Reliability Allocation Technique

Reliability Allocation Technique
F e b r u a r y 2 0 1 1

Reliability Allocation Technique | February 2011

2011, HCL Technologies. Reproduction Prohibited. This document is protected under Copyright by the Author, all rights reserved.

TABLE OF CONTENTS

Abstract ............................................................................................. 3
Abbreviations .................................................................................... 4
Market trend/ Challenges .................................................................. 5
Solution ............................................................................................. 7
Best Practices ................................................................................. 11
Common Issues .............................................................................. 12
Conclusion....................................................................................... 13
Reference ........................................................................................ 14
Author Info ....................................................................................... 14


3
Abstract
Every system has a reliability goal that needs to be achieved.
Reliability allocations are used to set the goals for various sub-
system or functional blocks such that the overall system level
reliability can be achieved in an effective way. There are various
methodologies that exist to provide guidelines on the allocation
techniques, which are more theoretical. The allocation technique
described here ensures that the allocation is done rationally with
consideration of factors such as complexity, state of art and duty
cycle of the functional group or sub-system. This approach was
experimented in one of the HCL Project and found the approach to
be more pragmatic than compared to the other allocation
techniques.


4
Abbreviations
Sl. No. Acronyms (Page No.) Full form
1 AGREE (5) Advisory Group
on Reliability of
Electronic
Equipment
2 C (8,9,10) Complexity
3 Co (8,9,10) Cost of Reliability
Enhancement
4 Cr (8,9,10) Criticality
5 D (10,11,12) Duty Cycle
6 R (7,10) Reliability
7 R
t
(7) Target Reliability
8 S (8,9,10) State of the art
9 Z (8,9,10) Proportionality
Factor
10 (7,10) Weightage factor


5
Market trend/ Challenges
Generally, as mentioned in the abstract, there are several methods
to do a reliability allocation. These methods are selected based on
the information available about the system on its application.
1. Equal Apportionment
The simplest method of all for allocating reliability is to distribute the
target reliability equally among all sub-systems. For example, if the
target reliability for a system is 0.95 and it has got 3 sub-systems,
then the uniform allocation of reliability to all the components may
require each component to have a reliability of 0.984. While this is
the easy method of allocating the reliability, it is not always the best
method of allocation. The weakness of this method is that
subsystem goals are not assigned in accordance with the degree of
difficulty associated with realization of allocated target reliability.
2. ARINC
The ARINC method assumes that failure rates of the subsystems
are known. These rates can be obtained from either existing failure
data or failure rate prediction standards. This method reduces
subsystem failure rates by equal percentages such that the failure
rate goal is reached. The rationale behind the ARINC method is that
it requires equal effort to reduce failure rates by an equal
percentage of failure rates. Even if the effort to reduce the failure
rate increases non-linearly with the percentage of failure rate, it
leads to the minimum overall effort needed to achieve the failure
rate goal.
3. AGREE
This method takes into consideration subsystem complexity,
mission time, and importance. Equal effective failure consequences
are allocated to all elements. Failure rate allocation of a subsystem
is proportional to its complexity. Failure rate allocation of a
subsystem is inversely proportional to its mission time. Failure rate
allocation of a subsystem is inversely proportional to its importance.
When the importance of all elements is the same, the AGREE
method allocates equal effective failure rates for all elements.
4. Feasibility of Objectives
This method was developed primarily to allocate the reliability of
non-repairable mechanical-electrical systems. Subsystem allocation
factors are computed as a function of numerical ratings of system
intricacy, state of the art, performance time, and environmental
conditions. On the basis of their experience, design engineers
estimate and assign ratings on scales from 1 to 10.

Reliability is not by Chance


6
Challenges
The four methods described earlier are available for the reliability
engineer to do the reliability allocation. The result of allocation
varies based on the method used and is always debatable. The
choice and the subjectiveness in the method selection results in
variation of allocated targets and hence leads to situations where
the sub systems / modules are over / under budgeted with respect
to reliability. Even the most sought Feasibility of objectyive
methodology focus on only four important factors and misses out
other factors which could have a sever impact on module /
subsystem reliability.
If the reliability allocation result is very stiff / easy, it has different
impacts on the product design . The stiff target could puts pressure
on the designers in selection of COTS items, material, process and
increase the cost while the easy target means the design is not
sufficiently challenged and is putting extra allocation on complex
sub systems.
The challenge stated above opens a area of research to devise a
new technique which can be tailored each time based on the
product application and product knowledge. This will help to
minimize the subjectiveness and helps to consider each / every
possible factor which influence the reliability of the module / sub
system.


7
Solution
In the theoretical approach of most sought feasibility of objective
methodology, only four factors such as Intricacy, State of Art,
Operating time and Environment were considered, but in our
approach, we have considered cost and criticality factors which play
a vital role in product development and product safety. This
approach is defined as Modified Feasibility of Objectives reliability
allocation technique and can be tailored with additional factors to
refine the allocation depending on the product and its application.
Approach
As we are now aware, Reliability allocation is the process of
allocation of system reliability target to sub-system or functional
groups according to rational factors so that the target reliability
requirement or goal into subsystem and component requirements or
goals. The balancing act of allocation is done as per the below
process:
Identification of all the functions associated with the
system.
Grouping of system units according to its function which
should be traceable to system function
Identification of applicable rational factors that should
be considered for apportionment
Assignment of relative grades to each functional group
under respective factor considered for apportionment.
Allocation of apportioned reliability to each functional
group with weightage factor.

Rational Factors Considered
The relationship between apportioned reliability of i
th
functional
group (R
i
) and target reliability (R
t
) is defined with weightage factor
(
i
)
R
i
= (R
t
)
i

Also weightage factor (i) can be expressed with proportionality
factor (Zi)
i
= Z
i
/ Z
i
Proportionality factor (Zi) in turn bears relationship with various
rational factors considered for apportionment. In following paragraph
such relationships has been defined considering the factors
mentioned. The factors can be increased / decreased based on
product and its application.

Reliability Allocation is the
Delicate Art of Balancing the
Budget


8
Complexity (C)
Higher the complexity of functional group, more difficult it would be
to attain the target reliability. Therefore the functional group having
relatively higher complexity should be allocated lower reliability
target. The following guidelines have been adhered to arrive at the
relative grade for complexity
- Multiple functional relationships with the
other groups
- Architectural complexity with higher number
of components
Criticality (Cr)
Functionally critical sub-systems should be allocated higher
reliability target and thus Zi is proportional to criticality. The following
guidelines have been adhered to arrive at the relative grade for
Criticality
- The failure effect of the functional group on
system
- Frequency of failure
State of Art (S)
It is expected that state-of-art system should have higher reliability.
The functional group with high novelty should be apportioned higher
reliability target. Relative consideration of novelty of technology
used is considered to arrive at the relative grade for Start of Art
Cost (Co)
Higher the reliability enhancement cost, lower should be the
apportioned target. This relationship defines the practical approach
towards attaining higher reliability targets.
Duty Cycle (D)
The functional groups with higher duty cycles should be apportioned
higher reliability target. It provides assurance under continuous
operation of functional group the desired level of reliability is
maintains. Relative operational time of the functional group w.r.t the
total system operating time is considered to arrive at the relative
grade for Duty Cycle
Thus proportionality factor can be expressed as

Z
i
= C* Co /(S * Cr * D)


9
Table 1 provides the guidelines for selecting a relative grade factor

Table 1 Guideline on selection of relative grade factor
Factors
Scale
C Cr S Co D
10
High High Novelty-High High High 9
8
7
Medium Medium Novelty-Medium Medium Medium
6
5
4
3
Low Low Novelty-Low Low Low 2
1


10
Table 2 shows the reliability apportionment done for a project
(Indigo - Life Science), where the system reliability requirement was
0.99907 for its 10 hr operation.
Table 2 Guideline on selection of relative grade factor

Functional
Group
(C) (Cr) (S) (Co) (D) Zi i Ri
PCB 9 10 8 6 10 0.0675 0.02482 0.99998
Valve 5 5 5 9 2 0.9000 0.33093 0.99969
Sensors 5 6 5 7 10 0.1166 0.04289 0.99996
Backup Ckt 3 6 2 3 2 0.3750 0.13788 0.99987
Display 6 8 4 5 10 0.0937 0.03447 0.99997
Heater 3 3 3 7 2 1.1666 0.42898 0.99960


11
Best Practices
However the industry and the reliability practitioners are still aligned
to the feasibility of objective methodology against other methgods
mentiuoned, the successful use of the proposed allocation method
provides a unique approach to consider the cost, criticality and
other factors of the product for reliability allocation. This approach
has helped the design engineers to focus on improving the reliability
of the functional group with consideration of Cost constraint and the
Safety of the product in the project refered in the paper.
The proposed methodology was successfully used for different
projects.
The process of allocation of relative grades should to be carried out
as a team exercise, comprising of experienced members from the
each of the functional group identified.

Step with care and great tact
And remember that Lifes a
Great Balancing Act
Just never forget to be
dexterous and deft
And never mix up your right
foot with your left.
- Dr. Suess, Oh, the
places Youll Go.


12
Common Issues
The major challenge in the propsed solution is the subjectivity in
selecting the factors and then rating them as per the method
proposed. This subjectiveness varies with the experience of the
reliability practitioner. For example, it may be possible for different
practitioners to select different factors (apart from the factors
suggested here) and they can grade them differently based on the
individual / team knowledge. However despite this challenge, this
method deemed to be best suited to address the challenges for
doing the reliability allocation.

Common Issues are not so
common

Commom Issues are not SO
Common


13
Conclusion
Reliability Allocation is always a tricky task which needs balancing
act to allocate reliability targets to the components or sub-system
and also ensure that the reliability requirements are met as a
system, without compromising on performance or cost or safety of
the product.
Reliability allocation by Modified Feasibility of Objectives method
helps us to perform this balancing act in a pragmatic approach
rather than a theoretical approach. This methodology can be
applied to any system which needs reliability allocation to be
performed for its sub-systems or functional groups.
Further studies can be performed to eliminate the subjectivity in
selecting the relative grade factor.
The authors also suggests the allocation exercise to be rationally
planned and implemented so that it will be feasible to meet overall
system reliability target. Apart from the proposed top down
approach of reliability allocation, one can try the non conventional
bottoms up approach of reliability allocation where reliability data for
similar components exits and can be best used for this exercise.

Conclusions are most of times
The Beginning


14
Reference
[1] Reliability Resources in www.relex.com
[2] Reliability Allocation Report Indigo
[3] Paper by Prof K.B.Mishra on Reliability Allocation Technique.
[4] Reliability and Six Sigma By Dinesh Kumar, U. Dinesh Kumar

Author Info

Prateeck Biswas: Mr. Biswas is a reliability
consultant and has been working in the field of
reliability and quality for more than 25 years,
including about 20 years with aviation industries.
He is heading reliability engineering practice in
HCLT for last 5 years. He holds his post-
graduate degree from Indian Institute of
Technology (IIT), Bombay in Reliability
Engineering. He has been associated with the
leading aviation industries of the country like
Indian Airlines, Hindustan Aeronautics Limited
and Aeronautical Development Agency (ADA).
He has worked as a senior reliability professional
and a led team of engineers to carry out R&S
analysis on civil and military development aircraft
projects during his association with ADA. His
work on aircraft system safety assessment and
lessons learnt in R&S during development of
aircraft has been published in Annual Reliability
and Maintainability Symposium (RAMS), a
renowned international journal in the field of
relibility. His work on measurement uncertainty
has also been published in international journal.
He has worked extensively to propagate
reliability concepts to practicing engineers at
various national workshops and seminars.

But it's not just a game of
finding literary references.
- Dan Simmons


15

Arunkumar S: Mr. Arunkumar is a reliability
practitioner and has been working in the field of
reliability and quality for more than 12 years He
holds his engineering in electrical and
electronics. He is a Certified Reliability Engineer
and a Certified Quality Engineer from American
Society of Quality. He is also a Certified Green
Belt.
He has been associated with HCL Technologies
Ltd from last 4 years and has worked on various
aerospace, hitech & life sciences programs on
Reliability planning, Reliability testing, Project
Planning, Co-ordination, Data Analysis and
System Safety. and has good exposure to
various standards and tools used in reliability
engineering. Prior to HCL technologies, he has
served as reliability practioner in Honeywell.

Abhay Waghmare: Mr. Abhay Waghmare is a
reliability practitioner and has been working in
the field of reliability and design for more than
10 years. He holds his post graduate degree in
Production Engineering from REC Allahabad
and his bachelors in Mechanical Engineering
from Nagpur University. He is a Certified
Reliability Engineer from American Society of
Quality. He has undergone the two semester
course in Reliability Engineering & Testing
under Prof. Dimitri from Univeristy of Arizona.
He is also a Certified Green Belt from GE.
He has been associated with HCL Technologies
Ltd from last 5 years and has worked on various
aerospace, hitech & life sciences programs on
Reliability planning, Reliability testing, Project
Planning, Co-ordination, Data Analysis and
System Safety. and has good exposure to
various standards and tools used in reliability
engineering. Prior to HCL technologies, he has
served as reliability practioner in GE India.

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About HCL
About HCL Technologies
HCL Technologies is a leading global IT services company, working
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st

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