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RELIABILITY:
• Reliability’ of a unit or a product is the probability that the unit perform its Intended function
adequately for a given period of time under stated operating condition.
• Reliability in its simplest form means the probability that a failure may not occur in a given
time interval.
IMPORTANCE OF RELIABILITY:
1. Reputation: A company's reputation is very closely related to the reliability of their products.
The more reliable a product is, the more likely the company is to have a favorable reputation.
2. Customer satisfaction: An unreliable product will negatively affect customer satisfaction
severely. Thus, reliability is a mandatory requirement for customer satisfaction.
3. Warranty costs: If a product fails to perform its function within the warranty period, the
replacement and repair costs will negatively affect profits, as well as gain unwanted negative
attention.
4. Repeat business: A concentrated effort towards improved reliability shows existing
customers that a manufacturer is serious about their product, and committed to customer
satisfaction. This type of attitude has a positive impact on future business.
METHODS TO IMPROVE THE RELIABILITY OF A SYSTEM:
1. Parts improvement method: In parts improvement method, either the reliability of all the
constituent components is improved or the most critical components are5 identified and
their reliabilities are improved.
2. Effective and creative design approach: In this technique the devices are operated at levels
that are below their specified operating limits. Designing excess strength into components or
careful selection of material or parts will decrease the probability of failure. e.g. a material
with a tensile strength of 10000 kg/cm2 may be used where only 7000 kg/cm2 is required.
3. Choice of technology: Choice of technology such as mechanical versus electronic can have
significant effect on reliability, e.g. a mechanical tachometer is more reliable than an
electronic tachometer.
4. System simplification: Reducing the complexity of the system will also reduce the failure rate.
5. Quality control program: Good quality control program, inspection and acceptance sampling
procedures during manufacturing process will increase reliability.
6. Preventive maintenance policies: Once the product becomes operational, failures may be
reduced through preventive maintenance policies.
FAILURE:
• A failure is the partial or total loss or change of those properties of a device (or system) in
such a way that its functioning is seriously or completely stopped.
• Some components have Well defined failures; others not. For example, switches and electric
bulb have well defined failures. Either they are good or bad. Such devices are known as two
state devices.
• Devices like voltage-stabilizers, resistors, etc., have a range of operating conditions. The
device is said to have failed only when the operation conditions crosses these limits.
• Reliability specialists often describe the lifetime of a population of products using a graphical
representation called the bathtub curve.
• When failure rate is plotted against time the resulting graph is called as bath tub curve.
• The term ‘bathtub’ arises from the fact that the shape of the curve resembles a bathtub.
• In less technical terms, in the early life of a product adhering to the bathtub curve, the failure
rate is high but rapidly decreasing as defective products are identified and discarded.
• In the mid-life of a product generally, once it reaches consumers the failure rate is low and
constant.
• In the late life of the product, the failure rate increases, as age and wear take their toll on the
product.
• The curve represents the observation that the life span of a population of products is
comprised of three distinct periods, viz., initial failure, random failures and wear-out failure.
• System reliability stands for the reliability of a system consisting of two or more components.
• It is difficult to estimate the reliability of the system composing of many elements. Following
approach is used to determine the reliability of a system.
1. Reliability of individual components and sub-systems of the system is determined.
2. Manner in which sub-systems and components are arranged in the system is identified,
ie., logical manner in which elements are arranged is represented in a block diagram.
3. Based on the manner in which the sub-systems are connected in the system, the
probability rules are applied to find the system reliability.
2. Parallel configuration:
• In parallel configuration, elements or components are arranged in a parallel.
• In parallel configuration, satisfactory functioning of any one of the elements leads the
successful operation of the system.
3. Mixed configuration:
• In practice, the components of a system are not connected in simple series or parallel.
• Life tests are carried out in order to access the useful working life of a product.
• Life testing helps to discover potential problems with the design as early as possible.
• Different approaches to life testing are discussed below.
1. Burn-in testing: These are tests carried out during the initial equipment operational hours.
A relatively high early failure rate is usually due to the variability of the production process.
Burn-in has been long recognized as a useful method for detecting and eliminating systems
with early failures before customer delivery.
2. Test under actual working conditions: In tests under actual working conditions, the
component is subjected to actual working conditions for full duration of life test. This test
is time consuming and is not practical.
3. Accelerated life testing: These tests are conducted under severe operating conditions to
quicken the product failure. The purpose of accelerated life testing is to induce failure at a
much faster rate by providing a harsher environment. In such a test the product is expected
to fail in the lab just as it would have failed in the field, but in much less time. For example,
exposing a circuit to a high voltage and current, subjecting lathe to high vibrations, etc.
STANDARDIZATION:
• One popular approach to improving quality is called Total Quality Management (TQM). Total
Quality' Management Is defined in ISO 8402 as the ‘Management approach of an
organization, centered on quality', based on the participation of all its members and aiming
at long term success through customer satisfaction, and benefits to all members of the
organization and society'.
• Conventional quality management approach focuses on ensuring that the customers get a
defect-free product or service (small q concept).
• It emphasizes inspection to prevent delivering defect products to customers. For this
purpose, management sets up a quality control and quality assurance department to ensure
that specifications are met.
• This approach often leads to a situation where the quality control department becomes
overburdened with the sole responsibility for product quality and attending to customer
complaints in a company; production, marketing or other service agencies of the company
are thus able to avoid the responsibility for any deficiency.
• Quality circles can be defined as a small group of employees of the same work area, doing
similar work that meets voluntarily and regularly to identify, analyze and resolve work related
problems.
• The proposed solutions of various problems are presented to the management for
consideration, approval and implementation.
• A senior officer from the same department (workshop) is nominated as facilitator which
guides the activities of the group. A management committee at senior level is also formed,
which overview the progress of quality circles.
• Training of members and facilities are given to improve the efficiency of the program.
• Quality circles help to build mutual trust and greater understanding between management
and the workers.
Objectives of quality circles
1. To improve the quality and productivity and thus contribute to the improvements and
developments of the enterprise.
2. To reduce the cost of products or services by waste reduction, safety, effective utilization of
resources, avoiding unnecessary errors and defects.