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Design for Reliability

Most companies already practice reliability engineering within design, whether formally or informally. However, implementing a structured reliability programme can significantly improve your business. Through our DFR capabilities, we can help you reduce returns and warranty costs, enhance quality assurance and comply with latest standards.

Software and Consulting

We believe that performance and time to market is significantly improved by integrating reliability into product and process development from its earliest design stages, whether safety-critical industrial equipment or consumer items.

As a reliability consultancy, training organisation and channel partner for the leading ReliaSoft software, we can assist the creation, development and enhancement of structured Design for Reliability processes or undertake DFR tasks on behalf of clients. For clients without the short-term capacity to develop an in-house reliability engineering capability, we can look after the entire reliability project including on-site secondments as appropriate.

Our capabilities include Failure Modes Effects (Criticality) Analysis (FMEA/FMECA) facilitation, life data analysis (Weibull), MTBF studies, Accelerated Life Testing (ALT), warranty analysis, system-level analysis with Fault Tree Analysis (FTA) and Reliability Block Diagrams (RBDs) and reliability growth prediction.

We support many FMEA industry standards, including SAE J1739, IEC 60812, MIL-STD-1629A and ISO 14971.  For standard-based reliability assessments, we are highly familiar with  MIL-HDBK-217F, Bellcore/Telecordia & FIDES in addition to other standards such as MIL-M-38510, NPRD-95 and EPRD-97.

To help acquire and manage reliability, quality, safety and risk management data from multiple locations, we have implemented ReliaSoft-based FRACAS / DRACAS web-based systems within client sites that integrate seamlessly with their DFR tools.

We can also use our in-house Engineering Simulation capabilities to help predict, understand and resolve failure modes.

Solutions

FMEA / FMECA

Methodologies designed to identify potential failure modes for a product or process before the problems occur.

Failure Mode and Effect Analysis (FMEA) and Failure Modes, Effects and Criticality Analysis (FMECA) are methodologies designed to identify potential failure modes for a product or process before the problems occur, to assess the risk associated with those failure modes and to identify and carry out measures to address the most serious concerns.

Although the purpose, terminology and other details can vary according to type (e.g. ProcessFMEA – PFMEA, Design FMEA – DFMEA, System FMEA, Product FMEA and FMECA), the basic methodology is similar for all. The fundamental steps, from assembling the team and gathering relevant information, to evaluating the risk from issues identified and distributing the information, can be facilitated by our comprehensive FMEA / FMECA training and consulting services and ReliaSoft’s comprehensive XFMEA software.

Our Reliability Engineers have extensive experience of hosting FMEA and FMECA workshops in the Design, Process or Functional context. The workshops are performed to Industry specified requirements either as stand-alone activities or pre-cursors to RCM or Fault Tree activities.

Life Data Analysis / Accelerated Life Testing

Estimate life characteristics of a product such as reliability or probability of failure at a specific time.

Due to the long life-times of today’s products it can be difficult for an engineer to analyse the time-to-failure data obtained under normal operating conditions. However, Life Data Analysis (Weibull Analysis) enables you to predict the life of a product by fitting a statistical distribution to life data from a representative sample of units. This data set can then be used to estimate important life characteristics of the product such as reliability or probability of failure at a specific time, the mean life and the failure rate. ReliaSoft Weibull++ software is extremely popular for a wide range of statistical analysis.

In typical life data analysis, the practitioner analyzes life data from a sampling of units operated under normal conditions. This analysis allows the practitioner to quantify the life characteristics of the product and make general predictions about all of the products in the population. For a variety of reasons, engineers may wish to obtain reliability results for their products more quickly than they can with data obtained under normal operating conditions. As an alternative, these engineers may use quantitative accelerated life tests to capture life data under accelerated stress conditions that will cause the products to fail more quickly without introducing unrealistic failure mechanisms.

Our Reliability team supports clients through a number of Life Data Analysis and Accelerated Life Testing activities including Warranty Analysis, advice and recommendations on what data to be capturing to enable Life Data Analysis, Determining product reliability, product mean life or failure rate to support System Reliability Modelling. Our engineers support the development of Product Test planning, the determination of the number of samples to be tested and the level to which stressor levels are to be applied.

System Reliability Modelling

Improve or optimise overall system reliability, maintainability and/or availability using logic diagrams.

A system is a collection of subsystems, assemblies and/or components arranged in a specific design in order to achieve desired functions with acceptable performance and reliability. The types of components, their quantities, their qualities and the manner in which they are arranged within the system have a direct effect on the system’s reliability. Therefore, in addition to the reliability of the components, the relationship between these components is also considered and decisions as to the choice of components can be made to improve or optimize the overall system reliability, maintainability and/or availability. This reliability relationship is usually expressed using logic diagrams, such as reliability block diagrams (RBDs) and/or fault trees.

Supporting both product design and asset management functions, our Engineers develop and analyse system Reliability Block Diagrams and Fault Trees, usually as part of a Reliability project. These models can be made-up from a variety of sources of data from standards-based libraries, to real-world test/field data or from Supplier’s product technical specification data.

Using exact computations or discrete event simulation, our Engineers use ReliaSoft’s BlockSim software to undertake a wide variety of analyses for both repairable and non-repairable systems. This includes reliability analysis, reliability optimization, and sensitivity studies, exploring the effect of redundancy on improved reliability against increased cost.#

Standards Based Prediction

Predict reliability for systems and components (mostly electronics) based on failure rate estimates.

Standards based reliability prediction is a methodology for predicting reliability for systems and components (mostly electronics) based on failure rate estimates published by globally recognized military or commercial standards. Standards based reliability prediction is especially useful in the initial stages of development when hard failure data is not yet available or when manufacturers are obliged contractually by their customers to use published standards for their reliability predictions.

Using ReliaSoft’s Lambda Predict software, our engineers can predict the reliability of your system to several standards including: MIL 217, FIDES, Bellcore/Telcordia; Siemens SN29500 and NSWC. Results are often subsequently used in System Reliability Models where test or manufacturer’s data is unavailable

Reliability Growth Analysis

Apply reliability growth models to analyze data from both developmental testing and fielded repairable systems.

A well-structured reliability growth programme helps you find reliability problems by testing, incorporating corrective actions and monitoring the increase of the product’s reliability throughout the test phases. Reliability growth analysis is the process of collecting, modeling, analysing and interpreting data from this programme, whether sourced from development testing and/or collected from the field.

Reliability growth is the improvement in the reliability of a product (component, subsystem or system) over a period of time due to changes in the design and/or manufacturing process.

Working with Reliability and Test Engineers, our Reliability team can support the development of reliability goals, processes and test plans, thereby providing confidence in reliability growth projections and calculating optimum overhaul times for repairable systems.

FRACAS / DRACAS

Report failures and/or defects and track their corrective actions

Failure Reporting Analysis and Corrective Action System and Defect Report Analysis and Corrective Action System are commonly used terms for a system that is used to report failures and/or defects and track their corrective actions. Other commonly used names include DRACAS (Data Reporting Analysis and Corrective Action System), DCACAS (Data Collection Analysis and Corrective Action System) and CAPA software (Corrective And Preventive Action software).

For every installation of ReliaSoft’s XFRACAS software for FRACAS or DRACAS applications, our Reliability team works closely with our Clients to help configure and implement the software into the Client’s FRACAS/DRACAS processes. Our team can help develop the process if one isn’t already in place.

A key aspect of our work is the mass import of data into the XFRACAS system from external sources using a number of Data Analytics methods and the management of data that can interact with other Client systems.

Design of Experiments (DOE)

Assess the relationship between different parameters influencing a product or process and their effect on performance.

When variation is anticipated or to be identified during testing, good experimental design is fundamental. By the careful selection of variables and the experiments that are consequently performed, your designs can be investigated and optimised effectively.

For both physical (prototype / shop trial) and virtual (simulation) testing, we offer dedicated software to assist the selection of variables and analysis of results. ReliaSoft software can be applied to a wide range of physical and virtual testing techniques, while there are integrated DOE modules for ANSYS simulation products. For both solutions, we can provide comprehensive training and consulting services.

The DfR Process

Design for Reliability (DfR) can be described as a systematic, streamlined, concurrent engineering programme that supports product and process design (typically from early in the concept stage all the way through to product obsolescence) to ensure that customer expectations for reliability are fully met throughout the life of the product with low overall life-cycle costs. It relies on an array of reliability engineering tools along with a proper understanding of when and how to use these tools throughout the design cycle.

The DFR process encompasses a variety of techniques and practices, describing the overall order of deployment that an organisation needs to follow in order to design reliability into its products. This process is supported by ReliaSoft software, comprising tools that integrate for storing and transferring data between applications through a centralised database.

Example Projects

  • Standards based prediction using MIL-HDBK-217F for satellite components and military runway landing lights

  • Reliability Gap Analysis, Life Data Analysis and Design for Reliability review for LED lighting

  • Fault Tree Analysis (FTA) on automotive active roll control system

  • Design FMEA, parts count prediction and Accelerated Life Testing (ALT) on LED based train signalling system

  • Life Data Analysis of of high performance air flow sensors for wind turbines

  • Reliability support for incorporating API RP 17N standard within subsea production

  • FMECA and standard based reliability predictions for aircraft control system

  • Weibull Analysis on an articulated dump truck

  • Risk population studies on casting components

  • Root Cause Analysis (RCA), gap analysis, training & implementation support for haemodialysis equipment

  • Design for Reliability assessments and warranty predictions for domestic heating boilers

  • Training to improve the efficiency of ‘burn in’ activities within electronic components and systems

Our Approach to DfR Strategy Improvement

Design for Reliability improvement strategies often combine services and mentoring with investment in appropriate software. We typically start with a Reliability Gap Analysis to identify a client’s current DFR methodology and identify any weaknesses or opportunities for enhancement.

A Gap Analysis is an opportunity to conduct an in-depth holistic analysis at a strategic and technical level normally involving a larger number of stakeholders within your business than a typical consultation.

The problem was understood and resolved straight away. Good work, thank you.

Edwards Ltd (Burgess Hill)

I was delighted to find new and efficient ways to use the software, I’ve already used for 6 months. It was definitely a good learning experience.

Quanta Fluid Solutions

Course pitched at just the right level. Demos maintain interest and workshops enforce understanding.

GlaxoSmithKline

I currently use Weibull++, BlockSim & Lambda Predict and am very pleased with the software. I have been an every day user of alternative suppliers’ reliability software and found ReliaSoft to be the most comprehensive and user friendly.

Seagate Systems UK

... certainly impressed with ReliaSoft products, having had chance to use Weibull++ for themselves, and shared in the analysis of their paper-clip exercise on ALTA PRO. BlockSim just did everything that they would expect.

University of Warwick

ReliaSoft is indeed an excellent software, I would like to be an ambassador and recommend it to more people …..I am also very, very satisfied with all your services

Offshore Renewable Energy Catapult

The [ReliaSoft] Weibull++ software is a powerful, practical and easy to use package for life data analysis. Its graphical user interface enables new users to master this tool in a relatively short period of time. I recommend this tool in my organisation.

Chevron Texaco

Excellent introduction into Reliability Engineering.

Ultra Electronics Controls

Reliability engineering is becoming ever more important, particularly with extended warranties. It was good working with a tutor who took the time to prepare training material from our own generated data. We will find the software particularly useful.

Ideal Boilers

The course was very well structured and the content was very applicable without being overbearing. The tutor kept the group – which included a wide range of ages and experience levels – engaged at all times and put the information across very clearly. I would definitely recommend the course.

Presses Jacks & Hammers Ltd

An excellent course, very knowledgeable and patient tutor.

GE Healthcare

Very knowledgeable on FMECA processes & reliability aspects.

Genzyme

I currently use Weibull++, BlockSim & Lambda Predict and am very pleased with the software. I have been an every day user of alternative suppliers’ reliability software and found ReliaSoft to be the most comprehensive and user friendly.

Xyratex Storage Systems

Very useful [ReliaSoft] tools to conduct reliability analysis.

Dyson

[ReliaSoft] BlockSim is very useful and of high quality.

Lockheed Martin

Excellent [reliability] training, very expertly delivered... An excellent [reliability] course. A++

Rolls-Royce Aerospace

How Can We Support Your Design for Reliability Objectives?

Please contact us or complete the form opposite for an informal, no-obligation discussion of your requirements.

From an initial phone call we can often give you an idea of price and time scales.

With subsequent details, we can then send you some solution ideas, scopes of work and a formal quotation.

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