Reliability by Design

1. Reliability by
Design
Mac Klingler
13 August
2013
© M. G. Klingler, Ltd. 20131

2. Reliability by Design
 Designed-in Reliability
 How do we structure a design program to
achieve the best possible outcome?
 OEM Issues and Action
 Field Service Reliability
 How should owners analyze data?
 What should the reliability strategy be?
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3. Reliability by Design
 Business Imperative Often Trumps Good
Engineering Judgment
 Be Careful What You Ask of People
 If you ask them to go faster they will
 If you ask them to do it cheaper they will
 But….You won’t like the result
 Once Built a Prototype Resists Concept
Change
 Reliability by Necessity takes a back seat to
Performance, Life and Cost
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4. Wind Turbine Evolution
 Machines increased an ORDER OF
MAGNITUDE in output in about a decade
 No practical field feedback of RELIABILTIY
or LIFE before the next iteration
 Obvious Engineering Conclusion?
 “We did everything right”
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5. Definition of Reliability
Broad Definition of Reliability: Reliability is a science aimed
at predicting, analyzing, preventing, and mitigating failures
over time.
Narrow Definition of Reliability: Reliability is the probability
that a device will operate successfully for a specified
period of time and under specified conditions when used
in the manner and for the purpose intended.
Simple Definition of Reliability: Conformance to quality
standards over many increments of time
FOUR KEY PARAMETERS THAT GOVERN RELIABILITY:
1. Customer Expectations
2. Intended Function
3. Specified Life
4. Specified Operating Conditions

6. Bathtub Curve
Life Periods
Rate of
Occurrence
of Failure
Design Life
GoalFPM LIFE
Goal
% Of MDP
Goal
FPM WAR
Goal

7. Decompose the Problem
13 August 2013
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r, Ltd. 2013
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Component
E-Build Part &
Tooling Release
Architecture
Performance
Component
E-Build Part &
Tooling Release
Verification
General SpecGeneral Spec
Product Product
Verification
Machine Systems Machine systems
Verification
Manufacturing &
Durability
Customer use
Validation
Customer needs
Requirements Capture
Allocation

8. Reliability by Design
 Five Basic Design Project Documents
 General Specification
 Defines WHAT the Design Does, not HOW
 Specific by Function
 Defines Acceptance Criteria-How do I know
when I’m done
 Bill of Material-Line by Line
 Cost Spreadsheet-by increasing detail
 Weight Spreadsheet-by increasing detail
 Reliability Spreadsheet-by increasing detail
13 August 2013
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. Klingler, Ltd. 2013
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9.  Inherent Reliability
 Planning Tool in Specification Stage
 Before Design is Finalized
 Reasonably attained by Mature System
 The Best a Machine can be under the current
strategy
 Can the proposed design meet the objectives?
 Initial Reliability
 Predicted/Estimated reliability at the beginning of
System development, prior to hardware testing
 Where should we apply our efforts?
 Basis for Test Plan
Reliability Modeling
© M. G. Klingler, Ltd. 2013

10. © M. G. Klingler, Ltd. 2013

11. Decompose the Problem
13 August 2013
M. G. KlingleKlin© M. G. Klingler, Ltd. 2013
r, Ltd. 2013
11
Component
E-Build Part &
Tooling Release
Architecture
Performance
Component
E-Build Part &
Tooling Release
Verification
General SpecGeneral Spec
Product Product
Verification
Machine Systems Machine systems
Verification
Manufacturing &
Durability
Customer use
Validation
Customer needs
Requirements Capture
Allocation

12. Reliability by Design
 FMEA as the Primary Reliability Tool
 Teams of Diverse Expertise
 Most “Experienced” Grey Beards
 Not too much emotional ownership of the
design
 These are the people who call the baby ugly
 Identify and Rank (RPN’s) not just probable but
all POSSIBLE Failure Modes
 DO SOMETHING TO RESOLVE EVERY ISSUE
 Ideas have consequences but only if you do
something about them
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Klin© M. G. Klingler, Ltd. 2013
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13. Decompose the Problem
13 August 2013
M. G. KlingleKlin© M. G. Klingler, Ltd. 2013
r, Ltd. 2013
13
Component
E-Build Part &
Tooling Release
Architecture
Performance
Component
E-Build Part &
Tooling Release
Verification
General SpecGeneral Spec
Product Product
Verification
Machine Systems Machine systems
Verification
Manufacturing &
Durability
Customer use
Validation
Customer needs
Requirements Capture
Allocation

14. Reliability by Design
 Verification “Contract” Document
 What Methods Will Be Used to Verify the
Acceptance Criteria of the Design ?
 Modeling & Simulation-Primary Performance
Tool
 Analysis-Primary Life Tools
 Component Test-Verification of Modeling
 Prototype Test-Primarily Performance
Verification and Certification
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. Klingler, Ltd. 2013
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15. Reliability by Design
 How Will We Validate the Specification ?
 Does the Spec meet customer expectations?
 How will you validate your spec?
 How will you validate your hardware?
 Does IEC Code adequately express customer
need?
 Does Certification serve the customer?
13 August 2013
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. Klingler, Ltd. 2013
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16. Reliability is Part of Design
Include time for reliability activities
in the program plan/schedule
 The sooner they occur, the more benefit
they will have
Address ALL failures uncovered
during development
 There are NO fluke failures
 Never assume they will get fixed later
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17. Field Service Reliability
 Keep good records
 Discipline field techs to record failed parts
 Teach Root Cause Analysis
 Join Industry Databases
 Compare to Industry Norms
 Are your failures typical
 Segregate by Make & Model
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18. Field Service Reliability
 Address FREQUENCY of FAILURE in
preference to just high cost or high
downtime failures
 High Frequency Failures effect the most
machines and give the biggest payback
for your efforts
 Try to replace failed parts with BETTER,
Longer Life parts
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19. Conclusions
 Build a comprehensive General Spec
 Function
 Cost
 Weight
 Inherent Reliability Model as a Base
 Make RIGOROUS FMEA’s your primary
Reliability Tool
 Prioritize Field Failures by Frequency-Total
Fleet Downtime
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