Blueprint for a Comprehensive Reliability Program

TABLEOFCONTENTS
1Introduction………………………………………………………………………………………1
2FoundationsofReliability………………………………………………………………….2
2.1FosteringaCultureofReliability………………………………………………………………..2
2.2ProductMission………………………………………………………………………………………3
2.2.1ReliabilitySpecifications…………………………………………………………………………………3
2.3UniversalFailureDefinitions……………………………………………………………………..4
3ReliabilityTesting……………………………………………………………………………..6
3.1CustomerUsageProfiling…………………………………………………………………………6
3.2TestTypes……………………………………………………………………………………………..6
3.2.1DevelopmentTesting……………………………………………………………………………………..7
3.2.2ManufacturingTesting……………………………………………………………………………………8
4FieldData………………………………………………………………………………………..10
4.1The“Disconnect”BetweenIn-HouseandFieldData…………………………………..10
4.2SalesandForecasting(Shipping)Data…………………………………………………….10
4.3WarrantyData……………………………………………………………………………………….11
4.4FieldServiceData………………………………………………………………………………….11
4.5CustomerSupportData………………………………………………………………………….12
4.6ReturnedParts/FailureAnalysisData……………………………………………………….12
5DataCollection………………………………………………………………………………..13
5.1In-HouseTestDataCollection…………………………………………………………………13
5.1.1TestLog……………………………………………………………………………………………………..14
5.1.2FailureLog………………………………………………………………………………………………….14
5.1.3ServiceLog…………………………………………………………………………………………………15
5.2FieldDataCollection………………………………………………………………………………16
5.2.1ReliaSoft’sDashboard………………………………………………………………………………….16
6DataAnalysisandReporting……………………………………………………………19
6.1Non-ParametricAnalysis………………………………………………………………………..19
6.1.1Non-ParametricReliabilityAnalysis………………………………………………………………..19
6.2ParametricAnalysis……………………………………………………………………………….21
6.2.1ExamplesofReportingforParametricDataAnalysis……………………………………….22
6.2.1.1ProbabilityPlot………………………………………………………………………………………22
6.2.1.2ReliabilityFunction………………………………………………………………………………..23
6.2.1.3ProbabilityDensityFunction……………………………………………………………………23
6.2.1.4FailureRateFunction…………………………………………………………………………….23
6.2.1.5Lifevs.Stress……………………………………………………………………………………….24
6.2.1.6LikelihoodFunction………………………………………………………………………………..24
6.2.1.7ReliabilityImportance…………………………………………………………………………….25
6.2.1.8ReliabilityGrowth…………………………………………………………………………………..25
7BringingItAllTogether……………………………………………………………………26
7.1ConnectingFieldandLabData……………………………………………………………….26
7.2ReliabilityGrowth…………………………………………………………………………………..26
7.3OptimumDesignLevelDetermination………………………………………………………27
7.4CompetitiveAssessment………………………………………………………………………..28
7.5MarketingandAdvertising………………………………………………………………………28