

For the component to be reliable, we must


give some provision during the earliest design
concept stage,carried through the detailed
design development,and maintained during
the many steps in manufacture
The elements of integrating reliability into
design process are-

Testing, analysis, correct materials and process


specifications, quality control, scheduled
inspection and maintenance and repair and
replacement

Causes of unreliability
Design mistakes
Manufacturing defects
Maintenance
Exceeding design limits
Environmental factors

Minimizing failure
Margin of safety
Derating
Redundancy load sharing by components,
stand by units
Durability resistance to
corrosion,erosion,corrosion,fatigue etc
Damage tolerance

Ease of inspection
Simplicity in components and assemblies
Specificity use standard items

Assessing design reliability-procedure


Have a well established problem statement or
system definition
Draw the reliability block diagram which is
similar to functional block diagram stressing
areas which influence reliability
Prepare a list of parts in each block of
reliability block diagram

Collect data on failure and performance for each


component
Calculate the hazard rate or failure rate for each
component
Knowing failure rate of each component in each
block, combine the failure rates to calculate the
failure rate of each block
Compute the system reliability, its failure rate and
the mean time between the failures
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