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QM ZG528 L-1

Reliability Engineering
BITS Pilani
Pilani Campus

Gajanand Gupta
Department of Mechanical Engineering

BITS Pilani
Pilani Campus

Introduction and Objectives


Chapter - 1

Course Description
Objectives, Basic reliability models, Constant failure rate
model,
Time-dependent failure models, Reliability of systems,
State-Dependent systems, Physical Reliability Models,
Design for Reliability,
Maintainability, Design for Maintainability,
Availability,
Reliability Estimation and Application

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Objective and Scope of the Course

The objective of the course is to understand the


concepts of reliability and maintainability engineering
and their importance in industry.
The scope of this course is to prepare the student for
more advanced study in reliability and maintainability
engineering and to enable the student to access the
increasing amount of technical material available in the
literature.
This course will enable the student to collect and
analyze failure and repair data, derive appropriate
reliability and maintainability models, and apply these
models in the design of products, components and
systems.
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Prescribed Text Book


Charles E. Ebeling: An introduction to Reliability and
maintainability engineering, edition 2000, Fourteen
reprint 2011, TMH, New Delhi

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Prescribed Reference Book


Reliability Engineering Handbook, Volume 1 by Dimitri
Kececioglu, DEStech Publications 2002
(http://www.books24x7.com/)
Reliability Engineering Handbook, Volume 2 by Dimitri
Kececioglu, DEStech Publications 2002
(http://www.books24x7.com/)

Handbook of Reliability Engineering by Hoang Pham


(ed), Springer 2003 (http://www.books24x7.com/)

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Course Plan
Lecture Chapter name
No:

Topics

Study of Reliability and maintainability,


Concepts, Terms and Definition, Why
reliability engineering?, applications and T1 Ch1
benefits, complexity of products, world R1 Ch 1
industrial competition and reliability
engineering, optimization of reliability

Introduction and
objectives

Text book

2
The Failure distribution

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Constant failure rate
model

The five important analytical functions in


reliability engineering, Reliability function,
Mean time to failure, Hazard rate function,
Bathtub curve, conditional Reliability

The exponential reliability function, Failure


modes, Applications, The two parameter
exponential distribution, Poisson process,
Redundancy and the CFR Model

T1 Ch 2
R1 Ch 3,4

T1 Ch 3
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The Weibull
distribution

distribution,

The

Exponential

T1 Ch 4
R1 Ch 5,6

The Normal
distribution

distribution,

The

Lognormal

T1 Ch 4
R1 Ch 7,8

Time Dependent
Failure models

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T1 Ch 5
R2 Ch 1,2

Serial Configuration, Parallel Configuration


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Reliability of systems
Combined Series-parallel
configuration

systems,

Complex

T1 Ch 5
R2 Ch 5

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T1 Ch 6
State -dependent Load-sharing system, standby systems, Degraded
R2 Ch 3,
systems
systems
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Review Session

10

Physical
Reliability
Models

Covariate models, Static Models,


Models, Physics of failure models

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Design for
Reliability

Reliability
specification
and
measurements, Reliability allocation,
Methods, Failure analysis

Dynamic

system
Design

T1 Ch 7

T1 Ch 8

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Maintainability

Analysis of downtime, The repair-time


distribution, system repair time, reliability
under
preventive
maintenance,
Statedependent systems with repair

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Design for
maintainability

Maintenance Requirements, design methods,


human factors and ergonomics, maintenance
and spares provisioning

T1 Ch10

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Availability

Concepts and Definitions, exponential


availability model, System availability,
inspection and repair availability model

T1 Ch11

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Data collection
and empirical
methods

Data
collection,
Empirical
methods,
Reliability testing, Reliability Growth testing

T1 Ch 12,13,
14

T1 Ch 9

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Reliability
Estimation and
Application

Application of Reliability estimation

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Implementation

Economics of Reliability and maintainability and


T1 Ch 18
system design, Software reliability

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T1 Ch 17

Review Session

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Evaluation Scheme
EC Evaluation
No. Component &
Type of
Examination

Duration Weightage Day, Date,


Session,Time

EC-1

Quiz

5%
5%
5%

EC-2

Mid-Semester Test
(Closed Book)*

2 Hours

35%

EC-3

Comprehensive
Exam
(Open Book)*

3 Hours

50%

August 16 to 26,
September 16 - 26,
October 13 - 23,
2014

Sunday,
14/09/2014 (FN)
10 AM 12 Noon
Sunday,
09/11/2014 (FN)
9 AM 12 Noon
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Nature of Exam
Closed Book Test: No reference material of any kind will
be permitted inside the exam hall.
Open Book Exam: Use of any printed / written reference
material (books and notebooks) will be permitted inside
the exam hall. Loose sheets of paper will not be
permitted. Computers of any kind will not be allowed
inside the exam hall. Use of calculators will be allowed in
all exams. No exchange of any material will be allowed.

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Note
It shall be the responsibility of the individual student to be regular in
maintaining the self study schedule as given in the course handout, attend
the online/on demand lectures as per details that would be put up in the
BITS LMS Taxila website www.taxila.bits-pilani.ac.in and take all the
prescribed components of the evaluation such as Assignment (Course Page
on LMS Taxila), Mid Semester Test and Comprehensive Examination
according to the Evaluation Scheme given in the respective Course Handout.
If the student is unable to appear for the Regular Test/Examination due to
genuine exigencies, the student must refer to the procedure for applying for
Make-up Test/Examination, which will be available through the Important
Information link on the BITS WILP website on the date of the Regular
Test/Examination. The Make-up Tests/Exams will be conducted only at
selected exam centres on the dates to be announced later.

BITS Pilani, Pilani Campus

BITS Pilani
Pilani Campus

Introduction and Objectives


Chapter - 1

Objectives
The need for reliability engineering
The applications of and the benefits from the applications
of reliability engineering.
The need to design higher reliabilities into parts and components
because of the increasing complexity of new products.
The need for countries to know and apply reliability
engineering diligently to their products to survive the intense,
worldwide industrial competition.
The fact that industry quotes and advertises reliability ratings

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Why Reliability Engineering?


Reliability is the probability that parts, components, products,
or systems will perform their designed-for functions without
failure in specified environments for desired periods at a given
confidence level.

Reliability is the best quantitative measure of the integrity of a


designed part, component, product, or system
Reliability engineering and product assurance programs
represent the single best return-on-investment opportunity for
most companies today.
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Reasons For Reliability Engineering Programs


The complexity of most products is increasing continuously
The customers and the public are becoming more and
more reliability conscious every day as they realize how costly
unreliability is becoming in their daily efforts.
World industry is introducing reliability engineering practices, so
to stay ahead of world competition, all industries need to be
knowledgeable of and institute to
reliability engineering
programs.
More and more products are being advertised by
their reliability ratings, such as their failure rate, mean time
between failures (MTBF), and reliability
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Reasons For Reliability Engineering Programs


How complexity affects the reliability of series equipment.
Individual component reliability
Number of components in
series

99.999%

99.99%

Equipment reliability
100

99.90%

99.01%

250

99.75%

97.53%

500

99.50%

95.12%

1,000

99.01%

90.48%

10,000

90.48%

36.79%

100,000

36.79%

0.01%
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Applications And Benefits


Implement an integrated reliability engineering and product
assurance program in purchasing, engineering, research,
development, manufacturing, quality control, inspection,
testing, packaging, shipping, installation, start up, operation,
field service, and performance feedback, take corrective
actions wherever and whenever indicated, and incorporate the
correct, complete, and comprehensive reliability and
maintainability specifications into all of these company
activities that come in contact with the product from birth to
death.

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Applications And Benefits


Study the types of failures experienced by parts, components,
products and systems and recommend design, research, and
development efforts to minimize these failures.
Establish what failures occur at what time in the life of an
equipment and be prepared to cope with them.
Determine the time-to-failure distribution of parts,
components, products, and systems.
Study the effects of age, mission duration, and application and
operation stress levels on reliability.
Predict the reliability of equipments, products, and systems to
see if the established goals can be met.
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Applications And Benefits


Indicate areas in which design changes would be most
beneficial from the reliability improvement and cost reduction
point of view.
Provide a basis for comparing two or more designs and for
choosing the best from the reliability point of view.
Evaluate the amount of redundancy present in the design.
Estimate the required redundancy to achieve the
specified reliability.
Conduct failure modes, effects, and criticality analyses to
identify areas which should receive concentrated design,
research, and development effort.
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Applications And Benefits


Pinpoint areas where research and development money can best be
spent.
Provide guidelines for critical reliability design reviews.
Provide guidelines for manufacturing processes and techniques.
Help provide guidelines for quality control practices.
Help provide guidelines for value engineering practices.
Help provide guidelines for human factors engineering practices.
Establish no-charge and goodwill cost reduction areas.
Scientifically allocate the target product or system reliability to their
subsystems, all the way down to their components and parts.

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Complexity of Products
How complexity affects system reliability. [*]

Number of critical
components

Individual component reliability


99.999%

99.99%

99.9%

System reliability
10

99.99%

99.90%

99.00%

100

99.90%

99.01%

90.48%

250

99.75%

97.53%

77.87%

500

99.50%

95.12%

60.64%

1,000

99.01%

90.48%

36.77%

10,000

90.48%

36.79%

<0.1%

100,000

36.79%

<0.1%

<0.1%

[*]It

is assumed that all critical components are reliability wise in series.

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Optimization Through Integrated Reliability Engineering


Programs In Industry
An aggressive, integrated reliability and maintainability effort
results in a simpler, improved, more reliable, more
maintainable, and less costly product through the:1. reduction of the number of components needed,
2. better arrangement of the components in a system,
3. better selection of materials,
4. proper selection of stress, strain, and stress-time relations
when the components are being designed.
5. use of probabilistic and statistical methods to establish the
optimum design. and stress and strength distributions
6. use of the applications and benefits of reliability engineering
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Thanks

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