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Chapter 1 Introduction to Reliability Engineering

Chapter One introduces Reliability Engineering (RE), defining it as the study of a product's ability to perform its functions without failure over time under specified conditions. It emphasizes the importance of reliability in manufacturing for maximizing output and profitability while discussing the drawbacks of reactive management techniques. The chapter also explores the concepts of probability and its relationship to reliability, including the use of random variables and probability functions in analyzing system performance.

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Avi Patel
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4 views

Chapter 1 Introduction to Reliability Engineering

Chapter One introduces Reliability Engineering (RE), defining it as the study of a product's ability to perform its functions without failure over time under specified conditions. It emphasizes the importance of reliability in manufacturing for maximizing output and profitability while discussing the drawbacks of reactive management techniques. The chapter also explores the concepts of probability and its relationship to reliability, including the use of random variables and probability functions in analyzing system performance.

Uploaded by

Avi Patel
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Chapter One

Introduction to Reliability Engineering

Topics:
• What is RE?
• Why Reliability?
• Reactive Management Technique
• Concept of Probability & it Link to Reliability
• Cost of Reliability
What is RE?
• Reliability means "yielding the same,"

• The word "reliable" means something is dependable and that


it will give the same outcome every time.

• Reliability engineering is an engineering framework that


enables the definition of a complete production regime
and deals with the study of the ability of the product to
perform its required functions under stated conditions for a
specified period of time.
• Reliability engineering is applied to a

component, product, plant, or process in

order to assure that it performs its intended

function, without failure, for the required

time duration in a specified environment.


• A product has to endure for several years of
its life and also perform its desired function,
despite all the threatening stresses applied to
it, such as temperature, vibration, shock,
voltage, and other environmental factors.
• It analyzes the failure and repair of the systems
to improve their use by increasing their design
life, mitigating defect risks, and reducing the
likelihood of failures.
• Reliability engineering is closely related to
statistics and probability theory.
• Reliability is also defined as the probability
that a component (or an entire system) will
perform its function for a specified period of
time, when operating in its design
environment.
• The broader definition of reliability is that
"reliability is the science to predict, analyze,
prevent and mitigate failures over time.“

• We can try to prevent potential failures, acting


on the design and manage complex systems,
materials and maintenance over their life
cycles.
Why Reliability?
The Need for Reliability

• Every manufacturing facility wants production

equipment to operate reliably.

• When the equipment does what it needs to do

when it needs to do it, plant output and

profitability is maximized.
• No organization wants assets

– to break down,

– to produce poor quality products, or

– to operate inefficiently.

• We want them to operate perfectly.


• Unfortunately
– we don’t live in an ideal world

– no physical asset operates flawlessly forever.

– In most organizations, breakdowns are the norm.

– Quality and productivity losses are high.

– Scheduled shipments are missed.


Reactive Management Technique
• Run to failure maintenance is a reactive management
technique that waits for machine or equipment
failure before any maintenance action is taken.
• It is the most expensive way to manage maintenance.
• Reactive maintenance centers on the craftsperson.
• When a problem develops, a craftsperson is
dispatched to identify and correct the failure or
deficiency.
• Usually, he must make multiple trips to the:
– tool room for additional tools,
– shop for additional technical information, and
– spare parts storeroom to get spare parts to repair the
problem
• In most cases, this approach results in
– the equipment to run to failure
– excessive downtime, lower availability
– low productivity and high costs
– high production and maintenance effort-hours.
• This reactive management method forces the

maintenance department to maintain extensive spare

parts inventories that include spare machines or at least

all major components for all critical equipment in the

plant.

• Analysis of maintenance costs indicate that a repair

performed in the reactive or run to failure mode will

average about three times higher than the same repair

made within a scheduled or preventive mode.


• If the right systems, structure, processes and
procedures are in place and executed well, losses
are minimized, the operation is stable, production
output is maximized and quality is high.
• We call this a state of Reliability Excellence (Rx).
Concept of Probability & it Link to Reliability
• Probability is a measure of the certainty in which an event might
occur.
• This definition is easily implemented when dealing with several
distinct events.
• When a continues random variable is examined, however, it becomes
harder to use this definition directly, because the term "event" is
somewhat elusive.
• Random variable
• In probability and statistics, a random variable, random quantity,
or stochastic variable is described as a variable whose values
depend on outcomes of a random phenomenon.
Types of Random Variables

• In general, most problems in reliability engineering deal with

quantitative measures, such as the time-to-failure of a

component

• There are two types of random variables that can be used in the

analysis of this type of data.

• In judging a component to be defective or non-defective, only two

outcomes are possible.

• In this case, X is a random variable that can take on only two

discreet values (let's say defective = 0 and non-defective = 1), the

variable is said to be a discrete random variable.


• In the case of times-to-failure data, our random
variable X can take on the time-to-failure of the
product or component and can be in a range from 0 to
infinity (since we do not know the exact time apriori).

• The product can be found failed at any time after time


0 (e.g. at 12.4 hours or at 100.12 hours and so forth),
thus X can take on any value in this range.

• In this case, our random variable X is said to be


a continuous random variable.
PMF, PDF and CDF
• For a discrete random variable X that takes on a finite or countably
infinite number of possible values, we determined P(X = x) for all
of the possible values of X, and called it the probability mass
function (PMF).

• If X is a continuous random variable, then the probability density


function, pdf, of X is a function f(x) such that for two
numbers, a and b with a <= b:

P(a < X < b) = .

• That is, the probability that X takes on a value in the interval [a,b]
is the area under the probability density function from a to b.
• From probability and statistics, given a (continuous)
random variable X, we denote:
– The probability density pdf, as f(x).
– The cumulative density cdf, as F(x).
• The cumulative distribution function (cdf), a
function F(x), is the probability that the variable
takes a value less than or equal to x.

• For a continuous distribution, this can be expressed

mathematically as F(x) = P(X<x) =

• For a discrete distribution, the cdf can be expressed

as

F(x) = )
• Note that depending on the function denoted by f(x),
or more specifically the distribution denoted by f(x),
the limits will vary depending on the region over
which the distribution is defined.
• For example, this range would be [0,+ꝏ], [- ꝏ,+ ꝏ]
or [γ,+ꝏ].
• In the case of [γ,+ꝏ] we use the constant γ to
denote an arbitrary non-zero point or location
The Difference Between PDF and CDF:
• This means that PDF looks at a
fixed point or an interval whereas
CDF looks at everything below a
point.
• The CDF is the integral of PDF,
hence PDF is the derivative of CDF.

• The horizontal axis is the allowable domain for the given probability
function.
• Since the vertical axis is a probability, it must fall between zero and one.
The mathematical relationship between the pdf and cdf
• The CDF is derived from the PDF by summing the amount of
probability in each increasing class in order to sum to one
with the probability on the final class.

• Thus, the mathematical relationship between

the pdf and cdf is given by:

• Were s is a dummy integration variable.


• Conversely:

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