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Home » Articles » on Product Reliability » Reliability Knowledge

Reliability Knowledge

Welcome to "Reliability Knowledge," a series dedicated to sharing insights and expertise on the critical role of reliability in product development, useful life, and wear-out life. The articles and videos are designed for engineers, product developers, and anyone interested in understanding how to create products that not only meet but exceed reliability expectations throughout their entire lifecycle.

Reliability in Product Development. Useful Life Reliability. Wear Out Life Reliability. Here you'll gain access to a wealth of knowledge that bridges the gap between theory and practice in reliability engineering.

by Semion Gengrinovich Leave a Comment

Historical Data

Historical Data

The power of historical failure data is a gold mine of information for reliability engineers. It provides a window into the life cycle of products, revealing patterns and trends that can inform future designs and manufacturing processes. By analyzing this data, we can identify common failure modes, detect early life failures indicating quality or production issues, determine the onset of wear-out stages, and predict time to failure for similar products.

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

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Can we Predict all Failures?

Can we Predict all Failures?

Predicting all failures in any system, including the automotive industry, is an inherently complex and challenging task. The inherent unpredictability of certain failure modes, coupled with the vast array of variables in operational environments, makes it impossible to foresee every potential failure. However, through strategic approaches and methodologies, it is possible to minimize major failures and reduce the infant mortality failure rate, thereby enhancing the reliability and safety of automotive products.

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

by Semion Gengrinovich Leave a Comment

Reliability Importance During Design Phases

Reliability Importance During Design Phases

In the fast-evolving world of electric vehicles EVs), the Precision and reliability of components such as electromechanical valves are critical. These valves, which control the flow of coolant to manage battery temperature, must perform flawlessly under varying conditions. This article delves into the importance of reliability at each stage of product development, from design review to customer release.

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

by Semion Gengrinovich Leave a Comment

DfR – who are you?

DfR – who are you?

Design for Reliability (DfR) is a critical aspect of the product development process, particularly for electromechanical products where the interplay between electrical and mechanical components can introduce complex failure modes. DfR is a systematic approach to ensuring that a product is reliable over its intended lifespan and under the conditions it will face during use. It involves a variety of techniques and practices aimed at identifying and mitigating potential failure points early in the design process.

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

by Semion Gengrinovich 1 Comment

Solution Implementation

Solution Implementation

When faced with recurring equipment failures, identifying the root cause is only half the battle. The real challenge lies in implementing an effective solution that addresses the issue while considering various stakeholder perspectives. In this article, we’ll explore a comprehensive approach to optimizing decision-making for equipment failure.

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

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Sample size during Product Validation

Sample size during Product Validation

After successful DV testing, the product moves into the PV phase. PV testing is conducted on units that are manufactured using the final production process, materials, and equipment. The purpose of PV is to validate that the production process can consistently produce units that meet the design specifications.

The sample size for PV is typically smaller than for DV, as indicated by the user input of around 10 samples. This is because the focus of PV is on the consistency and capability of the production process rather than the design itself.

These tests are crucial for products that incorporate complex mechanical, electrical, and chemical components, as they must perform reliably under a wide range of operating conditions and comply with stringent safety and environmental regulations.

[Read more…]

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by Semion Gengrinovich Leave a Comment

Reliability Test can be Done in Parallel to Design Validation

Reliability Test can be Done in Parallel to Design Validation

Yes, reliability testing can be done in parallel with design validation (DV). This approach has both advantages and disadvantages, which are important to consider in the context of product development and testing. Pros of conducting reliability testing in parallel with design validation include time efficiency. Conducting reliability testing in parallel with (DV) can significantly reduce the overall time required for product development. By overlapping these processes, you can identify and address potential issues earlier, which can accelerate the time to market. Early detection of issues running reliability tests alongside (DV) allows for the early detection of design flaws or weaknesses. This can lead to quicker iterations and improvements, enhancing the overall quality and robustness.

[Read more…]

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Sample size during Design Validation (DV)

Sample size during Design Validation (DV)

The allocation of samples for different tests during the design validation stage in the automotive industry can vary depending on the specific requirements of the product and the risks associated with its failure. However, based on the general practice of using a total of 30 samples for design validation, we can provide a hypothetical allocation for the different tests. It’s important to note that these numbers are illustrative and should be adjusted based on the actual testing needs, regulatory requirements, and industry standards.

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

by Semion Gengrinovich 1 Comment

SRE vs Reliability Engineer

SRE vs Reliability Engineer

In the world of engineering reliability, there is a crucial aspect that spans various domains, the two fields that often get confused due to their similar names. While site reliability engineering (SRE) and hardware reliability engineering are both aimed at ensuring the dependability of systems, they focus on vastly different areas and employ distinct methodologies.

Let’s explore the key differences between these two disciplines and delve into the history behind the SR naming convention.

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

by Semion Gengrinovich Leave a Comment

Sample Size During Feasibility/Prototyping

Sample Size During Feasibility/Prototyping

During the first prototype stage of product development, there is no one-size-fits-all answer for the right sample size. The appropriate sample size depends on various factors, including the objectives of your research, the nature of the prototype, the variability of the measurements, and the constraints of your project such as budget and timeline.

At the prototype stages of product development, especially for electromechanical devices, understanding the safety factor in your design is crucial. The safety factor, often referred to as the Factor of Safety (FoS), is a measure of the load-carrying capacity of a system beyond the expected or actual loads. Essentially, it indicates how much stronger the system is than it usually needs to be under normal conditions. A common approach to validate the safety factor in design, particularly for new and untested devices, is through step-stress accelerated life testing (SSALT). This method involves subjecting the prototype to increasing stress levels until failure occurs, providing insights into the product’s durability and reliability under various conditions. [Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

by Semion Gengrinovich Leave a Comment

Wear Out Prediction Model

Wear Out Prediction Model

In the realm of mechanical engineering the reliability and longevity of pumps are critical for numerous industrial applications. Predicting wear out of pumps can significantly enhance maintenance strategies, reduce downtime, and optimize operational efficiency. One effective approach to predicting wear out is by monitoring the revolutions per minute RPM of pumps over a large population in extended time periods.

This video delves into the methodology of creating a wear out prediction model.

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

by Semion Gengrinovich Leave a Comment

Why Weibull is so popular?

Why Weibull is so popular?

The Weibull distribution’s popularity across various industries stems from its remarkable flexibility and adaptability in modeling a wide range of data types, especially in reliability engineering and failure time analysis. This versatility is primarily due to the Weibull distribution’s shape parameter, which allows it to model different failure rates over time, aligning closely with the real-world behavior of many systems and components.

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

by Semion Gengrinovich Leave a Comment

Continuous Improvement

Continuous Improvement

Continuous Improvement in product development is a systematic and ongoing approach to enhancing products processes and services. This concept is crucial for organizations to stay competitive, meet evolving customer needs, and maintain product quality.

Let’s explore the key concepts of continuous Improvement in product development. Continuous Improvement is an iterative process tha 2involves constantly evaluating and refining products and processes. It’s not a one-time effort but a cyclical approach that allows for ongoing enhancements based on feedback.

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

by Semion Gengrinovich Leave a Comment

Quality vs. Reliability

Quality vs. Reliability

Quality: A Snapshot at Time Zero

Quality is a measure of how well a product meets specified requirements and standards at the beginning of its life. It’s a static measure that can be controlled and measured with accuracy. Quality engineers focus on designing and implementing quality control processes, conducting inspections and testing, and identifying and addressing defects or issues.

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

by Semion Gengrinovich 1 Comment

Reliability Allocation

Reliability Allocation

Given the reliability goal for a system, we often need to understand the reliaility goals for elements within the system. It is a balance between safety, cost, and performance. This short video discussed how to approach allocating reliability goals within a complex system.

[Read more…]

Filed Under: Articles, on Product Reliability, Reliability Knowledge

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