Quality Basics

6th Edition

Chapter 11
Reliability

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 Reliability
• Reliability is defined as the probability that a
product, piece of equipment, or system performs
its intended function for a stated period of time
under specified operating conditions.
• Key elements:
– Probability
– Time
– Performance
– Operating conditions

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 Chapter 11: Reliability
• Reliability and maintainability are key ingredients
to preserving production efficiency. Properly
managed, they lead to lower total life cycle costs,
helping organizations maintain a competitive
edge.

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 Chapter 11: Reliability
• Reliability is the probability that
machinery/equipment can perform continuously,
without failure, for a specified interval of time
when operating under stated conditions.
Increased reliability implies less failure and
consequently less downtime and loss of
production.

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 Chapter 11: Reliability
• Maintainability is a characteristic of design,
installation, and operation, usually expressed as
the probability that a machine can be retained in,
or restored to, specified operable condition within
a specified interval of time when maintenance is
performed in accordance with prescribe
procedures.

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 Reliability:

1.Reliability refers to the ability of a system or

product to consistently perform its intended
functions under specified conditions for a
specified period.
2.It focuses on the probability that a system will
operate without failure within a certain
timeframe or under certain conditions.
3.Reliability is measured in terms of mean time
between failures (MTBF), which indicates the
average time a system or product functions
before a failure occurs.
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 Maintainability

• Maintainability is the ease with which a system or

product can be repaired, serviced, or maintained when
it does experience a failure or requires routine
maintenance.
• It focuses on minimizing downtime, repair time, and
cost when addressing issues or conducting scheduled
maintenance.
• Maintainability includes factors like accessibility,
modularity, documentation, and the availability of
replacement parts.
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 Chapter 11: Reliability
• Reliability engineering provides the theoretical and
practical tools used to determine the capability of
parts, components, equipment, subsystems and
systems to perform their required functions
without failure for specified periods in specified
environments.

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 Types of Failures

• Functional failure – failure that occurs at the start

of product life due to manufacturing or material
detects
• Reliability failure – failure after some period of use

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 10

Mathematics of Reliability
• Reliability is determined by the number of failures
per unit time during the duration under
consideration (called the failure rate, λ).
– For items that must be replaced when a failure occurs,
the reciprocal of the failure rate (having dimensions of
time units per failure) is called the mean time to failure
(MTTF). ( non repairable unit)
– For repairable items, the mean time between failures
(MTBF) is used.
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 11

Computing the Failure Rate

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 12

Example 7.7

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 13

Product Life Characteristics Curve

• Many electronic components commonly exhibit a
high, but decreasing, failure rate early in their
lives, followed by a period of a relatively constant
failure rate, and ending with an increasing failure
rate.

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 Chapter 11: Reliability
• Life Cycle Curve

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 Chapter 11: Reliability
• Infant Mortality Failure Causes:
– Inadequate test specifications
– Inadequate quality control
– Inadequate manufacturing processes or tooling
– Inadequate materials
– Improper handling or packaging
– Marginal components
– Overstressed components
– Improper setup or installation
– Improper use procedures
– Power surges
– Inadequate marketing
– Inadequate training
– Incomplete final testing
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 Chapter 11: Reliability
• Random Failure Causes:
– Insufficient design margins
– Misapplication: overstress
– Use in wrong environment
– Predictable failure levels
– Inherent manufacturing failures

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 Chapter 11: Reliability
• Wear-out Failure Causes:
– Scratching
– Material wear
– Aging
– Incipient stresses
– Limited-life components
– Inadequate or improper preventive maintenance
– Assembly interference fits
– Loose hardware
– Misalignments

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 Chapter 11: Reliability
• Reasons for Reliability Programs:
– Successful companies are able to control the reliability of their
products
– Increasing complexity of products requires higher component
reliability
– Consumers are becoming more reliability conscious

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 Chapter 11: Reliability
• Basic functions of a reliability program:
– Establish reliability in design.
– Assure reliability by proper manufacturing.
– Assure reliability through quality assurance.
– Verify reliability by well designed test programs.
– Maintain reliability by proper packaging and shipping methods.
– Assure reliability by proper field service and training.
– Improve reliability through feedback to design, engineer, purchase,
manufacture, package, ship, sell, and service.

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 Chapter 11: Reliability
• A well thought out reliability program will include
the areas of design, testing, manufacture, raw
material and component purchases, production,
packaging, shipping, marketing, field service, and
maintenance.

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 Chapter 11: Reliability
• A sound reliability program will consider:
– The entire system
– The humans in the system
– Maintenance of the system
– Simplicity of design
– Redundant and fail-safe designs
– Manufacturing methods and purchasing requirements
– Maintenance of complete product or system
performance records
– Communication

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 22

Reliability Function
• The reliability function, R(T), characterizes the
probability of survival to time T.
• Properties:
1. R(0) = 1 ( no error)
2. As T becomes larger, R(T) is non-increasing
3. R(T) = 1 - F(T), where F(T) is the cumulative probability
distribution of failures

 Reliability function (probability of survival) Exponential

reliability
R(T) = 1 – F(T) = e-lT
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 23

Example 7.9

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 24

Figure 7.16

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 25

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 26

Using the MTTF

• For nonrepairable items, θ = 1/λ is defined as the
mean time to failure (MTTF). For exponential
assumptions:

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 27

Example 7.10

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 System Reliability

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 29

System Reliability
• Series system: all components must function or
the system will fail.
– the reliability of the system is the product of the
individual reliabilities

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 30

Example 7.11

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 31

Series Systems with Exponential

Reliability

• Example 7.12

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 32

• Parallel
Systemsystem: uses redundancy.
Reliability
The system will successfully operate
as long as one component
functions.
– The reliability is calculated as

– If all components have identical

reliabilities R, then

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 33

Example 7.13

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 34

Example

• The probability of survival for 100 hours of

this parallel system?

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 35

Series-Parallel Systems
To compute the reliability of systems with both series and parallel
components, decompose the system into smaller series and/or
parallel subsets of component, compute the reliabilities of these
subsets, and continue until you are left with a simple series or
parallel system.

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 36

Determine the reliability of this system.

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 37

Example 7.15

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 38

Determine the reliability of this system.

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 39

Example 7.15 (continued)

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 40

Design for Reliability

• Reliability requirements are determined during the

product design phase.

• The designer may use these techniques to determine

the effects of adding redundancy, substituting different
components, or reconfiguring the design.

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 41

Example 7.16

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 42

Example 7.16 (continued)

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 Chapter 11: Reliability
• Causes of Unreliability:
– Improper design
– Improper materials
– Manufacturing errors
– Assembly and inspection errors
– Improper testing
– Improper packaging and shipping
– Improper start-up
– User abuse
– Misapplication

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 Chapter 11: Reliability
• Calculating System Reliability
– Reliability in Series

– Rs = R1 x R2 X R3

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 Chapter 11: Reliability
• Calculating System Reliability
– Reliability in Parallel

– Rp = 1 – (1 – R1)(1 – R2)

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 Chapter 11: Reliability
• Calculating System Reliability
– Reliability of Redundant or Back-up components

Element 1

Element
backup

– Rb = R1 + Rb(1 – R1)

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 Chapter 11: Reliability
• Calculating Overall System Reliability
– Identify and calculate R values for elements in parallel.
– Identify and calculate R values for elements with
backup elements.
– Calculate elements, including new R values for
elements in parallel and backup, as a series.

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 Chapter 11: Reliability

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