1. Project Reliability Approach
Weibull Reliability Engineering Workshop©
Project Reliability Approach
Ing. R. Schop
Sr. Reliability Engineer

2. Reliability Tools in Program Phases and DFSS
Weibull Reliability Engineering Workshop©
Reliability Tools in Program Phases and DFSS
Design For Six Sigma (DFSS) integration in the Product Creation Process
The application of Reliability Tools & Methods in the Product Creation Process to ensure the realization of Reliability Targets

3. Agenda
Agenda
The relation between the Program Development Phases and Six Sigma DFSS Steps
Reliability Tools and Methods in the Program Phases
Summary & Overview

4. The Program Phases The Product Creation Process Phases:
The relation between Program Phases and Six Sigma
The Program Phases
The Product Creation Process Phases:
Orientation or Concept Phase
Definition Phase
Development / Engineering Phase
System Test Phase / Product Validation Phase
Production / Process Validation Phase
Volume Production Phase
Evaluation Phase

5. The Program Phases The relation between Program Phases and Six Sigma
Milestone
Milestone
Milestone
Milestone
Milestone
Orientation
Definition
Develop-ment
Testing
Production
Validation
Volume Produc-tion
Evaluation

6. Comparing Program Phases with Six Sigma Steps
The relation between Program Phases and Six Sigma
Comparing Program Phases with Six Sigma Steps
Six Sigma DMAIC to improve existing processes:
Define: Identify requirements and project scope
Measure: Establish data collection plan
Analyse: Identify Key Process In/Out Variables
Improve: Validate optimum operating conditions
Control: Monitor and sustain improvements

7. Comparing Program Phases with Six Sigma
The relation between Program Phases and Six Sigma
Comparing Program Phases with Six Sigma
Design For Six Sigma DFFS using IDDOVE for
New Developments:
Identify: Identify requirements and opportunities
Define: Define project content and strategy
Design: Define and Design engineering solutions
Optimise: Decompose and optimise robust design
Validate: Verify Reliability
Evaluate: Measure and Sustain Reliability
Each of these can be mapped on Program Phases

8. The Program Phases and DFSS
The relation between Program Phases and Six Sigma
The Program Phases and DFSS
Orientation
Definition
Develop-ment
Testing
Production
Validation
Volume Produc-tion
Evaluation
Identify
Define
Design
Optimize
Validate
Evaluate

9. The Program Phases and DFSS
Reliability Objectives of Program Phases and Six Sigma
The Program Phases and DFSS
Orientation
Definition
Develop-ment
Testing
Production
Validation
Volume Produc-tion
Evaluation
Identify
Define
Design
Optimize
Validate
Evaluate
Prove that Reliability Targets will be met
Verify Reliability Targets
Evaluate Project Achieve-
ments
Realize and monitor Reliability Growth
Define & Check Feasible Reliability Targets
Gather Reliability Information
Prove that Process targets are met
Control

10. The Program Phases Orientation Phase Gather Reliability Information
Definition
Develop-ment
Testing
Production
Validation
Volume Produc-tion
Evaluation
Gather Reliability Information
Historical data
Actual field performance
Test results previous projects
Competitive information
DFSS Tools
Field Reliability Data Base (FRDB)
Warranty Field Performance
Document retention system
Benchmarking

11. DFSS Tools & Explanation
Orientation Phase
DFSS Tools & Explanation
Field Reliability Data Base (FRDB) measures Field Reliability and Durability performance over multiple years including Competitor performance, if possible
Warranty Field Performance measures Costs and Warranty Reliability. Large and complete database for quick signalling and measuring effects of implemented improvements
Document retention system; Source of history on Systems and Components problems reported during Development and Usage in the Field
FRDB Weibull analysis; Quantitative information on current product + competitors Reliability Performance (Benchmark)

12. Field Reliability Database
Orientation Phase
Gather Reliability Information
Field Reliability Database
Reflection of the total population mix
Sample Number of Systems to be tracked over a longer
period, depending on targets set.
- EACH failure / repair
- Usage / Time per system
- Seriousness of failure
- Failure Root-Cause
- Repair Analyses
- Competitors performance

13. Field Reliability Database
Orientation Phase
Field Reliability Database
Minimal Sample-size & Test-length for:
 = 2,5; > 3 failures; B(10) = hours
90% Probability of Detection

14. The Program Phases The relation between Program Phases and Six Sigma
Orientation
Definition
Develop-ment
Testing
Production
Validation
Volume Produc-tion
Evaluation
Define Reliability Targets
Identify innovation content & systems (New / Carry-Over)
Define Reference System Reliability Target
Check feasibility of Targets
Realistic assumptions / Actual system performance
Comparison with similar parts or systems
Tools
Project / System Specification
Company Reliability Target Book (CRTB)

15. DFSS Tools & Explanation
Definition Phase
The Project or System Specification should state the Reliability requirements on System level, including brake down to Component or Group level plus New/Carry-Over overview.
Company Reliability Target Book (CRTB) lists the latest Reliability Targets on Component and Group level. If NEW components are developed, the GENERIC Company targets conform the CRTB shall be used.

16. Define Reliability Targets
Definition Phase
Define Reliability Targets
Assure Reliability Targets are Feasible and can be met.
Project content (New / Carry-Over / Improved)
Current System Performance (FRDB / Warranty)
Set proper Reliability Targets for New Components (CRTB)
Project
Target

17. Company Reliability Targets
Definition Phase
Company Reliability Targets
Listing of all Components of a System
The total System is split-up in Components that are recognisable by both Customer and Manufacturer
Each Component has a target assigned
Proportional partition of System target over Components
System target = SUM of Component targets
Targets are:
Acceptable by the Customers
Achievable by the Industry
Supporting Project Specification requirements
Matching with Lease Contract Policies

18. Function of Reliability Targets
Definition Phase
Function of Reliability Targets
Clear Reliability targets for all Components, in order to achieve the Customer Requirements
Utilization:
Engineers design criteria
Components or Systems Specifications
Communication and agreements with Suppliers
Set-up adequate Reliability Validation Plan
Assess Supplier Reliability Validation Plan
Assess Reliability Validation test results
Initiate corrective actions during testing
Check feasibility of project target

19. Sample GENERIC Targets
Definition Phase
Sample GENERIC Targets

20. Sample Combined Target Plot
Definition Phase
Sample Combined Target Plot
Beta <1
Beta >1
Beta >> 5

21. The Program Phases The relation between Program Phases and Six Sigma
Orientation
Definition
Develop-ment
Testing
Production
Validation
Volume Produc-tion
Evaluation
Verified Reliability Targets
Decide on reliable technical solutions
Specify and Agree on Technical Requirements of Systems
Identify most significant performance characteristics
Identify Technical Risks and define Risk Reduction Plans
Tools
Quality Function Deployment (QFD)
Baseline specifications (BSL)
Top Level Score Cards (TLSC)
Risk Analysis; Failure Mode Effect Analysis (FMEA)
Design Validation Plan & Report (DVP&R)

22. DFSS Tools & Explanation
Development Phase
DFSS Tools & Explanation
Quality Function Deployment (QFD); Translates customer requirements into measurable dimensions
Baseline specifications (BSL); Specification that describe what Functional, Fit & Reliability aspects have to be met.
Top Level Score Card (TLSC); Functionality, Fit & Reliability measurables out of the Baseline are tracked during project.
Failure Mode & Effect Analysis (FMEA) identifies Design and Process Risks and planned Risk Reduction activities
Design Validation Plan & Report (DVP&R); Risk Reduction Plan for all Activities from FMEA planned in Time

23. BASELINE Specifications
Development Phase
BASELINE Specifications
Sample BASELINE CONTENTS
Scope and Field of Application
Property Requirements
Noise
Ergonomics
Reliability
Durability
Safety
Cost of Ownership
Weight
Fit and Finish
Legislative Requirements
Functional requirements
Function Description
Diagnostics
Software quality requirements
Architecture
Boundary Conditions
Configurations / Variants
Operating conditions
Interfacing
Layout and packaging
Process requirements
References and Standards
Annexes
Specify System and Component targets on:
Functionality
Fit & Interface
Reliability

24. BASELINE Specifications
Development Phase
BASELINE Specifications
Track Baseline Creation and Approval in Time
BSL is part of the Supplier Development Contract

25. Top Level Score card (TLSC)
Development Phase
Top Level Score card (TLSC)
Keep Track of Key System Performance indicators and Critical Dimensions during development.

26. Design Validation Plan&Report (DVP&R)
Development Phase
Design Validation Plan&Report (DVP&R)
Plan, Measure and Track all the (in FMEA) identified Risk Reduction Activities in Time during the project.

27. The Program Phases The relation between Program Phases and Six Sigma
Orientation
Definition
Develop-ment
Testing
Production
Validation
Volume Produc-tion
Evaluation
Realize and Monitor Reliability Growth
Type of testing + minimal Sample-size
Manage Identified Problems and Corrective Actions
Prove capability of product, assess Top Level Score Card
Define Critical To Quality specifications
Tools
Project Test Plan; Reliability Validation Plans (RVP); Field-test
Reliability Forecast, DVP&R, FRACAS
Supplier Project Progress Reviews / Design Reviews / TLSC
CTQ Score Cards on Drawing Level

28. DFSS Tools & Explanation
Testing Phase
DFSS Tools & Explanation
Decide on the Type of Testing
Robust Design
Reliability Improvement
Meet the Requirements
Project Test-plan; Reliability Validation Plan (RVP); Field-test; Determine minimal test-length and sample-size
Interim Reliability Forecast, DVP&R status, FRACAS status for managing project risks and corrective actions
Supplier Project Progress Reviews / Design Reviews / TLSC assessment to assure Product meets requirements
Score Cards on Drawing Level CTQ’s, Check Measurement System Analysis (MSA), Show current Capability (Cp), Install Control Plans

29. Testing Phase
Robust Design
Test to a MUCH higher level than the Requirement Level in order to quickly find Failures and IMPROVE THEM to get the most ROBUST (=Reliable) Design you can get.
This is NOT a Reliability Forecast Technique
Testing to Failure
Methods:
HALT (Highly Accelerated Life Testing)

30. Robust Design HALT & Six Sigma Testing Phase Strength Failures Stress

31. Reliability Improvement
Testing Phase
Reliability Improvement
Test to higher than the Requirement Level up to Failures in order to predict the Component Reliability Performance.
Success & Failure Testing
Methods:
Weibull Analysis
Sudden Death Testing
Back to Back (OLD / NEW) testing

32. Meet the Requirements Success Run Testing
Testing Phase
Meet the Requirements
Test up to the Requirement Level, in order to prove that the requirements are met.
Success Run Testing
Methods:
Weibayes Analysis
ZERO Failure Testing

33. Preferred Testing Methodologies
Testing Phase
Preferred Testing Methodologies
1 - Start with HALT Testing during early development. Get a ROBUST Design
2 - Use Reliability Improvement Testing to check correlation Field-Performance and testing methods. Get a Reliability Forecast
3 - Use the Meet the Requirements Testing as MINIMAL to-be-performed project. This only if other testing is not possible. Get a Minimal to be expected Reliability

34. Project Test Plan Testing Phase
Create an overall testing plan that assures a sufficient probability of detecting failure-modes during the project validation taking all generic failure-modes in account.

35. Reliability Validation Plan (RVP)
Testing Phase
Reliability Validation Plan (RVP)
Derive the “High Risk” Items from FMEA
Use “Gut Feeling” too … ... !
Create OBJECTIVE , Statistically supported Test-Plans, assessing the Confidence level to meet the Reliability Target with all Activities Planned.
RVP Results:
Objective % Confidence gained per planned Activity.
Shows “Uncovered Failure-Modes” & “Overkill’s”
Shows contribution (%C) per Activity.
Leads to Cost Effective Testing / Activity Plan.

36. Reliability Validation Plan (RVP)
Testing Phase
Reliability Validation Plan (RVP)

37. Testing Phase
Field Test
Define Field-Test Minimal Sample-size for Process and Random Modes.

38. The Program Phases The relation between Program Phases and Six Sigma
Orientation
Definition
Develop-ment
Testing
Production
Validation
Volume Produc-tion
Evaluation
Prove that Reliability Targets will be met:
Evaluate RVP results & Reliability data, and check with Targets
Measure Reliability Growth
Prove capability of processes, measure CTQ’s
Assess Supplier Process Readiness
Tools
Weibull analysis
FRACAS and Crow-AMSAA MTBF Growth
Score Cards on Drawing Level
Process Control Plans / Supplier Readiness Reviews (SRR)

39. DFSS Tools & Explanation
Production Validation Phase
DFSS Tools & Explanation
RVP status; Weibayes for Zero Failures; Weibull analysis if failures occur
FRACAS to manage corrective actions; Crow-AMSAA to measure MTBF Growth and Development Process effectiveness in solving problems
CTQ Score Cards on Drawing Level to prove process capabilities
Process Control Plans

40. Production Validation Phase
FRACAS
Failure Report And Corrective Action System
Identify ALL Failures. Report clearly and Track from first Reporting to final Validation of the Solution.
All items in FRACAS are assessed by the FRB (Failure Review Board)
ALL failures to report to the Failure Review Board (FRB)
FRB to address each issue to appropriate Person / Department
FRB makes sure that proposed change is indeed an improvement
There are no INCIDENTS!
An Incident is the beginning of a Trend...
The “I- Word” … …

41. Production Validation Phase
FRACAS & FRB

42. Production Validation Phase
Weibull Analysis

43. Production Validation Phase
Weibull Analysis

44. Crow-AMSAA Reliability Growth
Production Validation Phase
Crow-AMSAA Reliability Growth
Measure the Reliability Growth of the Overall Project during the Validation Process.
Planned Test Hours
Target MTBF
300

45. The Program Phases The relation between Program Phases and Six Sigma
Orientation
Definition
Develop-ment
Testing
Production
Validation
Volume Produc-tion
Evaluation
Prove that Process Targets are met
Agreements with suppliers on “Fit for Use”
Prove Process Capabilities
Review Supplier Readiness
Tools
Supplier Sign Off / Supplier Readiness Review
Process Control Plan
Production Parts Approval Process (PPAP)
Statistic Process Control (SPC)

46. DFSS Tools & Explanation
Volume Production Phase
DFSS Tools & Explanation
Supplier Sign Off (SSO); Formal Document where Supplier states that his System is Fit to serve the Purpose in the System
Supplier Readiness Reviews (SRR); Review, based on RVP results, MTBF Growth, Top Level & CTQ Score Cards Results
Process Control Plans, based on MSA and Capability Study results
Production Parts Approval Process (PPAP); Official approval for Start Of Production
Statistic Process Control (SPC) to Control the Process in Time (Cpk)

47. The Program Phases The relation between Program Phases and Six Sigma
Orientation
Definition
Develop-ment
Testing
Production
Validation
Volume Produc-tion
Evaluation
Evaluate project Achievements
Identify new Field Reliability Fleet
Early Warning System for immediate corrective actions
Tools
Field Reliability Data Base (FRDB)
Field Introduction Fleet

48. DFSS Tools & Explanation
Evaluation Phase
DFSS Tools & Explanation
Set-Up a new Field Reliability Data Base (FRDB) for the new type of Systems
Decide on an Field Introduction Fleet that Tracks the first sales very close with the customers ON TOP OF the standard Warranty procedures.

49. FRACAS, DVP&R & Score Cards
The relation between Program Phases and Six Sigma
Overview
Orientation
Definition
Develop-ment
Testing
Production
Validation
Volume Produc-tion
Evaluation
Identify
Define
Design
Optimize
Validate
Evaluate
Historical
Data
(FRDB / Weibull)
Reliability
Targets
(CRTB)
Specify
(BSL)
Risk
Analysis
(FMEA + DVP&R)
Validation
Plan
(RVP)
Manage
FRACAS
& FRB
Reliability
Growth
(CA / Weibull)
Field
Validation
(FRDB / Weibull)
Top Level Score Card
CTQ’s Score Card
Supplier System Sign-Off
FRACAS, DVP&R & Score Cards

50. SUMMARY We have; The DATA The TOOLS The METHODS We have the medicine,
The relation between Program Phases and Six Sigma
SUMMARY
PAST
NOW
GOAL
RISKS
FOCUS
CONTROL
CORRECT
FORECAST
We have;
The DATA
The TOOLS
The METHODS
We have the medicine,
we just have to take it !