Blueprint for a Comprehensive Reliability Program

xar7879

TABLE OF CONTENTS
1 Introduction...................................................................................................1
2 Foundations of Reliability ............................................................................2
2.1 Fostering a Culture of Reliability .......................................................................... 2
2.2 Product Mission ................................................................................................... 3
2.2.1 Reliability Specifications .............................................................................................3
2.3 Universal Failure Definitions ................................................................................ 4
3 Reliability Testing .........................................................................................6
3.1 Customer Usage Profiling .................................................................................... 6
3.2 Test Types ........................................................................................................... 6
3.2.1 Development Testing..................................................................................................7
3.2.2 Manufacturing Testing ................................................................................................8
4 Field Data.....................................................................................................10
4.1 The “Disconnect” Between In-House and Field Data......................................... 10
4.2 Sales and Forecasting (Shipping) Data ............................................................. 10
4.3 Warranty Data.................................................................................................... 11
4.4 Field Service Data.............................................................................................. 11
4.5 Customer Support Data ..................................................................................... 12
4.6 Returned Parts/Failure Analysis Data................................................................ 12
5 Data Collection............................................................................................13
5.1 In-House Test Data Collection ........................................................................... 13
5.1.1 Test Log ....................................................................................................................14
5.1.2 Failure Log................................................................................................................14
5.1.3 Service Log...............................................................................................................15
5.2 Field Data Collection.......................................................................................... 16
5.2.1 ReliaSoft’s Dashboard ..............................................................................................16
6 Data Analysis and Reporting .....................................................................19
6.1 Non-Parametric Analysis ................................................................................... 19
6.1.1 Non-Parametric Reliability Analysis..........................................................................19
6.2 Parametric Analysis ........................................................................................... 21
6.2.1 Examples of Reporting for Parametric Data Analysis ..............................................22
6.2.1.1 Probability Plot...................................................................................................22
6.2.1.2 Reliability Function ............................................................................................23
6.2.1.3 Probability Density Function..............................................................................23
6.2.1.4 Failure Rate Function ........................................................................................23
6.2.1.5 Life vs. Stress ....................................................................................................24
6.2.1.6 Likelihood Function............................................................................................24
6.2.1.7 Reliability Importance ........................................................................................25
6.2.1.8 Reliability Growth...............................................................................................25
7 Bringing It All Together ..............................................................................26
7.1 Connecting Field and Lab Data ......................................................................... 26
7.2 Reliability Growth ............................................................................................... 26
7.3 Optimum Design Level Determination ............................................................... 27
7.4 Competitive Assessment ................................................................................... 28
7.5 Marketing and Advertising ................................................................................. 28



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