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Chapter-8-Design For Reliability - Updated

The document discusses design for reliability which includes specifying reliability goals, translating goals to component specifications, proper selection of parts and materials, stress-strength analysis, and failure mode and effects analysis. It describes various design methods like redundancy, derating, and complexity reduction to improve reliability.

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51 views37 pages

Chapter-8-Design For Reliability - Updated

The document discusses design for reliability which includes specifying reliability goals, translating goals to component specifications, proper selection of parts and materials, stress-strength analysis, and failure mode and effects analysis. It describes various design methods like redundancy, derating, and complexity reduction to improve reliability.

Uploaded by

Flexiblepp
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Taibah University

College of Engineering
Industrial Engineering Department

IE-442-Engineering Reliability and


Maintainability

Chapter 8: Design for Reliability


Design for Reliability

 Reliability design is an iterative


process that begins with the
specification of reliability goals
consistent with cost and performance
objectives.
 Reliability goals must be translated
into individual components,
subcomponents and part
specification.

 Design method is applied to meet the


goals.
Design for Reliability

Design method include the proper


selection of parts and material, stress-
strength analysis and identification of
technologies

FMEA/FMECA An iterative process


that influences design by identifying
failure modes, assessing their
probabilities of occurrence and their
effects on the system, isolating their
causes, and determining corrective
action or preventive measures (page
167).
Physical Reliability Models

 Table 8.1 shows the typical product life cycles and the major activities
influencing reliability.
Reliability Specification and System Effectiveness

 Unless a component has a constant failure rate, the MTTF or MTBF (Mean
Time Between Failures) are insufficient to characterize its reliability.
 Specifying a desired reliability R(t) at time t for a component is more useful that
specifying MTTF or MTBF.

- Example: 99% reliability after 2 years (or after 2,000 cycles) is more
informative that MTTF should be 10 years
Reliability Specification and System Effectiveness
Reliability Specification and System Effectiveness
System Effectiveness

 System Effectiveness
= Operational readiness × Availability × Design adequacy

Selection from among design alternatives:


- Maximize system effectiveness subject to life-cycle cost upper bound
- Minimize life-cycle cost subject to system effectiveness lower bound
But also count: Minimum acceptable reliability, product safety requirements, etc
Economic Analysis and Life-Cycle Costs

Life-cycle cost = acquisition costs + operations costs + failure cost + support


costs – net salvage value

Where Net salvage value = (salvage value – disposal cost)


Economic Analysis and Life-Cycle Costs

Life- cycle cost


Reliability Allocation

 How should you allocate reliabilities to components (or subcomponents)


of a system such that your system’s reliability goal is achieved?

 We want

 For series configuration of independent failure modes


Reliability Allocation… Optimal Allocations
Reliability Allocation… Optimal Allocations
Reliability Allocation… ARING Method
Assumptions:

– System composed on n components in serial configuration


– Components have constant failure rates λi (but could be applied
to non constant failure rates if averages are used).
– Largest failure rate is λ*
Reliability Allocation… AGREE Method

• AGREE: Advisory Group on Reliability of Electronic Equipment


• Assumptions:

– System composed on n components in serial configuration


– Components in composed of ni-sub-components (or modules)
Reliability Allocation… AGREE Method
Design Methods
Design Methods…Parts and Material Selection
• Tensile strength
• Hardness
• Impact Value
• Fatigue Life (Fatigue strength)

• Creep
• Heat capacity
• Thermal conductivity
• Electrical resistivity
• Magnetic permeability
• Etc

Selection of desirable properties is function of cost, ease of repair, parts


availability, energy requirements, weight, size, etc
Design Methods…Derating & Complexity and Technology

• Derating: Use of a component under stress significantly below its rated value
(Development of Derating curves: Failure rates versus applied stress/rated
stress)
– Electronic equipment: Design voltage significantly higher than
normal operating conditions.

• Complexity and Technology:

– Number of parts in a system is one measure of system complexity


• Part minimization: Reduce number of parts by replacing them with
multifunction parts.
• Part variation: Increase use of common part
– Use of alternative technologies to achieve the same goals with
greater reliability, less complexity, etc…
• Analog display vs digital display
Design Methods…Derating & Complexity and Technology
Design Methods…Stress-Strength Analysis

• Objective: Often performed for the objective of verifying that enough safety
margin (SF) has been design into the system

• Design approaches to respond to stress-strength


analysis:
– Select parts and material with sufficient strength to withstand the maximum
possible load
– Protect the part against excessive stresses

• Types of stress:
– Electrical, Thermal, Mechanical, Chemical
– Environmental (External) or Operating (Internal)
Design Methods…Redundancy

• Useful when some (or all) of the components’ reliabilities have already been
established by design

• May also increase reliability against external environmental


stresses.

• Again, design trade-off: Cost, weight of additional components,


maintenance & repair of additional components, etc.

• How redundancy Optimized:


– Marginal Analysis
– Lagrangian Multiplier
Design Methods…Redundancy
Failure Analysis

• FMEA/FMECA: Failure Mode and Effect Analysis/Failure Mode Effect


and Criticality Analysis.

FMEA/FMECA An iterative process that influences design by identifying


failure modes, assessing their probabilities of occurrence and their effects
on the system, isolating their causes, and determining corrective action or
preventive measures (page 167).
Failure Analysis

• FMEA/FMECA: Failure Mode and Effect Analysis/Failure Mode, Effect


and Criticality Analysis
Failure Analysis

 FMEA/FMECA steps

1. System definition
• identify system components that will be subject to failure
• Functional and physical (hardware) Description of the system
• A physical description of the system is presented by a diagram showing
subassemblies, components, and parts along with hierarchical
relationships.
Failure Analysis

 FMEA/FMECA steps

2. Identification of failure mode


• failure mode will be identified either by
component(hardware) or function
Failure Analysis

 FMEA/FMECA steps

3. Determination of cause

• For each failure made an assessment is made as to


the probable cause or causes.

 Examples of causes.
Failure Analysis
Failure Analysis

 FMEA/FMECA steps

4. Assessment of effect
• the impact of each failure has on the operation or
status of the system is assessed.
Failure Analysis

 FMEA/FMECA steps

5. Classification of severity
• A severity classification is assigned to each failure.
Failure Analysis

 FMEA/FMECA steps

6. Estimation of probability of occurrence


Failure Analysis

 FMEA/FMECA steps

7. Computation of critical index


this is a quantitative measure of the criticality of the failure modes
that combines the probability of the failure mode with its severity
ranking.

8. Determination of corrective action


This is very dependent on the problem.
Failure modes, cause, effects
Corrective actions

 Design activity should be oriented toward for

- Removing the cause of the failure


- Decreasing the probability of occurrence of failure
- Reducing the severity of the failure
Questions?

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