Reliability Prediction and Testing Textbook

By Lev M. Klyatis and Edward L. Anderson

This textbook reviews the methodologies of reliability prediction as currently used in industries such as electronics, automotive, aircraft, aerospace, off-highway, farm machinery, and others. It then discusses why these are not successful; and, presents methods developed by the authors for obtaining accurate information for successful prediction. The approach is founded on approaches that accurately duplicate the real world use of the product. Their approach is based on two fundamental components needed for successful reliability prediction; first, the methodology necessary; and, second, use of accelerated reliability and durability testing as a source of the necessary data.

Applicable to all areas of engineering, this textbook details the newest techniques and tools to achieve successful reliabilityprediction and testing. It demonstrates practical examples of the implementation of the approaches described. This book is a tool for engineers, managers, researchers, in industry, teachers, and students. The reader will learn the importance of the interactions of the influencing factors and the interconnections of safety and human factors in product prediction and testing.

• Language: English
• Publisher: Wiley
• Release date: Jul 12, 2018
• ISBN: 9781119411932

Lev M. Klyatis

Lev M. Klyatis, PhD, Habilitated Dr.-Ing., Sc.D., Head of Reliability Department Eccol, Inc., has been Professor of Engineering Technology at Moscow State Agricultural University, research leader and chairman of State Enterprise TESTMASH, and served on the USA Technical Advisory Group for the International Electrotechnical Commission, the ISO/IEC Joint Study Group in Safety Aspects of Risk Assessment, the United Nations European Economical Commission, and World Quality Council.

Book preview

Introduction

Lev M. Klyatis

What is reliability?

Reliability as used in this text is the science aimed at predicting, analysing, preventing, and mitigating failures over time. Reliability is quality over time. A reliable, trouble‐free product continues to satisfy customers for a long time. In the narrow sense, reliability is the probability that a device will operate successfully for a specific period of time and under specified conditions when used in a manner consistent with the purpose intended.

It is the authors' contention that the money invested in adequate testing during design and production for developing a reliable product will result in greater profitability during both the warranty period and the service life of the product.

Who gains from improved reliability?

The short answer is everyone, specifically:

The manufacturer, because their product has additional customer appeal, through higher quality, improved in‐service time, faster service, lower cost of recalls, and a reduced need for changes in the manufacturing processes.

The customer, because the equipment purchased performs as expected, is easier and less costly to support, and has reduced out‐of‐service time (better availability).

Society, because there are reduced deaths, injuries, lost productivity, and associated impact resulting directly or indirectly from failures of the product.

Reliability‐related costs are not just the costs of reliability testing, but include all the costs resulting from product field failures or perceived failures from the time of shipment throughout the life of the product. They include warranty costs, recall costs, design change cost, manufacturing change cost, and the opportunity cost of lost customers.

Improvements in reliability made early in the equipment life cycle may also result in total life‐cycle costs saving (significant decreasing of maintenance and inventory costs).

Failure analysis is the process of collecting and analysing data to determine the cause of a failure and developing methods of remediation. Failure analysis is an important aspect of many branches of manufacturing, especially in electronics, where it is a vital tool used in the development of new products and for the improvement of existing products. Effective failure analysis is especially important in the manufacturing and use of life‐safety and mission‐critical equipment. Of course, it is also important for other areas of industry. Failure analysis may be applied to both products and processes. Failure analysis may be conducted at the design stage, manufacturing, or field‐use stage of the product life cycle.

While successful prediction is a key element in product development, too often reliability prediction has been demonstrated to be less than successful. Historically, the term prediction has been used to denote the process of applying mathematical models and data to estimate the field performance of a product or process. This was frequently done before empirical data were available for the product or system. Prediction is successful if it prevents unexpected failures of the product or improves the product's reliability characteristics.

Introduction

Lev M. Klyatis

What is reliability?

Reliability as used in this text is the science aimed at predicting, analysing, preventing, and mitigating failures over time. Reliability is quality over time. A reliable, trouble‐free product continues to satisfy customers for a long time. In the narrow sense, reliability is the probability that a device will operate successfully for a specific period of time and under specified conditions when used in a manner consistent with the purpose