Quality Control

Chapter 11- Reliability

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Besterfield
Quality Control, 8e


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Outline


D Fundamental Aspects
D Additional Statistical Aspects
D Life and Reliability Testing Plans
D Availability and Maintainability























Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Learning Objectives


When you have completed this chapter you should
be able to:

D Know the definition of reliability and the
factors associated with it.

D Know the various techniques to obtain reliability.
D Understand the probability distributions, failure
curves, and reliability curves as a factor of time.












Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Learning Objectives contd.


When you have completed this chapter you
should be able to:

D Calculate the failure rate under different
conditions.

D Construct the life history curve and describe its
three phases.

D Calculate the normal, exponential, and Weibull
failure rate.








Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Learning Objectives contd.


When you have completed this chapter you
should be able to:
D Construct the OC Curve

D Determine life and reliability test curves

D Calculate the normal, exponential, and Weibull failure rate

D Understand the different types of test design

D Understand the concepts of availability and maintainability














Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Reliability


D Generally defined as the ability of a product to
perform as expected over time.

D Formally defined as the probability that a
product, piece of equipment, or system will
perform its intended function for a stated period
of time under specified operating conditions.

















Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Reliability


D Means quality over the long run.
D A product that works for a long period
of time is a reliable one.

D Since all units of a product will fail at
different times, reliability is a
probability.
















Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Reliability


There are four factors associated with Reliability:
1. Numerical Value.
D The numerical value is the probability that
the product will function satisfactorily
during a particular time.




















Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Reliability


There are four factors associated with Reliability:
2. Intended Function.
D Product are designed for particular
applications and are expected to be able to
perform those applications.




















Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Reliability


There are four factors associated with Reliability:
3. Life.
D How long the product is expected to last.
Product life is specified as a function of
usage, time, or both.





















Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Reliability


There are four factors associated with Reliability:
4. Environmental Conditions
D Indoors.
D Outdoors.
D Storage.
D Transportation.















Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Achieving Reliability


Emphasis:
1. The Consumer Protection Act of 1972.
2. Products are more complicated.
3. Automation.























Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
System Reliability


D As products become more complex (have more
components), the chance that they will not
function increases.

D The method of arranging the components affects
the reliability of the entire system.

D Components can be arranged in series, parallel,
or a combination.












Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Series System


D For a series systems, the reliability is the
product of the individual components.




1 2 n





R
S
= R
1
R
2
... R
n



D As components are added to the series, the
system reliability decreases.







Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Parallel System



1

2




n
R
s
= 1 - (1 - R
1
) (1 - R
2
)... (1 - R
n
)



D When a component does not function, the product
continues to function, using another component,
until all parallel components do not function.







Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
R
Series-Parallel System


C
R
A
R
B
R
D

C
A B D
C

R
C


D Convert to equivalent series system


R
A
R
B
R
D


A B C D



R
C
= 1 (1-R
C
)(1-R
C
)

Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Design


D The most important aspect of reliability is the
design.

D It should be as simple as possible.
D The fewer the number of components, the
greater the reliability.

D Another way of achieving reliability is to have a
backup or redundant component (parallel
component).








Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Design


D Reliability can be achieved by overdesign.
D The use of large factors of safety can increase the
reliability of a product.

D When an unreliable product can lead to a fatality
or substantial financial loss, a fail-safe type of
device should be used.

D The maintenance of the system is an important
factor in reliability.








Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Production


D The second most important aspect of
reliability is the production process.

D Emphasis should be placed on those
components which are least reliable.

D Production personnel.




















Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Transportation


D The third most important aspect of reliability
is the transportation.

D Packaging
D Shipment
D Performance of the product by the customer
is the final evaluation.

D Good packaging techniques and shipment
evaluation are essential.







Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Additional Statistical Aspects


Distributions Applicable to Reliability:
D Exponential distribution.
D Normal distribution.
D Weibull distribution.
Reliability Curves:
D The curves as a function of time.














Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Additional Statistical Aspects


Reliability Curves:
D The reliability curves for the exponential,
normal and Weibull distributions as a
function of time are given in Figure 11-2(b) .
























Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Additional Statistical Aspects


Failure-Rate Curve:
D It is important in describing the life-history
curve of a product.

D See Figure 11-2.
























Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Life History Curve


D The curve, sometimes referred to as the
bathtub curve, is a comparison of failure
rate with time.

D It has three distinct phases:
D The debugging phase.
D The chance failure phase.
D The wear-out phase.











Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Life History Curve















Infant
mortality
period



Debugging
Phase


Chance Failure
Phase
Wear Out
Phase




















Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Life History Curve


1. The debugging phase:
It is characterized by marginal and short-life
parts that cause a rapid decrease in the
failure rate.

It may be part of the testing activity prior to
shipment for some products.

The Weibull distribution <1 is used to
describe the occurrence of failures.








Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Life History Curve


2. The chance failure phase:
Failures occur in a random manner due to the
constant failure rate. The Exponential and the
Weibull distributions = 1 are best suited to
describe this phase.

3. The wear-out phase:
Is depicted by a sharp raise in failure rates. The
Normal distribution and the Weibull distribution
>1 are used to describe this phase.




Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Normal Failure Analysis


D The Weibull distribution is usually uses.
D The Normal distribution.














R(t): Reliability at time t
P(t): Probability of failure or area of the
normal curve to the left of time t. Table A.






Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Exponential Failure Analysis




Exponential distribution:




Rt = e
t/





Where:
t: Time or cycles.
: Mean life.









Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Weibull Failure Analysis


D Can be used for the debugging phase (<1)
and the chance failure phase (=1).

D By setting = 1, the Weibull equals the
exponential.

D By setting =3.4, the Weibull approximates
the Normal.


Rt = e
(t/)




Where is the Weibull slope.


Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
OC Curve Construction


Steps:
1. Assume values for the mean life .

2. These values are converted to the failure
rate, l =1/ .

3. Calculate the expected average number of
failures nTl.

4. From Table C of the Appendix using nTl and
c value, get Pa.







Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Life and Reliability Testing Plans


Type of Tests:
D Failure-Terminated: These life-test sample
plans are terminated when a preassigned
number of failures occurs to the sample.

D Time-Terminated: This life-test sampling
plan is terminated when the sample obtains
a predetermined test time.












Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Life and Reliability Testing Plans


Type of Tests contd.:
D Sequential: A third type of life-testing
plan is a sequential life-test sampling
plan whereby neither the number of
failures nor the time required to reach
a decision are fixed in advance.

















Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Life and Reliability Testing Plans


Tests are based on one or more of the
following characteristics:

D Mean life: the average life of the product.
D Failure rate: the percentage of failures per
unit time or number of cycles.




















Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Life and Reliability Testing Plans


Test are based on one or more of the following
characteristics contd.:

D Hazard rate: the instantaneous failure rate
at a specified time.

D Reliable life: the life beyond which some
specified portion of the items in the lot will
survive.












Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Handbook H108


D Quality Control Reliability Handbook H108 gives
sampling procedures and tables for life and
reliability testing.

D Sampling plans in the handbook are based on
the exponential distribution.

D Provides for the three different types of test:
failure-terminated, time-terminated, and
sequential.








Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Handbook H108


D The handbook is over 70 pages long.
D The time-terminated plan:
1. Stipulated producers risk, consumers
risk, and sample size.

2. Stipulated producers risk, rejection
number, and sample size.

3. Stipulated producers risk, consumers
risk, and test time.







Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Reliability Management


D Define customer performance requirements.
D Determine important economic factors and
relationship with reliability requirements.

D Define the environment and conditions of
product use.




















Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Reliability Management


D Select components, designs, and
vendors that meet reliability and cost
criteria.

D Determine reliability requirements for
machines and equipments.

D Analyze field reliability for
improvement.












Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Availability and Maintainability


For long-lasting products and services such as
refrigerators, electric power lines, and front-line
services, the time-related factors of availability,
reliability, and maintainability are interrelated.

























Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Availability


D It is a time-related factor that measures
the ability of a product or service to
perform its designated function.

D The product or service is available when it
is in the operational state, which includes
active and standby use.

















Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Availability











Where:

MTBM = mean time between
maintenance


MDT = mean down time

MTBF = mean time between failures
MTTR = mean time to repair

Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Maintainability


Maintainability is the probability that a system
or product can be retained in, or one that has
failed can be restored to, operating condition in
a specified amount of time.

























Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved
Maintainability


D Maintainability is the totality of design
factors that allows maintenance to be
accomplished easily.

D Preventive maintenance reduces the risk of
failure.

D Corrective maintenance is the response to
failures.












Besterfield: Quality Control, 8
th
ed.. 2009 Pearson Education, Upper Saddle River, NJ 07458.
All rights reserved