application of mil-hdbk-189 reliability growth analysis ... · 3 approved for public release,...
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Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Application of MIL-HDBK-189 Reliability Growth Analysis (RGA) on Mobile Gun System (MGS) Product Verification Test (PVT)
Sharad Kumar, Senior Director, System EngineeringJohn Paulson, Director, Stryker Program
Dmitry E. Tananko, Ph.D., Manager, Reliability and Robust Engineering
Jenny Chang, PM SBCT, TACOM
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Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Agenda
What is MGSSuccess Factors of MGS PVT
Program Management – Integrated TeamSystem Engineering and Reliability AttainmentReliability Data Analysis – RGA
FDSC – Failure Definition Scoring CriteriaFailure CategoriesInherent vs. Induced ReliabilityMission Profile and Life VariableData Grouping and Modeling Instantaneous vs. Cumulative Reliability
MGS Lesson Learned - DFR
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Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
AgendaWhat is MGSSuccess Factors of MGS PVT
Program Management – Integrated TeamSystem Engineering and Reliability AttainmentReliability Data Analysis – RGA
FDSC – Failure Definition Scoring CriteriaFailure CategoriesInherent vs. Induced ReliabilityMission Profile and Life VariableData Grouping and Modeling Instantaneous vs. Cumulative Reliability
MGS Lesson Learned - DFR
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Stryker Family of Vehicles
NBC Reconnaissance Vehicle NBC Reconnaissance Vehicle (NBCRV) 3(NBCRV) 3
120mm Mounted Mortar Carrier120mm Mounted Mortar Carrier(MC(MC--B) 37B) 37
Fire Support Vehicle Fire Support Vehicle (FSV) 14(FSV) 14
Medical Evacuation Vehicle Medical Evacuation Vehicle (MEV) 16(MEV) 16
Commander’s Vehicle Commander’s Vehicle (CV) 28(CV) 28
Anti Tank Guided Missile Anti Tank Guided Missile (ATGM) 10(ATGM) 10
Reconnaissance Vehicle Reconnaissance Vehicle (RV) 52(RV) 52
Infantry Carrier Vehicle Infantry Carrier Vehicle (ICV) 130(ICV) 130
Engineer Squad Vehicle Engineer Squad Vehicle (ESV) 13(ESV) 13
Mobile Gun System (MGS) 27Mobile Gun System (MGS) 27
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Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Mobile Gun System – The Bunker Buster
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BLUF – Key Factors for Successful Reliability Growth Program
Program Management – Integrated TeamThe systems, tools, and practices now in place between the US Government and General Dynamics Land Systems allowed the system’s reliability to grow (repeatable process)Reliability growth requires commitments from Material Developer Team, Combat Developer, and Independent Test and Evaluation Communities (requirements, test, data, methodology, tools)
System Engineering – Reliability BackboneIntegrates All Reliability TasksRedirects Tasks Toward a Single ObjectiveCrosses Boundaries Affecting Operational ReliabilityProvides Program Manager Authority, Funding, and Focus on Engineering, Processes, Documentation, Training, Manufacturing, and Testing for Reliability
Reliability Data Analysis – Reliability AssessmentFDSC – Failure Definition Scoring CriteriaFailure Categories
Inherent vs. Induced ReliabilityMission Profile and Life VariableData Grouping and Modeling Instantaneous vs. Cumulative Reliability
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7
Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Agenda
What is MGSSuccess Factors of MGS PVT
Program Management – Integrated TeamSystem Engineering and Reliability AttainmentReliability Data Analysis – RGA
FDSC – Failure Definition Scoring CriteriaFailure CategoriesInherent vs. Induced ReliabilityMission Profile and Life VariableData Grouping and Modeling Instantaneous vs. Cumulative Reliability
MGS Lesson Learned - DFR
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Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
MGS Program Management
Phase I - Conduct an Additional Reliability Test (ART)
Validate effectiveness of 216 PQT and Post-PQT corrective actions
Phase II - Implement changes to Government and GDLS Systems Engineering Processes
Management and process changes
Phase III - Redesign of Sub-System components and integration
Additional Reliability Testing (DEC 2004 – MAR 2005)
2 vehiclesPre-ART – XXX rounds & X00 milesART – XXX rounds & X,000 milesReliability Point Estimate XX MRBSA
Reliability Growth Test (JUL-AUG 2005)2 VehiclesXXX roundsX,000 milesReliability Point Estimate XX MRBSA
Production Verification Testing (APR 2006 - DEC 2007)
3 VehiclesXXXX roundsXX,000 milesOn-going – Current estimate XXX MRBSA
Plan Tests
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Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
MGS Rebaselined MEP Idealized Growth CurveRGT Demonstrated Reliability
0
10
20
30
40
50
60
70
80
90
100
0 1000 2000 3000 4000 5000 6000 7000 8000
Rounds Fired
MRB
SA
Rebaselined Idealized Growth Curve
PreART & ART(909 rds)
RGT(688 rds)
PVT(5160 rds)
20% RGT Threshold50 MRBSA
93 MRBSA
81 MRBSA 80% Conf.
47 MRBSA
Input ParametersMTBFi = 47ti = 909T=6757α = 0.22
RGT Demostrated Reliability57 MRBSA
MGS Idealized Growth Curve
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Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
AgendaWhat is MGSSuccess Factors of MGS PVT
Program Management – Integrated TeamSystem Engineering and Reliability AttainmentReliability Data Analysis – RGA
FDSC – Failure Definition Scoring CriteriaFailure CategoriesInherent vs. Induced ReliabilityMission Profile and Life VariableData Grouping and Modeling Instantaneous vs. Cumulative Reliability
MGS Lesson Learned - DFR
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MGS - Systems Engineering Approach
Integrates All Reliability Tasks
Redirects Tasks Toward a Single Objective
Crosses Boundaries Affecting Operational Reliability
Provides Program Manager Authority, Funding, and Focus on Engineering, Processes, Documentation, Training, Manufacturing, and Testing for Reliability
Approach Provides Metrics that can be Measured
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Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
SE Approach to Reliability
ModelingAllocationPrediction
FMEAParts Program
FRACASFailure
Prevention & & Review Board
Verification
Potential MTBF
Design Phase RG/DT
Manage Growth Potential
Higher Initial MTBF At Start Of Test
Increase Design Effectiveness Using Robust Design Methodology
Failure PreventionFailure CategorizationTimely Corrective Actions
Increase Initial MTBF
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ReliabilityReliabilityGrowthGrowth
In DesignIn Design
IssuesIssuesResolved / Resolved /
ClosedClosed
Outputs, Results, IssuesOutputs, Results, Issues
CriticalCriticalIssuesIssues
Design for Reliability Management Focuses on Failure Prevention
Failure Prevention and Failure Prevention and Review BoardReview BoardFMEA andFMEA and
Fault TreeFault Tree
VerificationVerification
ValidationValidation
Reliability GrowthReliability Growth
IRGT, FRACASIRGT, FRACAS
MaintainabilityMaintainabilityRequirementsRequirements
SafetySafetyRequirementsRequirements
ReliabilityReliabilityRequirementsRequirements
DefinitionsDefinitions
EnvironmentalEnvironmentalRequirementsRequirements
ManufacturingManufacturingfor Reliabilityfor Reliability
Parts SelectionParts Selection
MaintainabilityMaintainabilityAnalysisAnalysis
SafetySafety
Design Design –– StressStressReliabilityReliability
Reliability DesignReliability DesignTradeoffTradeoff
Requirements Review
Analyses
PerformancePerformanceRequirementsRequirements
SupportSupportRequirementsRequirements
Testing
Failure ModeFailure ModeMitigationMitigationRisk ModesRisk Modes
Expanded FMEAExpanded FMEAWorksheetWorksheet
Design forReliability
Update Status
DARTDARTProcessProcess
InteractiveInteractiveReliability andReliability andDesign ActivityDesign ActivityAnd ReviewsAnd Reviews
FPRBFPRB
Management SystemsIdentify
Risk Modes
© 2000 – 2007 Dr. Larry H. Crow Used by GDLS With The Permission of Dr. Crow.
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Stryker – Mobile Gun SystemFailure Prevention and Resolution Implementation
FPRB SteeringCommittee
Weekly
FPRBDaily
Corrective Action
2X per Week
PVT Retrofit Review
2X per Week
Quality Committee
2X per Week
Failure Analysis2X per Week
Prevention & Systemic
Issue Committee
Weekly
HYDRAULICLEAK
FOCUS TEAM
HARNESS &ELECTRICALFOCUS TEAM
ISSUES
ISSUES
ISSUES
ISSUES
CA Design Oversight
STATUS
STATUS
STATUS
STATUS
DECISIONSAPPROVAL
DECISIONSAPPROVAL
DECISIONSAPPROVAL
DECISIONSAPPROVAL
DECISIONS / APPROVAL
STA
TUS
ISSU
ES
DEC
ISIO
NS
DEC
ISIO
NS
STATUS
LRU &SIGHTS
FOCUS TEAMADDITIONAL
TEAMSAS REQ’D
INDEPENDENT(MUNRO)
FOCUS TEAM
Reliability Assessments
and PredictionsSTATUS
External Experts
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Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Agenda
What is MGSSuccess Factors of MGS PVT
Program Management – Integrated TeamSystem Engineering and Reliability AttainmentReliability Data Analysis – RGA
FDSC – Failure Definition Scoring CriteriaFailure CategoriesInherent vs. Induced ReliabilityMission Profile and Life VariableData Grouping and Modeling Instantaneous vs. Cumulative Reliability
MGS Lesson Learned - DFR
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Reliability Data Analysis
Proper Reliability Assessment is a key for the program success at PVTReliability Assessment must be discussed up front and consensus should be reached on:
FDSC – Failure Definition Scoring CriteriaFailure Categories
Inherent vs. Induced ReliabilityMission Profile and Life VariableData Grouping and Modeling Instantaneous vs. Cumulative Reliability
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FDSC – Failure Definition Scoring Criteria
FDSC is Contractual Document that definesFailure/non-Failure EventTest related Event Severity of Failure as it relates to the MissionCause of the Failure
FDSC is prepared as required by Army Regulation 70-1, Army Acquisition Policy.FDSC is being used through out the test for Scoring purposes, hence it is a major document for Reliability Assessment
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Failure Categories
Performance FM – FM is repeatable with 100% probability of failure for the given procedure/conditions. (Example: TDS overheating) Software FM – same as above, but software related.Quality FM – happens when vehicle is not built/maintained/operated as designed and is not repeatable after fixing (probability of failure =0%). Can be broken down into Initial Quality, Maintenance, Operator error, etc. (Example: Improperly installed harness, turret lock bended, etc.)Potential Reliability FM – happens when vehicle was built/maintained/operated as designed/intended; probability of failure is greater than 0% and less than 100%; usually happens due to wear out, environment, insufficient design, manufacturingvariability, etc.
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Failure Mode Categorization ProcessInherent vs. Induced Failure
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Categorize Failures and take Relevant Management Actions
Failure Chargeability
Human26%
Performance43%
Quality7%
Reliability24%
HumanPerformanceQualityReliability
Training and ManualsDesign SimplificationsManagement of Maintenance Actions
Robust DesignAdequate Design MarginDFMEAStep-wise Verification
Root Cause AnalysisDesign CorrectionsSelective Redesigns
Supplier Quality Management
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Data GroupingKnown Equivalent Time Unknown Equivalent Time
Miles
Roun
ds
Actual Mission Profile Run
OMS / MP
AEC Grouping
Miles
Rou
nds
0
Instantaneous MRBSA vs Rounds
Rounds
Inst
anta
neou
s M
RB
SA
Crow (NHPP)
Beta=0.5945
Inst
anta
neou
s M
RB
SA
0
Instantaneous Failure Intensity vs. Rounds
Rounds
Inst
ant.
Failu
re In
tens
ity
Crow (NHPP)
Beta=0.5827
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Rounds and Miles Accumulation per Vehicle vs. Calendar Time
UET model takes into account any discrepancies between different vehicles following through the test in calendar time
KET Model can be useful in the beginning of the test when vehicles have not accumulated enough mileage and rounds.
Cum Miles vs Calendar Time
Calendar Time
Cum
Mile
s
Cum Rounds vs Calendar Time
Calendar Time
Cum
Rou
nds
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Crow/AMSAA Model
Cum Number of Failures
Cum Failure Rate
Cum MTBF
Inst Failure Rate
Inst MTBF
βλ TNE ⋅=)(
1)( −⋅== βλ TTNErc
( ) ( ) 111 −−− ⋅== βλ TrMTBF cc
( ) 1))(( −⋅⋅=⋅
== ββ
βλλ tdt
tddt
NEdri
( ) ( ) 111 −−− ⋅⋅== ββλ TrMTBF ii
0
ReliaSoft's RGA 6 PRO - RGA.ReliaSoft.com
Cumulative Number of Failures vs Rounds
Rounds
Cum
. Num
ber o
f Fai
lure
s
Crow (NHPP)
Beta=0.5827
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Cumulative vs. Instantaneous Reliability
Reliability growth on the Development test is the result of Corrective Actions.Estimating Reliability of the product by taking the Cumulative reliability (total number of failures / total time on the test) does not take into account the growth on the test.
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Idealized Growth Curve and Observed Parametric Curve for Demonstrated Instantaneous MRBSA
Cu m Ro u n d s
Inst
. MR
BSA
Milestone 3
S C1 S C2 S C3 S C4 S C5/5a S C6 S C7 S C8 S C9
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Agenda
What is MGSSuccess Factors of MGS PVT
Program Management – Integrated TeamSystem Engineering and Reliability AttainmentReliability Data Analysis – RGA
FDSC – Failure Definition Scoring CriteriaFailure CategoriesInherent vs. Induced ReliabilityMission Profile and Life VariableData Grouping and Modeling Instantaneous vs. Cumulative Reliability
MGS Lesson Learned - DFR
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DFR Process Elements
Boundary Diagram / System Block Boundary Diagram / System Block DiagramDiagramInterface matrixPP--DiagramDiagramDFMEADFMEAReliability & Robustness MetricsDVP&RDVP&RReliability Demonstration MetricsReliability Demonstration Metrics
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DFSS (DCOV) Flow of Analysis & Tools
Signifies the OPTIMUM S/N Set point…Signifies the OPTIMUM S/N Set point…
Function ModelingConcept Generation
& Selection
DoERobust Design & Tolerance Design
Functions
VOC KJ QFD
Customer Needs/Statements
Customer Requirements
FMEA
Technical Requirements
Reliability/Robustness Demonstration
0.1 1.0 10.0 100.0
1
2
3
5
10
20
30 40 50 60 70 80 90 95
99
Time to Failure
Per
cent
Probability Plot for time5Weibull Distribution-95.0% Conf idence Interv als
Censoring Column in censor5
ShapeScale
MeanStDev
MedianIQR
1.2257 7.8398
7.3357 6.0165
5.8135 7.3970
0.1 1.0 10.0 100.0
1
2
3
5
10
20
30 40 50 60 70 80 90 95
99
Time to Failure
Per
cent
Probability Plot for time5Weibull Distribution-95.0% Conf idence Interv als
Censoring Column in censor5
ShapeScale
MeanStDev
MedianIQR
1.2257 7.8398
7.3357 6.0165
5.8135 7.3970
Concepts
D
C
O
V
Boundary Diagram
P-DiagramDFMEA
Reliability & Robustness MetricsReliability
Demonstration
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Design For Reliability Map
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0
ReliaSoft's RGA 6 PRO - RGA.ReliaSoft.com
Instantaneous MRBSA vs Rounds
Rounds
Inst
anta
neou
s M
RB
SA
Crow (NHPP)
Beta=0.5945
MIL-HDBK-189 RGA MethodMGS MEP PVT Instantaneous MRBSA
Continuing the effort to ensure MGS reliability growth
• Systems Engineering Process continues to be worked “24/7”
• GDLS Senior Leadership briefed on a daily basis
• Focus on implementation of Corrective actions on both the Test Vehicles and the Fielded vehicles
• GDLS teams at our vendors to work failure analysis and ensure MGS gets their top priority
• Outside experts on reliability and quality regularly review our processes in engineering and Manufacturing so we keep getting better
Continuing the effort to ensure MGS reliability growth
• Systems Engineering Process continues to be worked “24/7”
• GDLS Senior Leadership briefed on a daily basis
• Focus on implementation of Corrective actions on both the Test Vehicles and the Fielded vehicles
• GDLS teams at our vendors to work failure analysis and ensure MGS gets their top priority
• Outside experts on reliability and quality regularly review our processes in engineering and Manufacturing so we keep getting better
• Failure Rate continues to decrease, thus demonstrating substantial reliability growth in PVT
• Sustained decrease of MGS Failure Rate suggests infant mortality region is passed and design is maturing
• Failure Rate continues to decrease, thus demonstrating substantial reliability growth in PVT
• Sustained decrease of MGS Failure Rate suggests infant mortality region is passed and design is maturing
• Demonstrated Instantaneous MRBSA for decision-makers
• Growth Rate is 0.4
• RGA Methodology was developed and agreed by RAM-T Community
• Demonstrated Instantaneous MRBSA for decision-makers
• Growth Rate is 0.4
• RGA Methodology was developed and agreed by RAM-T Community
0
ReliaSoft's RGA 6 PRO - RGA.ReliaSoft.com
Instantaneous Failure Intensity vs.Rounds
Rounds
Inst
ant.
Failu
re In
tens
ity
Crow (NHPP)
Beta=0.5945
Rounds
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Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Keys to Success
Program Management forms Integrated Team (Material Developers, Tester/Evaluators, User) that has clear priority and focus on Reliability with clear understanding of Evaluation Criteria and Test Methods up front.
System Engineering assembles Reliability tools into Disciplined processes and Working Organizations
Reliability Assessment is reached through in-depth analysis and consensus between all involved parties
Program Management + System Engineering + Reliability = Success
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Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Questions and Discussion
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Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
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Approved for Public Release, Distribution Unlimited, GDLS approved, log 2008-04, dated 02/11/08.
Dmitry Tananko, Ph.D.General Dynamics Land SystemsTel.: (586) 634-5071E-mail: [email protected]