Reliability Knowledge

Accelerated Life Testing (ALT) is a method used in reliability engineering to assess the lifespan and performance of a product under accelerated stress conditions. The goal is to uncover potential faults and failures in a shorter time frame than would be possible under normal operating conditions. ALT is particularly useful when the product’s expected lifespan is long, and waiting for failures to occur naturally is not feasible.

In the context of Design Verification (DV), ALT can help shorten the testing time by inducing failures more quickly than under normal conditions. This allows engineers to identify and address potential issues earlier in the product development process, thereby improving the product’s reliability and reducing the time to market. [Read more…]

The importance of failure repeatability lies in its role in understanding and improving systems, processes, and products. Failure repeatability refers to the consistency with which a system or device can reproduce an outcome under unchanged conditions. In the context of product design engineering and testing, being able to consistently replicate a failure means that the underlying cause can be more accurately identified and addressed.

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Degradation testing for electromechanical components such as pumps, valves, and sensors involves a series of steps to identify wear and tear that could lead to system failure. The goal is to detect these signs of degradation early enough to replace the part and prevent system failure.

For pumps, degradation can be monitored by sensors. A study on gear pumps used an accelerated life test (ALT) to monitor the degradation state. The volumetric efficiency of the pumps was measured over time, and the wear clearances were recorded. As the wear gap increased, the flow rate gradually decreased, indicating wear degradation.

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The 5-Whys approach in product development enhances reliability by understanding failure modes. The 5-wys technique is a powerful tool for root cause analysis. Originally developed by Sakichi Toyoda and later popularized by Keiichi Ono.

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Preventive maintenance is a proactive approach used by industries to ensure the longevity and optimal performance of their assets. It involves regular maintenance tasks such as cleaning, lubrication, parts replacement, and equipment repairs to prevent unplanned downtime and costly breakdowns.

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Software reliability and Hardware reliability are two distinct Concepts within the field of engineering each with its own unique characteristics and measurement challenges.

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Understanding the different types of data and their respective uses is critical for product development, testing, and analysis. Each type of data plays a role in ensuring that products meet quality standards and fulfill user needs. As a mechanical engineer with a focus on R&D testing and data analysis, you would likely encounter and utilize these various data types throughout the product development and validation process.

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Defining a proper product reliability goal is a critical step in ensuring that a product meets customer expectations and performs adequately throughout its intended lifespan. This also involves a careful balance between the required level of reliability and the associated costs and complexities of achieving that reliability.

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Defining a proper product reliability goal is a critical step in ensuring that a product meets customer expectations and performs adequately throughout its intended lifespan. This also involves a careful balance between the required level of reliability and the associated costs and complexities of achieving that reliability.

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Gage repeatability and reproducibility (GR&R) is a statistical tool used in quality control to assess a measurement system’s capability. It evaluates the amount of variation in the measurement data that is due to the measurement system itself rather than the product being measured. GR&R helps to determine if a measurement system is reliable and whether it’s producing repeatable and reproducible measurements.

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Gage Repeatability and Reproducibility (GR&R) is a statistical tool used in quality control to assess a measurement system’s capability. It evaluates the amount of variation in the measurement data that is due to the measurement system itself, rather than the product being measured.

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Accelerated life testing, ALT, is a method used in reliability engineering to assess the lifespan and performance of a product under accelerated stress conditions. The goal is to uncover potential faults and failures in a shorter time frame than would be possible under normal operating conditions. ALT is particularly useful when the product’s expected lifespan is long and waiting for failures to occur naturally is not feasible.

[Read more…]

Highly Accelerated Stress Screening (HASS) and Highly Accelerated Stress Audit (HASA) are advanced testing methods used to identify potential defects in full assemblies, while burn-in testing is typically applied at the component level. These tests are designed to expose products to extreme conditions to precipitate failures, allowing for corrective actions before the products reach customers.

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Six Sigma gives you the tools and techniques to determine what’s making the manufacturing process slow down, how you can eliminate the delays, improve the process, and fix further issues along the way. It is a methodology that has seen worldwide adoption. This video also provides detailed examples on how each of the two Six Sigma methodologies work. The example we’ll be considering is how a car manufacturing company is able to achieve its goals with the help of the Six Sigma methodologies, DMAIC and DMADV.

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Designing a proper test for the life of an electromechanical component involves several steps and considerations. Here next steps proposed to do:

Step #1: Define the Test Objectives: Clearly outline the expected functions and specifications of the component. Identify potential failure modes and criteria. This step is crucial to ensure that the test is aligned with the design specifications and customer requirements of the electromechanical device.

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