Executing Design for Reliability Within the Product Life Cycle

380 Pages·2019·39.727 MB·English

by  Ali Jamnia, Khaled Atua

Executing Design for
Reliability within the Product
Life Cycle

Executing Design for
Reliability within the Product
Life Cycle
Ali Jamnia and Khaled Atua
CRC Press
Taylor & Francis Group
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I would like to dedicate this book to Norah, my daughter and my best
friend, and the memory of my late father, the teacher.
Khaled Atua
In turn, I too would like to dedicate this work to Naseem, my daughter,
the apple of my eye, and to the memory of my late father.
Ali Jamnia

Contents
List of Figures ................................................................................................................................xv
Preface ...........................................................................................................................................xxi
Authors .......................................................................................................................................xxiii
1. Reliability, Risk, and Their Significance ...........................................................................1
Introduction ..............................................................................................................................1
A History of Reliability and Background on Design for Reliability (DfR) .....................2
Reliability Metrics ....................................................................................................................4
Cost and Return of Reliability ...............................................................................................5
Quality, Reliability, and Robustness .....................................................................................7
Organizational DfR Maturity and Reliability Competency ..............................................8
A Cross-Functional Process ...............................................................................................9
Product Risk ...........................................................................................................................13
Notes ........................................................................................................................................14
2. Design for Reliability Process ...........................................................................................17
Introduction ............................................................................................................................17
Reliability Requirements, Planning, and Execution in the Design Process..................18
Elements of Design for Reliability .......................................................................................18
Product Use Profile ...........................................................................................................19
Life Expectancy, Design Life, and Failure Rate ............................................................20
Product Reliability Prediction and Modeling ...............................................................20
Reliability Modeling ....................................................................................................20
Reliability Testing ........................................................................................................21
Reliability Data Analysis .............................................................................................22
Reliability Allocation ...................................................................................................23
Other Aspects of Reliability .................................................................................................23
Reliability and Its Association with Product Risk .......................................................24
Note ..........................................................................................................................................25
3. The Design Process and the V-Model ..............................................................................27
Introduction ............................................................................................................................27
Product Development Models .............................................................................................27
The V-Model for Life Cycle Management......................................................................29
Engineering Activities ......................................................................................................31
Systems and Requirements ..................................................................................................32
Voice of the Customer and Voice of Stakeholders ........................................................34
Design Documents ............................................................................................................35
Subsystem Design Document.....................................................................................38
Subsystem Architecture Document ..........................................................................38
Assembly Design Document ......................................................................................38
Developing Product Requirements .....................................................................................39
Defining the Product to Be Developed ..........................................................................39
vii
viii Contents
Measuring What Customers Need .................................................................................40
Development of Product Requirements ........................................................................41
Translation from Needs to Requirements ................................................................42
Product Requirements Document .............................................................................42
Quality Function Deployment ........................................................................................43
Using QFD in Product Development ........................................................................44
Requirements Decomposition ....................................................................................45
The V-Model in a Nutshell ...................................................................................................47
Reliability Planning and Execution in the V-Model .........................................................47
Notes ........................................................................................................................................50
4. Reliability Requirements, Modeling, and Allocation ..................................................51
Introduction ............................................................................................................................51
Developing Reliability Requirements .................................................................................52
Reliability Metrics .............................................................................................................52
Mean Time between Failures .....................................................................................52
Mean Time to Failure (MTTF) ....................................................................................53
Failure Rate ...................................................................................................................53
Reliability and Life .......................................................................................................54
Availability ....................................................................................................................54
Mean Cumulative Function ........................................................................................54
Probability of Success Rate and Out-of-Box Failures ..............................................55
Required Inputs for Developing Requirements ................................................................55
Reliability Requirements Based on Voice of Business .................................................56
Reliability Requirements Based on Voice of Customer ...............................................57
Reliability Requirements Based on Use Profile ............................................................57
Product Mission ............................................................................................................57
Product Use Distribution ............................................................................................58
Use and Operating Conditions ..................................................................................58
Reliability Modeling and Allocation...................................................................................58
Reliability Modeling .........................................................................................................59
Example .........................................................................................................................61
Reliability Requirement Allocation ................................................................................63
Example .........................................................................................................................64
Developing the Apportionment Table .......................................................................65
Reliability Requirements Feasibility and Gap Analysis .........................................66
Case Study .....................................................................................................................66
Other Considerations in Reliability Requirements Development .............................71
A Summary of Criteria for Reliability Requirements ..................................................72
Notes ........................................................................................................................................72
5. Reliability Planning.............................................................................................................73
Introduction ............................................................................................................................73
Design for Reliability Plan Process .....................................................................................76
Business Plan .....................................................................................................................76
Design and Development Plan .......................................................................................76
Needed Inputs ...................................................................................................................78
Functional Requirements Document and System Architecture ...........................78
Use Profile Document ..................................................................................................80
Contents ix
Detailed Design Documents .......................................................................................81
Failure Modes and Effects Analysis Documents .....................................................82
Test Articles ...................................................................................................................82
Design for Assembly (DfA) and Design for Serviceability (DfS) ..........................82
Design for Reliability Plan ...............................................................................................83
Baseline Reliability Model ..........................................................................................83
Design Documents .......................................................................................................83
Reliability Growth, Evaluation, and Demonstration Testing ................................83
Final Reliability Model ................................................................................................84
Highly Accelerated Stress Screening ........................................................................84
Design for Reliability Deliverables .................................................................................84
Notes ........................................................................................................................................85
6. Reliability Statistics .............................................................................................................87
Introduction ............................................................................................................................87
Basic Definitions ....................................................................................................................88
Continuous Distributions and Reliability Analysis .........................................................90
Normal Distribution Model.............................................................................................91
Example .........................................................................................................................92
Exponential Distribution Model .....................................................................................92
Example .........................................................................................................................93
Example .........................................................................................................................94
Gamma Distribution ........................................................................................................94
Application to Cumulative Damage ..........................................................................95
Case Study: Pressure Sensor First Failure after Partial Physical Damages .........95
Chi-Square Distribution ..............................................................................................97
Failure-Truncated Test .................................................................................................98
Time-Truncated Test.....................................................................................................98
Example .........................................................................................................................98
Lognormal Distribution ...................................................................................................99
Weibull Distribution .......................................................................................................100
A Modified Weibull Distribution .............................................................................101
Example .......................................................................................................................102
Selecting the Right Distribution for Continuous Variables ......................................102
The Exponential Distribution ...................................................................................103
The Lognormal Distribution ....................................................................................103
The Weibull Distribution ..........................................................................................104
Discrete Distributions and Their Applications to Reliability .......................................104
Binomial Distribution .....................................................................................................104
Example .......................................................................................................................105
Geometric Distribution ..................................................................................................106
Example .......................................................................................................................106
Hypergeometric Distribution ........................................................................................106
Example .......................................................................................................................107
Poisson Distribution .......................................................................................................108
Example .......................................................................................................................108
Case Study: New Product Launch ................................................................................109
Case Study: Expected Service Calls .............................................................................111
A Discussion on Reliability Metrics and the Bathtub Curve ........................................112
Notes ......................................................................................................................................114