IS JUST A WISH
MANUFACTURING
RELIABILITY PROGRAM PLAN
§2.2
§2.3
Reference: Z. Klim
§1.8
Definition
Known as Programs’ Concept phase, defines the reliability
requirements
Design
First round verification: assesses the reliability
Validation
Known as Programs' Development phase, analyses and improves the
reliability
Manufacturing
Assures the reliability
Operation
Monitors and controls reliability
What has been the past performance of the product ? For past
performance, we can use data from
Field analysis
HALT testing
Any other reliability studies
Predictions
If this is the first product, we can benchmark the product against
competitors in the industry and use their data
The gap analysis is a key part of the plan because it
sets the expectation on how much improvement is necessary from
the previous generation
it helps dictate the tools that will be needed to reach the new
reliability goals
it helps dictate the schedule / how long it will take to achieve these
goals
To make this task more manageable, we must break down by Assembly
What are the results for the current product by Assembly ?
What are the goals for the new product by Assembly ?
What is the Gap by Assembly ?
INDU 691/4 - Winter 2018 DR. SORIN VOICULESCU
RELIABILITY PROGRAM PLAN (EXTRA)
As with most programs, the gap will likely fall somewhere in between.
So, we must develop a well-balanced program that has selected tools
from each of the phases
Design tools
Prototype tools
Manufacturing tools
The implementation and integration of each tool is perhaps the most
difficult to plan. Here we must estimate the effects each tool will have
on the overall reliability to understand how we are closing the gap
For this, we must look at specific issues that occurred on previous
products and understand how a specific tool will help mitigate this
issue on this next generation
If we can quantify the effect an issue had and we can quantify the
reduction as a results, then we have evaluated how we are going to
close the gap.
Specifically, DFR describes the entire set of tools that support product
and process design (typically from early in the concept stage all the
way through to product obsolescence) to ensure that customer
expectations for reliability are fully met throughout the life of the
product with low overall life-cycle costs.
In other words, DFR is a systematic, streamlined, concurrent
engineering program in which reliability engineering is weaved into
the total development cycle. It relies on an array of reliability
engineering tools along with a proper understanding of when and
how to use these tools throughout the design cycle.
This process encompasses a variety of tools and practices and
describes the overall order of deployment that an organization needs
to follow in order to design reliability into its products.
DFR statements
1) Reliability must be designed into products and processes using the
best available science-based methods.
2) Knowing how to calculate reliability is important, but knowing how
to achieve reliability is equally, if not more, important.
3) Reliability practices must begin early in the design process and
must be well integrated into the overall product development cycle.
1.2 Status
5. Prevailing sentiment 5
4
1.3 Measured cost
of Unreliability
4.3 Reliability
3
Improvement Process
2
2.1 Requirement
4.2 Validation & and Planning
Verification
2.2 Training
and development
4.1 Failure data &
tracking analysis
3.2 Testing
INDU 691/4 - Winter 2018 DR. SORIN VOICULESCU
DFR PHILOSOPHY (REMINDER)
Scenario A: Both the actual and the assessed reliabilities are below the
target value and hence, further development is needed. Note that if
any of the constraints (e.g., development cost and/or development
time) are violated the development programme might be terminated.
Reference: Z. Klim
Reference: Z. Klim
RISK MANAGEMENT
determines the processes,
techniques, tools, and team roles
and responsibilities for a specific
project. The risk management
plan describes how risk
management will be structured
and performed on the project.
https://www.mitre.org/publications/systems-engineering-guide/acquisition-systems-
Reference:
engineering/risk-management/risk-management-approach-and-plan
INDU 691/4 - Winter 2018 DR. SORIN VOICULESCU
IDENTIFYING RISKS IN THE SYSTEMS
ENGINEERING PROGRAM - RELIABILITY
INDU 691/4 - Winter 2017 (Lecture 06, February 15een, 2017) DR. SORIN VOICULESCU 55
SIMILARITY
INDU 691/4 - Winter 2017 (Lecture 06, February 15een, 2017) DR. SORIN VOICULESCU 56
SIMILARITY ASSESMENT Identical (I) Similar (S) Different (D) Details
A. Design Parameters
1. Function
2. Specification/
Performances
3. Parts (based on bill of
materials)
4. Structure (for
mechanical components)
5. Material (for
mechanical components)
6. Shape/geometry (for
mechanical components)
7. Schematic/Circuit/
Boards/Packing etc.
8. Software
9. Components/Parts/
LRU/material supplier
10. Product Assembly
11. Development and
manufacturing Processing
12. Other
__________________
B. Operational Conditions
1. Duty Cycle
2. Voltage
3. Power
4. Pressure
5. Mechanical stress
6. Other
__________________
C. Environmental Conditions
1. Temperature
2. Vibration
3. Moisture
4. Electromagnetic
radiation
5. Humidity
6. Shock
7. Icing
8. Altitude
(pressurized/unpressurize
d)
9. Acceleration
10. Chemicals
11. Other
_____________________
Value
Design parameters
Operational Conditions
Environmental Conditions
TOTAL
INDU 691/4 - Winter 2017 (Lecture 06, February 15een, 2017) DR. SORIN VOICULESCU 57
SIMILARITY ASSESSMENT - OUTCOME
I S D
Identical to equipment
Similar to equipment
with sufficient field Different to equipment
with sufficient field data.
data or minor with sufficient field data.
Minor differences, on
Design Similarity differences, on Major difference in
characteristics that has a
characteristics that has design for at least one
major impact on
a demonstrated minor reliability driver.
component reliability.
impact on reliability.
Similar, minor Different, major
differences (differences differences (differences
not more than 15%) for more than 15%) for
Operational Conditions Identical
major operational major operational
reliability factors except reliability factors except
duty cycle. duty cycle.
Identical or the
environments, both Different, the
Similar, the environments,
amplitude and environments, both
both amplitude and
duration, encountered amplitude and duration,
duration, encountered by
by the unit providing encountered by unit
Environmental Conditions unit
field data have been with field data < 90%
with field data > 90%
more severe than the less severe than the
than the environments
environments intended environments intended
intended for new unit.
for new design. for new unit.
INDU 691/4 - Winter 2017 (Lecture 06, February 15een, 2017) DR. SORIN VOICULESCU 58
BREAK-DOWN SIMILAR INTO IDENTICAL
& DIFFERENT
For any result « similar », the item under study needs to be broken-
down further.
E.g.: similar design of a power supply because the connecters are new
but the electronic board is identical. Action: consider electrical
connectors as one item (different) and electronic board as a separate
item (identical)
https://www.mitre.org/publications/systems-engineering-guide/acquisition-systems-
Reference:
engineering/risk-management/risk-management-approach-and-plan
INDU 691/4 - Winter 2018 DR. SORIN VOICULESCU
RELIABILITY AND THE PROGRAM PLAN –
A RISK BASED APPROACH
The user should consider even the ones which seem not to be at risk
due to what might seem obvious reasons.
RISK LEVEL 2: any risk that cannot yet be fully justified and needs
extra validation but there are high chances that the validation will
reduce the risk to level 1
RISK LEVEL 3: new items (different from the similarity analysis)
RESULT I I I
Note: generally, for a simple case like this, the reliability is expected to
decrease by 5 times. This statement is true under some specific
assumptions
1. The dormant phase (80% of the duty cycle has a much lower
impact on the reliability than the operating phase), and
2. The dormant phase does not imply any action (e.g. bearing is
auto lubricated during the off phase) and, by eliminating it,
there is no impact on the operational phase.
Note: X value depends on the project and on the results of the reliability
matrix (see assess you assets chapter)