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.