Concurrent Engineering

QMZG663
BITS Pilani
Pilani Campus

Lecture 8

BITS Pilani
Pilani Campus

Design for
Reliability

Contents
Reliability
FMEA
Design for Safety

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Why Engineering items fail?

Inherently incapable design
Overstressed
Variation (Strength Load)
Wear out (Moving members, corrosion, Insulation
deterioration)
Sneaks or bugs
Errors in the assembly
Many others

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Classification of failures
Non - Repairable
Light bulb
Transistor
Diode
Domestic switches
Usually addressed by Mean Time To Failure (MTTF)

Repairable
Systems such as Automobiles, Air conditioners, refrigerators
Usually addressed by Mean Time Between Failure (MTBF)

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Objectives of Reliability Engg

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

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Reliability Economics

Traditional

Modern
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Definitions
Reliability:

- The

ability of an item to perform a required function under

stated conditions for a stated period of time ( BS 4778)

Hazard Rate(): (also called failure rate)

- Is the number of failures per unit time per the number of
items exposed for the same time
Like 1% per 1000 hour

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Bathtub curve

Applicable for electronic components

Initial failures (with in break-in) are
high due to infant mortality due to
design, mfg , installation failures.
Can be minimized by final QC at factory
to filter good from bad
After initial break- in, failure will occur
less and less and will reach constant
value only random failures occur at
constant failure rate. Finally wear out
will accelerate the failure
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Applicable for Mechanical

components
They do not exhibit constant
failure rate.

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Definitions
Mean time to failure (MTTF):
The sum of the survival time for all of the
components divided by the number of failures.
This is used for parts that are not repaired (light
bulb or transistor or spacecraft). When a part
fails , the system fails

Mean time between failures (MTBF):

The mean time between two successive
component failures. MTBF is similar to MTTF,
but applied for components or systems that can
be repaired.
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Examples

MTTF
- For example, assume you tested 3 identical systems starting from
time 0 until all of them failed. The first system failed at 10 hours, the
second failed at 12 hours and the third failed at 13 hours. The MTTF
is the average of the three failure times, which is 11.6667 hours .
(10+12+13) / 3 = 11.6667
MTBF
- If 10 components are tested for 100 hours, 2 components failed at 70 and 80
hours respectively, then MTBF is
((8*100) + 70 + 80) / 2 = 475
and failure rate () = 1/ MTBF = 1/475 = 0.021 (failure / hour)

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Average Failure Rates for a Variety of

Components and Systems

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Definitions
If R(t) is the reliability with respect to time,
then F(t) is the unreliability (probability of
failure) in the same time.
If components are put on test, the number
surviving to or at time t is , and the number
that failed between t=0 and t=t is .
Definition of reliability:
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Constant Failure Rate

For the special case of a constant failure rate

Also items which survive after the t period Ns= N0 exp (t ) --------- A

For example, if failure rate is 2 x 10- 6 failures / hour, what is the MTBF. Find
also Reliability and number of failures expected, for operating period of 50,000
hours if 2000 items are under testing.
MTBF =

R(t) =

which is 500,000 Hours

= 0.905

Survived items = 2000 x 0.905= 1810 (from A)

Failures expected = 2000 1810 = 190

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Derivation
If
there are Ns items surviving at time t, then in a small
period of ,

==ln Ns + ln C = t
Ns = C exp ( t ) ; If N0 is the number of items at t=0 then C = N0
Ns= N0 exp (t )
R(t) = = exp ( t )

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Reliability With A Variable Failure Rate

Mechanical failures, and some failures of electronic components, do

not exhibit a period of constant failure rate.

Since the failure rate is a function of time, the simple exponential

relation for reliability no longer applied.

Instead, reliability is expressed by the Weibull distribution:

m shape parameter
Scale parameter (Characteristic value)
t- random variable

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System Reliability

The overall reliability of the system depends on how the individual

components with their individual failure rates are arranged.

If the components are arranged so that the failure of any component

causes the system to fail, it is said to be arranged in series:

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System Reliability

A much better arrangement of components is one in which it is

necessary for all components in the system to fail in order for the
system to fail. This is called parallel reliability:

R System
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= 0.995

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System Reliability (2)

If we are dealing with a constant-failurerate system:
Series:
Parallel:

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Binomial distribution
The reliability of an n-out-of-m system is
given by a binomial distribution:

=4321=
4!
24

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Solved problem: (14.7 Dieter &Schmidt)

mplex engineering design can be described by a reliability block diagram as show

below. In subsystem A, two components must operate for the subsystem to fun
essfully. Subsystem C has true parallel reliability. Calculate the reliability of each
ystem and the overall system reliability.

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Solution

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Maintenance and Repair

An important category of reliability problems
deals with maintenance and repair of systems
If a failed component can be repaired while a
redundant component has replaced it in service,
then the overall reliability of the system is
improved
If components subject to wear can be replaced
before they have failed, then the system
reliability will be improved
Preventive maintenance is aimed at minimizing
system failure
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Maintainability

A redundant system continues to operate when a component has

failed, but it may become vulnerable to shutdown unless the
component is repaired and placed back in service.
Where MTBF= mean time between failures
MTTF=mean time to fail
MTTR=mean time to repair

Maintainabiltiy is the probability that a component or system that

has failed will be restored to service within a given time.

t- repair rate
r- permissible time to carry out the repair

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Maintainability

For a large computer installation, the maintenance crew logbook shows that
over a period of a month there were 15 unscheduled maintenance actions
or downtimes, and 1200 minutes in emergency maintenance status. Find
the permissible time in which 95% of maintenance action can be completed.

MTTR = 1200/15 = 80 minutes

the repair rate, t is 1/80 = 0.0125 repairs/minute

t = 240 minutes is the time in which 95% can be achieved.

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Availability
Availability is the concept that combines
both reliability and maintainability; it is the
proportion of time the system is working
on line to the total time, when that is
determined over a long working period.

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Design for Reliability

The design strategy used to ensure reliability can fall
between two broad extremes
The fail-safe approach is to identify the weak spot in the
system or component and provide some way to monitor
that weakness (redundancy etc)
Frequently an absolute worst-case approach is used, in it
the worst combination of parameters is identified and the
design is based on the premise that all can go wrong at
the same time
This is a very conservative approach, and is often leads to
overdesign
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Design for Reliability (2)

Two major areas of engineering activity
determine the reliability of an engineering
system:
1. Provision for reliability must be established during
the design concept stage, carried through the
detailed design development, and maintained
during the many steps in manufacture
2. Once the system becomes operational, it is
imperative that provision be made for its
continued maintenance during its service
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Causes of Unreliability
Design mistakes:
Among the common design errors are failure to include all important
operator factors, incomplete information on loads and environmental
conditions, erroneous calculations, and poor selection of materials

Manufacturing defects:
Poor surface finish, decarburization crack in heat-treated steel

Maintenance
Exceeding design limits:
Exceeding limits of temperature, speed, etc.

Environmental factors:
Subjecting equipment to environmental conditions for which it was not
designed
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Minimizing Failure
A variety of methods are used in
engineering design practice to improve
reliability:
Margin of safety
Derating
Redundancy
Durability
Damage tolerance
Ease of Inspection
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FMEA
Failure mode and effects analysis (FMEA) is a teambased methodology for identifying potential problems
with new or existing designs
FMEA was first used to identify and correct safety
hazards
FMEA identifies the mode of failure of every
component in a system and determines the effect on
the system of each potential failure
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Factors in Developing FMEA

Three factors are considered in developing a
FMEA:
The severity of a failure
The probability of occurrence of the failure.
The likelihood of detecting the failure in either design
or manufacturing, before the product is used by the
customer.

Risk Priority Number (RPN):

Value of RPN can vary from a maximum of
1000, the greatest risk, to a minimum of 1.
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Rating for Severity of Failure

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Rating of Occurrence of Failure

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Rating of Detection of Failure

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Results Of A FMEA Analysis

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An example of FMEA

After
improvement

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Creating a FMEA Chart

1. The design is reviewed to determine the interrelations of
assemblies and the interrelations of the components of
each subassembly
2. Now look more broadly, and ask what are the
consequences to the system of each failure identified in
step1
3. For each of the functions, list the potential failure mode
4. For each of the failure modes identifies, describe the
consequences or effect of the failure
5. Using the severity of failure table, enter the numerical
value
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Creating a FMEA Chart (2)

6. Identify the possible causes of the failure mode
7. Using the occurrence of failure table, enter a value for the
occurrence of the cause of each failure
8. Determine how the potential failure will be detected
9. Using Table shown earlier, enter a rating that reflects the
ability to detect the cause of the failure identified in step 8
10.Calculate the risk priority number (RPN)
11.For each potential failure, determine the corrective action
to remove a potential design, manufacturing, or
operational failure
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Design For Safety

Safety may well be the paramount issue in product design
Normally we take safety for granted, but the recall of an
unsafe product can be very costly in terms of product
liability suits, replaced product, or tarnished reputation
The product must be safe to:
Manufacture
Use
Dispose of after use

A safe product is one that does not cause injury or

property loss
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Aspects To Design for Safety

1. Make the product safe, design all hazards out of the
product
2. If it is not possible to make the product inherently
safe, then design in protective devices like guards,
automatic cutoff switches, and pressure-relief valves,
to mitigate the hazard
3. If step 2 cannot remove all hazards, then warn the
user of the product with appropriate warnings like
labels, flashing lights, and loud sounds
4. Provide training and protective clothing or devices to
the user or operator of the equipment
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Fail-Safe Design
A fail-safe design seeks to ensure that a failure will either not
affect the product or change it to a state in which no injury or
damage will occur
There are three variants of fail-safe design:
Fail-passive design:
When a failure occurs, the system is reduced to its lowest-energy state, and
the product will not operate until corrective action is taken

Fail-active design:
When failure occurs, the system remains energized and in a safe operating
mode

Fail-operational design:
The design is such that the device continues to provide its critical function
even though a part has failed
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Guidelines for Design for Safety

1. Recognize and identify the actual or potential hazards,
and then design the product so they will not affect its
functioning
2. Thoroughly test prototypes of the product to reveal any
hazards overlooked in the initial design
3. Design the product so it is easier to use safely than to
use unsafely
4. If field experience turns up a safety problem, determine
the root cause and redesign to eliminate the hazard
5. Realize that humans will do foolish things, and allow for
it in your design
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Guidelines for Design for Safety (2)

6. There is a close correspondence between good
ergonomic design and a safe design
7. Minimize the use of flammable materials, including
packaging materials
8. Paint and other surface finishing materials should be
chosen to comply with EPA and OSHA regulations for
toxicity to the user and for safety when they are burned,
recycled, or discarded
9. Think about the need for repair, service, or maintenance
10. Electrical products should be properly grounded to
prevent shock
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Warning Labels
With rapidly escalating costs of product liability,
manufacturers have responded by plastering their
products with warning labels
Warnings should supplement the safety related design
features by indicating how to avoid injury or damage
from the hazards that could not be feasibly designed out
of the product without seriously compromising its
performance
Attention is achieved by printing:
Danger
Warning
Caution
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Thank you

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