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Reliability Engineering: Kartik Gupta 2K13/PE/016

Reliability engineering aims to ensure products function as intended for a specified period. It focuses on preventing failures through design and manufacturing quality control. Key objectives include failure prevention, identification and correction of causes, and reliability estimation. Reliability is important for reputation, customer satisfaction, costs and competitive advantage. The bathtub curve models failure rates that initially decrease after early failures, then remain constant during useful life before increasing due to wear. Reliability testing helps discover design issues and ensure requirements are met.

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Kartik Gupta
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164 views

Reliability Engineering: Kartik Gupta 2K13/PE/016

Reliability engineering aims to ensure products function as intended for a specified period. It focuses on preventing failures through design and manufacturing quality control. Key objectives include failure prevention, identification and correction of causes, and reliability estimation. Reliability is important for reputation, customer satisfaction, costs and competitive advantage. The bathtub curve models failure rates that initially decrease after early failures, then remain constant during useful life before increasing due to wear. Reliability testing helps discover design issues and ensure requirements are met.

Uploaded by

Kartik Gupta
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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RELIABILITY

ENGINEERING
Kartik Gupta
2K13/PE/016

INTRODUCTION
Reliability engineeringisengineeringthat
emphasizesdependabilityin thelifecycle managementof
aproduct. Dependability, or reliability, describes the ability
of a system or component to function under stated
conditions for a specified period oftime.
Reliability is theoreticallydefined as theprobabilityof
success (Reliability=1-Probability of Failure), as the
frequency of failures, or in terms ofavailability, as a
probability derived from reliability and maintainability.
"Reliability is, after all, engineering in its most
practical form."

OBJECTIVES OF RELIABILITY ENGINEERING

The objectives of reliability engineering, in the order of


priority, are:
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 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.

A basic life project cycle

WHY IS RELIABILITY IMPORTANT?

Reputation
Customer Satisfaction
Warranty Costs
Repeat Business
Cost Analysis
Customer Requirements
Competitive Advantage

REASONS FOR FAILURE


The load and strength of an item may be generally known, however
there will always be an element of uncertainty. The actual strength
values of any population of components will vary; there will be
some that are relatively strong, others that are relatively weak, but
most will be of nearly average strength. Similarly there will be some
loads greater than others but mostly they will be average. Figure 1,
below shows the load strength relationship with no overlaps.

However if, as shown in figure 2, there is an overlap of the


two distributions then failures will occur. There therefore
needs to be a safety margin to ensure that there is no
overlap of these distributions.

MEASURING RELIABILITY
REQUIREMENTS
Many customers will produce a statement of the reliability
requirements that is included in the specification of the
product. This statement should include the following:
The definition of failure related to the products function
and should cover all failure modes relevant to the function
A full description of the environments in which the product
will be stored, transported, operated and maintained
A statement of the reliability requirement

THE BATH TUB CURVE


The bath-tub curve is a representation of the reliability
performance of components or non repaired items
1. The infant mortality or early failures portion shows that the
population will initially experience a high hazard function that
starts to decrease.
2. After the initial phase when the weak components have been
weeded out and mistakes corrected, the remaining population
reaches a relatively constant hazard function period, known as
the useful life period
3. The final portion of the bath-tub curve is called the wear-out
phase, this is when the hazard function increases with time

LIFE DISTRIBUTIONS
If you take a large number of measurements you can
draw a histogram to show the how the measurements vary.
A more useful diagram, for continuous data, is the
probability density function. The y axis is the percentage
measured in a range(shown on the x-axis) rather than the
frequency as in a histogram. If you reduce the ranges(or
intervals) then the histogram becomes a curve which
describes the distribution of the measurements or values.
This distribution is the probability density function or PDF.

Survival function is given by

RELIABILITY PREDICTION
Assuming all the parts in a system are independently
exponentially distributed, i.e. one part does not cause the
other to fail then the overall system failure rate can be
calculated using the series system model shown above. For
example, the failure rate of a printed circuit board is the
sum of the failure rates of each of the components.

RELIABILITY TESTING
The purpose of reliability testing is to discover
potential problems with the design as early as
possible and, ultimately, provide confidence that
the system meets its reliability requirements.
Reliability testing may be performed at several
levels and there are different types of testing.
Complex systems may be tested at component,
circuit board, unit, assembly, subsystem and
system levels

Reliability testing
on the basis of no.
of failures to the
total time of
operation

Difference between Quality and Reliability


So while this product may have a reliable design, its quality is
unacceptable because of the manufacturing process.
Just like a chain is only as strong as its weakest link, a highly
reliable product is only as good as the inherent reliability of the
product and the quality of the manufacturing process.

Six Sigma
Six Sigma at many organizations simply means a measure of
quality that strives for near perfection. Six Sigma is a disciplined,
data-driven approach and methodology for eliminating defects
(driving toward six standard deviations between the mean and
the nearest specification limit) in any process from
manufacturing to transactional and from product to service.
Thestatistical representationof Six Sigma describes
quantitatively how a process is performing. To achieve Six Sigma,
a process must not produce more than 3.4 defects per million
opportunities. A Six Sigma defect is defined as anything outside
of customer specifications. A Six Sigma opportunity is then the

CONCLUSION
Ultimately the aim for reliability engineering is to
maximize reliability during service life by
measurement & control of manufacturing, quality /
screening, optimized design & build process to
improve intrinsic reliability, assure no systematic
faults present in product and to provide sufficient
margin to meet life requirements.
Thus all these factors lead to customer
satisfaction which is of utmost importance to
every manufacturer.

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