reliability management benbow and broome (ch 1, 2, and 3) presented by dr. joan burtner certified...
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Reliability ManagementReliability Management
Benbow and Broome (Ch 1, 2, and 3)Benbow and Broome (Ch 1, 2, and 3)
Presented by Dr. Joan BurtnerPresented by Dr. Joan Burtner
Certified Quality Engineer Certified Quality Engineer
Associate Professor ofAssociate Professor of
Industrial Engineering and Industrial Industrial Engineering and Industrial ManagementManagement
Fall 2010 ETM 591 ISE Fall 2010 ETM 591 ISE 427 427
Dr. Joan Burtner, Associate Professor of Industrial EngineeringDr. Joan Burtner, Associate Professor of Industrial Engineering Slide Slide 22
OverviewOverview
Chapter 1 Strategic ManagementChapter 1 Strategic Management Definition of reliabilityDefinition of reliability Interrelationship of quality and reliabilityInterrelationship of quality and reliability Role of reliability in the organizationRole of reliability in the organization
Chapter 2 Reliability Program ManagementChapter 2 Reliability Program Management TerminologyTerminology Elements of a reliability programElements of a reliability program Product life cycle and costsProduct life cycle and costs
Chapter 3 Product Safety and ReliabilityChapter 3 Product Safety and Reliability Roles and responsibilities Roles and responsibilities Ethical issuesEthical issues Elements of a system safety programElements of a system safety program
Fall 2010 ETM 591 ISE Fall 2010 ETM 591 ISE 427 427
Dr. Joan Burtner, Associate Professor of Industrial EngineeringDr. Joan Burtner, Associate Professor of Industrial Engineering Slide Slide 33
Reliability Definition Reliability Definition
Reliability is defined as the probability that an Reliability is defined as the probability that an item will perform a required function without item will perform a required function without failure under stated conditions for a specified failure under stated conditions for a specified period of time.period of time.
Reliability statement components Reliability statement components Probability (at least ___ %) Probability (at least ___ %) Required function (by part, subassembly and assembled Required function (by part, subassembly and assembled
product)product) Stated conditions (may be mandated by Stated conditions (may be mandated by
industry/government regulations such as Underwriters industry/government regulations such as Underwriters Laboratory or Energy Star Program)Laboratory or Energy Star Program)
Specified period of time (duration in terms of hours, miles, Specified period of time (duration in terms of hours, miles, cycles, etc)cycles, etc)
Fall 2010 ETM 591 ISE Fall 2010 ETM 591 ISE 427 427
Dr. Joan Burtner, Associate Professor of Industrial EngineeringDr. Joan Burtner, Associate Professor of Industrial Engineering Slide Slide 44
Quality vs. Reliability Quality vs. Reliability
Strongly interrelatedStrongly interrelated Continuous improvementContinuous improvement Meet or exceed customer requirementsMeet or exceed customer requirements Important role in the design phaseImportant role in the design phase
Distinctions noted in the text Distinctions noted in the text Design process inputsDesign process inputs
• Quality – within tolerance at a reasonable costQuality – within tolerance at a reasonable cost• Reliability – functional for a longer period of timeReliability – functional for a longer period of time
Data collectionData collection• Quality – focus on manufacturing processQuality – focus on manufacturing process• Reliability – focus on manufactured productReliability – focus on manufactured product
In the workplace, functions often overlap.In the workplace, functions often overlap.
Fall 2010 ETM 591 ISE Fall 2010 ETM 591 ISE 427 427
Dr. Joan Burtner, Associate Professor of Industrial EngineeringDr. Joan Burtner, Associate Professor of Industrial Engineering Slide Slide 55
Role of Reliability in Role of Reliability in the Organization the Organization Traditionally, the focus of reliability engineering Traditionally, the focus of reliability engineering
is on product reliability, not human reliability.is on product reliability, not human reliability. What is the useful lifetime of the product?What is the useful lifetime of the product? What is the failure rate of in-house components and What is the failure rate of in-house components and
products?products? What is the failure rate of suppliers’ components?What is the failure rate of suppliers’ components?
Reliability techniques are also useful in other Reliability techniques are also useful in other areasareas Marketing and advertising (especially warranties)Marketing and advertising (especially warranties) Product liability (mitigate safety and health hazards)Product liability (mitigate safety and health hazards) Manufacturing processes (Do processes impact product Manufacturing processes (Do processes impact product
failure rates? How can preventive maintenance and failure rates? How can preventive maintenance and spare parts inventories improve reliability? Etc)spare parts inventories improve reliability? Etc)
Fall 2010 ETM 591 ISE Fall 2010 ETM 591 ISE 427 427
Dr. Joan Burtner, Associate Professor of Industrial EngineeringDr. Joan Burtner, Associate Professor of Industrial Engineering Slide Slide 66
Related I.A. Body of Related I.A. Body of Knowledge Topics Knowledge Topics Reliability in product and process development is Reliability in product and process development is
increasingly being implemented in the spirit of increasingly being implemented in the spirit of concurrent engineeringconcurrent engineering
Reliability engineers need to examine the Reliability engineers need to examine the consequences of failure, as opposed to a narrow consequences of failure, as opposed to a narrow focus on estimates of the probability of failurefocus on estimates of the probability of failure
Reliability engineers need to take the long-term view Reliability engineers need to take the long-term view and find cost-effective ways to reduce lifecycle costs.and find cost-effective ways to reduce lifecycle costs.
Listening to the Voice of the Customer applies to Listening to the Voice of the Customer applies to internal and external customers (beta testing, QFD).internal and external customers (beta testing, QFD).
Reliability professionals must have a working Reliability professionals must have a working understanding of project management tools.understanding of project management tools.
Fall 2010 ETM 591 ISE Fall 2010 ETM 591 ISE 427 427
Dr. Joan Burtner, Associate Professor of Industrial EngineeringDr. Joan Burtner, Associate Professor of Industrial Engineering Slide Slide 77
Reliability Terminology Reliability Terminology 1 1 Mean life definitionsMean life definitions
Average time to failure of identical products operating Average time to failure of identical products operating under identical conditionsunder identical conditions
Expected time to failureExpected time to failure
Mean time to failure (MTTF)Mean time to failure (MTTF) Applies to non-repairable productsApplies to non-repairable products Assumes the underlying failure distribution is Assumes the underlying failure distribution is
exponential and the failure rate is constantexponential and the failure rate is constant
Mean time between failures (MTBF)Mean time between failures (MTBF) Applies to repairable productsApplies to repairable products Assumes the underlying failure distribution is Assumes the underlying failure distribution is
exponential and the failure rate is constant exponential and the failure rate is constant
Fall 2010 ETM 591 ISE Fall 2010 ETM 591 ISE 427 427
Dr. Joan Burtner, Associate Professor of Industrial EngineeringDr. Joan Burtner, Associate Professor of Industrial Engineering Slide Slide 88
Reliability Terminology Reliability Terminology 2 2 Censored dataCensored data
Exact failure times Exact failure times (See Example 2.1)(See Example 2.1)
Right-censored data Right-censored data (only known might have failure happened after a certain (only known might have failure happened after a certain time) because item is still functioning when test is concluded)time) because item is still functioning when test is concluded)
Left-censored data Left-censored data (only known failure happened before a certain time (only known failure happened before a certain time because items were not checked at the beginning of the test period) because items were not checked at the beginning of the test period)
Interval-censored data Interval-censored data (only known failure happened between two times) (only known failure happened between two times)
Minitab users see caution on page 19Minitab users see caution on page 19 Mean time to repair (MTTR) is the average Mean time to repair (MTTR) is the average
time it takes to return the product to time it takes to return the product to operational statusoperational status
Failure rate (lambda) is the mathematical Failure rate (lambda) is the mathematical reciprocal of mean life: 1/MTBF or 1/MTTFreciprocal of mean life: 1/MTBF or 1/MTTF
Fall 2010 ETM 591 ISE Fall 2010 ETM 591 ISE 427 427
Dr. Joan Burtner, Associate Professor of Industrial EngineeringDr. Joan Burtner, Associate Professor of Industrial Engineering Slide Slide 99
Reliability Terminology Reliability Terminology 3 3 MaintainabilityMaintainability
Probability that a failed product will be repaired within a Probability that a failed product will be repaired within a given amount of time once it has failedgiven amount of time once it has failed
May be expressed as a function such as M(3) = .95May be expressed as a function such as M(3) = .95 Interpretation: There is a 95% probability that the product Interpretation: There is a 95% probability that the product
will be operable with three units of time (hours, days, etc)will be operable with three units of time (hours, days, etc) Maintenance definition should include a specific Maintenance definition should include a specific
maintenance action such as rebuild time or per maintenance action such as rebuild time or per procurement timeprocurement time
Availability Availability (equations on pp. 19-20)(equations on pp. 19-20)
Probability that a product is operable and Probability that a product is operable and in a committable in a committable state state when neededwhen needed
Probability that item has not failed or is not being repairedProbability that item has not failed or is not being repaired Takes into account an item’s reliability and maintainabilityTakes into account an item’s reliability and maintainability
Fall 2010 ETM 591 ISE Fall 2010 ETM 591 ISE 427 427
Dr. Joan Burtner, Associate Professor of Industrial EngineeringDr. Joan Burtner, Associate Professor of Industrial Engineering Slide Slide 1010
Six Elements of a Six Elements of a Reliability ProgramReliability Program Established reliability goals and requirementsEstablished reliability goals and requirements
• Minimum reliability requirements time dependent (reliability Minimum reliability requirements time dependent (reliability changes throughout life of product)changes throughout life of product)
Product designProduct design• Reliability requirements documented for each stageReliability requirements documented for each stage
Process designProcess design• Reliability requirements linked to process parametersReliability requirements linked to process parameters
Validation and verificationValidation and verification• Validate that requirements produce desired product reliabilityValidate that requirements produce desired product reliability• Verify that production can ‘deliver’ the valid requirementsVerify that production can ‘deliver’ the valid requirements
Post-production evaluationPost-production evaluation• Production samples, customer feedback, field service/warranty Production samples, customer feedback, field service/warranty
recordsrecords
Training and educationTraining and education
Fall 2010 ETM 591 ISE Fall 2010 ETM 591 ISE 427 427
Dr. Joan Burtner, Associate Professor of Industrial EngineeringDr. Joan Burtner, Associate Professor of Industrial Engineering Slide Slide 1111
Product Life-Cycle and Product Life-Cycle and Costs for HardwareCosts for Hardware Three stagesThree stages
Early failure (infant mortality or decreasing failure rate)Early failure (infant mortality or decreasing failure rate) Useful life stage (constant failure rate stage, random Useful life stage (constant failure rate stage, random
causes stage)causes stage) Wear-out stage (fatigue stage, increasing failure rate Wear-out stage (fatigue stage, increasing failure rate
stage)stage) See Bathtub Curve figure on page 23.See Bathtub Curve figure on page 23. Note that random causes are generally present Note that random causes are generally present
during all three stages.during all three stages. Change the curve / improve the productChange the curve / improve the product
Shorten the length and flatten the slope of early failureShorten the length and flatten the slope of early failure Decrease the constant failure rateDecrease the constant failure rate Delay the onset of the wear-out stage and reduce the Delay the onset of the wear-out stage and reduce the
slopeslope
Fall 2010 ETM 591 ISE Fall 2010 ETM 591 ISE 427 427
Dr. Joan Burtner, Associate Professor of Industrial EngineeringDr. Joan Burtner, Associate Professor of Industrial Engineering Slide Slide 1212
Product Life-Cycle and Product Life-Cycle and Costs for SoftwareCosts for Software Two stagesTwo stages
Test phaseTest phase Useful lifetimeUseful lifetime
See typical reliability curve on page 24.See typical reliability curve on page 24. It is better to prevent errors than to detect It is better to prevent errors than to detect
faults.faults. Change the curve / improve the software codeChange the curve / improve the software code
Make it modularMake it modular Keep it simpleKeep it simple Document, document, documentDocument, document, document
Fall 2010 ETM 591 ISE Fall 2010 ETM 591 ISE 427 427
Dr. Joan Burtner, Associate Professor of Industrial EngineeringDr. Joan Burtner, Associate Professor of Industrial Engineering Slide Slide 1313
Design EvaluationDesign Evaluation
Important at various stages throughout the life-Important at various stages throughout the life-cyclecycle
Failure prevention approaches for early stagesFailure prevention approaches for early stages Fault tolerance – redundant systemsFault tolerance – redundant systems Fault avoidance – design for more than minimum Fault avoidance – design for more than minimum
reliabilityreliability• Derating (“the practice of using components for lower Derating (“the practice of using components for lower
stress levels than specified by the standards” p. 128)stress levels than specified by the standards” p. 128) Evaluation for later stages Evaluation for later stages (See page 26)(See page 26)
Environmental stress screeningEnvironmental stress screening Reliability development/growth testsReliability development/growth tests Reliability qualification testsReliability qualification tests Production reliability acceptance testsProduction reliability acceptance tests
Fall 2010 ETM 591 ISE Fall 2010 ETM 591 ISE 427 427
Dr. Joan Burtner, Associate Professor of Industrial EngineeringDr. Joan Burtner, Associate Professor of Industrial Engineering Slide Slide 1414
Three Elements of a Three Elements of a System Safety System Safety ProgramProgram Identification of safety hazardsIdentification of safety hazards
““The reliability engineer must be innovative and diligent in the The reliability engineer must be innovative and diligent in the discovery of all possible ways … present a safety hazard to discovery of all possible ways … present a safety hazard to personnel.”personnel.”
Risk analysisRisk analysis Use standard analysis techniques such as FMEA,FMECA, Use standard analysis techniques such as FMEA,FMECA,
FTA,STA,FRACAS, and PRAT(production reliability acceptance test)FTA,STA,FRACAS, and PRAT(production reliability acceptance test) Use results to establish prioritized list to help resolve root causesUse results to establish prioritized list to help resolve root causes
Correction and preventionCorrection and prevention Implement change requests as necessaryImplement change requests as necessary Use mistake-proofing techniquesUse mistake-proofing techniques
• Physical barriers to errors such as shapesPhysical barriers to errors such as shapes• Visual reminders for usersVisual reminders for users• Use of automated equipment to mitigate a detected errorUse of automated equipment to mitigate a detected error• Standardizing operations for similar partsStandardizing operations for similar parts
Fall 2010 ETM 591 ISE Fall 2010 ETM 591 ISE 427 427
Dr. Joan Burtner, Associate Professor of Industrial EngineeringDr. Joan Burtner, Associate Professor of Industrial Engineering Slide Slide 1515
ReferencesReferences
Course Text:Course Text: Benbow, D.W. and Broome, H.W., Ed. (2009). Benbow, D.W. and Broome, H.W., Ed. (2009).
The Certified Reliability Engineer HandbookThe Certified Reliability Engineer Handbook . . Milwaukee,WI: ASQ Quality Press.Milwaukee,WI: ASQ Quality Press.
Additional Sources Additional Sources Westcott, R.T., Ed. (2006). Westcott, R.T., Ed. (2006). Certified Manager of Certified Manager of
Quality/Organizational Excellence HandbookQuality/Organizational Excellence Handbook (3 (3rdrd ed.). Milwaukee: ASQ Quality Press.ed.). Milwaukee: ASQ Quality Press.
Fall 2010 ETM 591 ISE Fall 2010 ETM 591 ISE 427 427
Dr. Joan Burtner, Associate Professor of Industrial EngineeringDr. Joan Burtner, Associate Professor of Industrial Engineering Slide Slide 1616
Contact InformationContact Information
Email: [email protected]: [email protected] US Mail:US Mail:
Mercer University School of Mercer University School of Engineering Engineering
1400 Coleman Avenue 1400 Coleman Avenue
Macon, GAMacon, GA Phone: (478) 301- 4127Phone: (478) 301- 4127