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Concurrent Engineering QMZG663: BITS Pilani
Concurrent Engineering QMZG663: BITS Pilani
QMZG663
BITS Pilani
Pilani Campus
Lecture 8
BITS Pilani
Pilani Campus
Design for
Reliability
Contents
Reliability
FMEA
Design for Safety
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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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To identify and correct the causes of failures that do occur, despite the
efforts to prevent them.
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
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Bathtub curve
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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
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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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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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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) =
= 0.905
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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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m shape parameter
Scale parameter (Characteristic value)
t- random variable
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System Reliability
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System Reliability
R System
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= 0.995
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Binomial distribution
The reliability of an n-out-of-m system is
given by a binomial distribution:
=4321=
4!
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Solution
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Maintainability
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.
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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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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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An example of FMEA
After
improvement
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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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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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