Reliability

Reliability, Availability, Maintainability and Safety - (RAMS)

ReliaSystem (making designs and products more reliable), is a leading “Reliability, Availability, Maintainability, and Safety (RAMS) Services, Consultancy and Training” provider in the fields of Defense, Aerospace, Medical Device, Semiconductor, Automobile, Oil & Gas, Energy and Industrial Products. Our experts assist clients in meeting the Industry and Product specific reliability requirements and international Reliability standards including MIL, IEC, AIAG, ISO, AAMI etc

Reliability in Concept & Feasibility Stage:

  • System Reliability Project Planning
  • Reliability requirements analysis
  • Benchmarking
  • Product Feasibility study
  • Reliability Goal setting
  • Reliability Engineering Training to Cross functional Team

Reliability in Design & Development Stage:

  • System Reliability Block Diagram (RBD)
  • Reliability Allocation
  • Supplier selection & validation
  • Component Stress vs. Strength and Derating Analysis
  • Reliability Prediction
  • DFMEA and PFMEA
  • Thermal Analysis
  • Fault tree analysis (FTA)
  • Design for X (DFX): assembly, testability, maintainability

Reliability Testing:

  • Reliability Test Planning
  • Test Fixture Design & Development and Test Automation
  • Highly Accelerated Life Test (HALT)
  • Reliability Demonstration Test (RDT).
  • Reliability Growth Test
  • Accelerated Life Test (ALT)
  • Single Fault Testing(SFT)
  • Degradation ( wear–to- failure) testing
  • Environment Stress screening(ESS)
  • Test Data analysis and Reliability Estimation
  • Design verification

Reliability in Production Stage:

  • Highly Accelerated Stress Screening (HASS)
  • Product Reliability acceptance test(PRAT)
  • Development of Preventive Maintenance Plan
  • Development of Spare Part Strategy Plan
  • Warranty Cost Prediction
  • Prediction of Cost to Company for different Warranty Policy
  • Financial & Risk Analytics

Reliability in Maintenance and Service Stage:

  • Product field life Estimation
  • Reliability Centered Maintenance (RCM)
  • FRACAS (Failure reporting, analysis, and corrective action system)
  • Maintenance Analysis
  • Product Performance Monitoring Index within Warranty Period
  • Annual Maintenance Contract /Extended Warranty - Prediction for Cost to the Company
  • Spare Part Analysis
  • Customer Analytics
  • Supply Chain Analytics

Industry specific & International Reliability Engineering Standards we Support:

Reliasystem supports Industry specific Reliability, Safety and Environment testing standards for Medical, Defense, Aerospace, Oil & Gas, Energy and Automotive Industries.

ReliaSystem Reliability and Environmental Laboratory Services (NABL and ISO9001:2008 certified):

                            To enhance our surge capability and hence our rapid responsiveness to you, ReliaSystem Partnered with NABL accredited Reliability & Environment engineering laboratory. We offer a full range of Test requirement analysis, Test Protocol Development & Execution, Test Fixture Design & Development, Test Automation services as per product specific requirements. We can help you to assess the Design, Reliability and Safety of your products, compare the performance of your products with others.

Reliability Test Capabilities

  • Test Planning
  • Accelerated Life Test(ALT)
  • Highly Accelerated Life Test(HALT)
  • Reliability Demonstration Test(RDT)
  • Reliability Growth Test (RGT)
  • Single Fault Testing and Thermal Analysis
  • Highly Accelerated Stress Screening(HASS)
  • Environmental Testing
  • Thermal Analysis
  • Custom and Industry(Defense, Aerospace, Semiconductor, Automotive and Medical etc) specific Tests

Environmental Test Facilities:

  • Test Fixture Design and Development
  • Test Automation ( LabVIEW, Teststand etc)
  • Vibration Test at Ambient condition up to 70g and Frequency of 3000 Hz
  • Vibration Test at Hot and Cold Temperature from -40 to +200 Deg C, 98% RH
  • Thermal Shock test, basket transfer time 10s, -40 to +200 Deg C, 98% RH
  • Hot, Cold and Humidity Test
  • Push/ Pull test at different Speed and Load
  • Tensile and Compression Test
  • Tensile test at Hot and Cold Environment
  • Normal and Cyclic Corrosion Test
  • 3.5 Ton Vibration Shaker
  • Noise measurement System
  • Electrical and Mechanical Performance Test

ReliaSystem Reliability Engineering Training:

ReliaSystem has designed an exhaustive training program on Reliability Engineering Tools and Techniques for professionals from industry and user organizations. It provides training in Reliability Engineering as per the curriculum of American Society for Quality (ASQ), USA, a renowned global institution for Quality and Reliability. Training is going to provide by group of eminent experienced engineers having education (M.Tech in Reliability from IIT Khargpur and Certified Reliability Engineer from American Society of Quality & Reliability) and rich experience in leading and executing Reliability Engineering projects of top OEM’s in India and Overseas.

OBJECTIVE:

  • To provide the awareness and importance of the Reliability Engineering.
  • To provide sufficient knowledge to the participants on Reliability Engineering Tools and Techniques,which helps them to evaluate and improve Product Reliability, Availability, Maintainability and Safety.
  • To prepare participants and in turn their organizations to get certify by American Society for Quality (ASQ), USA, and align with Level of International Standards in Reliability Engineering.

BENEFITS TO THE PARTICIPANTS AND ORGANISATION:

  • Enhance product Reliability, Availability, Maintainability, Service and Safety.
  • Certification is a mark of Excellence
  • Meets Customer, Product, Government and industry specific Reliability requirements/ compliance which in turn Widens customer base, faster product release, better service and reduce product development time and cost.

WHO SHOULD PARTICIPATE:

System, Design, Reliability, Test, Quality, Production, Service Engineers and Maintenance& Marketing Managers can participate in this program.

Reliability Engineering Training Topics:

RELIABILITY MANAGEMENT

Strategic & Reliability Program management:Benefits of reliability engineering, Interrelationship of safety, quality, and reliability, Role of the reliability function in the organization, Reliability in product and process development, Failure consequence and liability management, Warranty management, Customer needs assessment, Supplier reliability. Reliability Terminology (e.g., MTTF, MTBF, MTTR, availability, failure rate, reliability, maintainability), Elements of a reliability program, Design evaluation, Systems engineering and integration.

II. PROBABILITY AND STATISTICS FOR RELIABILITY

  • Statistical terms: Population, parameter, statistic, sample, the central limit theorem.
  • Basic probability concepts: Use basic probability concepts (e.g., independence, mutually exclusive, conditional probability) and compute expected values.
  • Discrete and continuous probability distributions: Compare and contrast various distributions (binomial, Poisson, exponential, Wiebull, normal, log-normal, etc.) and their functions (e.g., cumulative distribution functions (CDFs), probability density functions (PDFs), hazard functions), and relate them to the bathtub curve. Poisson process model. Non-parametric statistical methods: Median, Kaplan-Meier, Mann- Whitney, etc
  • Sample size determination: Use various theories, tables, and formulas to determine appropriate sample sizes for statistical and reliability testing.
  • Statistical process control (SPC) and process capability
  • Statistical inference: Point estimates of parameters, Statistical interval estimates, Hypothesis testing (parametric and non-parametric)

III. RELIABILITY IN DESIGN AND DEVELOPMENT

  • Environmental and use factors
  • Stress-strength analysis
  • FMEA and FMECA,
  • Fault tree analysis (FTA) and success tree analysis (STA)
  • Tolerance and worst-case analyses
  • Design of experiments
  • Human factors
  • Design for X (DFX): Apply DFX techniques such as design for assembly, testability, maintainability Environment (recycling and disposal).
  • Reliability apportionment (allocation).
  • Parts and systems management
  • Derating methods and principles: Use methods such as S-N diagram, stress-life relationship, etc., to determine the relationship between applied stress and rated value, and to improve design.
  • Establishing specifications: Develop metrics for reliability, maintainability, and serviceability (e.g., MTBF, MTBR, MTBUMA, service interval) for product specifications.

IV. RELIABILITY MODELING AND PREDICTIONS

  • Sources and uses of reliability data: Describe sources of reliability data (prototype, development, test, field, warranty, published, etc.), their advantages and limitations, and how the data can be used to Measure and enhance product reliability.
  • Reliability block diagrams and models: Generate and analyze various types of block diagrams and models, including series, parallel, partial redundancy, time-dependent, etc.
  • Simulation techniques: Describe the advantages and limitations of the Monte Carlo and Markov models.
  • Dynamic reliability: Describe dynamic reliability as it relates to failure criteria that change over time or under different conditions.
  • Reliability predictions: Part count predictions and part stress analysis: Use parts failure rate data to estimate system and subsystem-level reliability. Use various reliability prediction methods for both repairable and non-repairable components and systems, incorporating test and field reliability data when available.

V. RELIABILITY TESTING

A. Testing during development

  • Reliability test Planning and Test conditions (Environment and operating)
  • Highly Accelerated Life Testing (HALT)
  • Accelerated Life Testing (ALT) (e.g., single-stress, multiple-stress, sequential stress, step stress)
  • Reliability Growth Testing (RGT) (e.g., test, analyze, and fix (TAAF), Duane)
  • Software testing (e.g., white-box, black-box, operational profile, and fault-injection)

B. Product testing

  • Qualification/demonstration testing (e.g., sequential tests, fixed-length tests)
  • Product reliability acceptance testing (PRAT)
  • Ongoing reliability testing (e.g., sequential probability ratio test [SPRT])
  • Stress screening (e.g., ESS, HASS, burn-in tests)
  • Attribute testing (e.g., binomial, hypergeometric)
  • Degradation (wear–to-failure) testing

VI. MAINTAINABILITY AND AVAILABILITY

A. Management strategies

  • Maintenance strategies: Identify the advantages and limitations of various maintenance strategies (e.g., reliability-centered maintenance (RCM), predictive maintenance, repair or replace decision making), and determine which strategy to use in specific situations.
  • Availability tradeoffs: Describe various types of availability (e.g., inherent, operational), and the tradeoffs in reliability and maintainability that might be required to achieve availability goals.

B. Maintenance and testing analysis

  • Preventive maintenance (PM) analysis: Define and use PM tasks, optimum PM intervals, and other elements of this analysis, and identify situations in which PM analysis is not appropriate.
  • Corrective maintenance analysis: Describe the elements of corrective maintenance analysis (e.g., fault-isolation time, repair/replace time, skill level, crew hours) and apply them in specific situations.
  • Non-destructive evaluation: Describe the types and uses of these tools (e.g., fatigue, vibration signature analysis) to look for potential defects.
  • Testability: Use various testability requirements and methods (e.g., built in tests (BITs), false alarm rates, diagnostics, error codes, fault tolerance) to achieve reliability goals
  • Spare parts analysis: Describe the relationship between spare parts requirements and reliability, Maintainability and availability requirements. Forecast spare parts requirements using field data, production lead time data, inventory and other prediction tools, etc.

VII. DATA COLLECTION AND USE

  • Product Life Prediction: Reliability, Failure rate, B(x) life, etc
  • Warranty Cost Prediction.
  • Prediction of Cost to Company for different Warranty Policy
  • Annual Maintenance Contract /Extended Warranty - Prediction for Cost to the Company
  • Customer Analytics
  • Sales & Marketing Analytics
  • Supply Chain Analytics:
  • Risk Analytics
  • FRACAS (Failure reporting, analysis, and corrective action system).