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BITSPilaniPilani Campus

QM ZG528 L-1

Reliability EngineeringGajanand Gupta

Department of Mechanical Engineering

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Introduction and b!ecti"e#Chapter - 1

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BITS Pilani, Pilani Campus

Objectives, asic reliabilit! models, Constant failure rate

model,

"ime-dependent failure models, #eliabilit! of s!stems,

$tate-Dependent s!stems, Ph!sical #eliabilit! Models,

Design for #eliabilit!,

Maintainabilit!, Design for Maintainabilit!,

%vailabilit!,

#eliabilit! Estimation and %pplication

$our#e %e#cri&tion

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' "he objective of the course is to understand the concepts

of reliabilit! and maintainabilit! engineering and their

importance in industr!(

' "he scope of this course is to prepare the student for more

advanced stud! in reliabilit! and maintainabilit! engineeringand to enable the student to access the increasing amount

of technical material available in the literature(

' "his course )ill enable the student to collect and anal!*e

failure and repair data, derive appropriate reliabilit! andmaintainabilit! models, and appl! these models in the

design of products, components and s!stems(

b!ecti"e and Sco&e o' t(e$our#e

+

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Charles E( Ebeling %n introduction to #eliabilit! and

maintainabilit! engineering, edition ..., /ourteen

reprint .11, "M0, e) Delhi

)re#cribed Te*t Boo+

2

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Lectu

reNo:

Chapter name Topics Text

book

1

Introduction andobjectives

Study of Reliability and maintainability,Concepts, Terms and Definition, Whyreliability engineering?, applications andbenefits, complexity of products, world

industrial competition and reliabilityengineering, optimization of reliability

T1 Ch1R1 Ch 1

2

The ailure distribution

The fi!e important analytical functions inreliability engineering, Reliability function,"ean time to failure, #azard rate function,

$athtub cur!e, conditional Reliability

T% Ch &R% Ch ',(

3

Constant failure ratemodel

The exponential reliability function, ailuremodes, )pplications, The two parameterexponential distribution, *oisson process,Redundancy and the CR "odel

T% Ch '

$our#e )lan

3

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4

Time Dependentailure models

The Weibull distribution, The +xponential

distribution

T% Ch (

R% Ch ,-

5

The .ormal distribution, The /ognormal

distribution

T% Ch (

R% Ch 0,1

6

Reliability of systems

Serial Configuration, *arallel Configuration,Combined Series2parallel systems, Complexconfiguration

T% Ch R& Ch %,&

7

State 2dependentsystems

/oad2sharing system, standby systems, Degradedsystems

T% Ch -R& Ch ', 1

4

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8Review Session

9 *hysicalReliability

"odels

Co!ariate models, Static "odels, Dynamic"odels, *hysics of failure models

T% Ch 0

1 Design forReliability

Reliability specification and systemmeasurements, Reliability allocation, Design

"ethods, ailure analysis

T% Ch 1

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11 "aintainability

)nalysis of downtime, The repair2time

distribution, system repair time, reliabilityunder pre!enti!e maintenance, State2dependent systems with repair

T% Ch 3

12Design for

maintainability

"aintenance Re4uirements, design methods,human factors and ergonomics, maintenanceand spares pro!isioning

T% Ch%5

13 )!ailabilityConcepts and Definitions, exponentiala!ailability model, System a!ailability,inspection and repair a!ailability model

T% Ch%%

14Data collectionand empirical

methods

Data collection, +mpirical methods,Reliability testing, Reliability 6rowth testing

T% Ch %&,%',%(

6

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15Reliability

+stimation and)pplication

)pplication of Reliability estimation T% Ch %0

16 Review Session

1.

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E"aluation Sc(e,e

E$o.

E"aluation$o,&onent /Ty&e o'E*a,ination

%uration 0eig(tage

%ay %ateSe##ionTi,e

EC-1 7ui* 282828

!eb" 1 to 1# 216

$arch 1 to 1#

216 $arch 25 to

%&ri' 3# 216

EC- Mid-$emester "est$lo#ed Boo+34

0ours &28 28(2(216 )%*+ 2,$ T- 4 ,$

EC-& ComprehensiveE9am

&en Boo+34

& 0ours 2.8 1(4(216 )%*+ 2,$ T- 5 ,$

11

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' Closed oo: "est o reference material of an! :ind )ill

be permitted inside the e9am hall(

' Open oo: E9am ;se of an! printed < )ritten reference

material =boo:s and noteboo:s> )ill be permitted inside

the e9am hall( ?oose sheets of paper )ill not be

permitted( Computers of an! :ind )ill not be allo)ed

inside the e9am hall( ;se of calculators )ill be allo)ed in

all e9ams( o e9change of an! material )ill be allo)ed(

ature o' E*a,

1

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ote

7t shall be the responsibility of the indi!idual student to be regular in

maintaining the self study schedule as gi!en in the course handout, attend

the online8on demand lectures as per details that would be put up in the

BITS LMS Taxila website www.taxila.bits-pilani.ac.in and ta9e all the

prescribed components of the e!aluation such as )ssignment (Course Pageon LMS Taxila), "id Semester Test and Comprehensi!e +xamination

according to the +!aluation Scheme gi!en in the respecti!e Course

#andout: 7f the student is unable to appear for the Regular Test8+xamination

due to genuine exigencies, the student must refer to the procedure for

applying for "a9e2up Test8+xamination, which will be a!ailable through the

7mportant 7nformation lin9 on the $7TS W7/* website on the date of the

Regular Test8+xamination: The "a9e2up Tests8+xams will be conducted

only at selected exam centres on the dates to be announced later:

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Introduction and b!ecti"e#Chapter - 1

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' The need for reliability engineering

' The applications 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 9now and apply reliability

engineering to their products to sur!i!e the intense, worldwide

industrial competition:

' The fact that industry 4uotes and ad!ertises reliability ratings

b!ecti"e#

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' Reliability is the probability that parts, components, products,

or systems will perform their designed2for functions without

failure in specified en!ironments for desired periods at a gi!en

confidence le!el:

' Reliability is the best 4uantitati!e measure of the integrity of a

designed part, component, product, or system

' Reliability engineering and product assurance programs

represent the single best return2on2in!estment opportunity for

most companies today:

W! "eliabilit! #ngineering

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' The complexity of most products is increasing continuously

' The customers and the public are becoming more and

more reliability conscious e!ery 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

9nowledgeable of and institute to reliability engineering

programs:

' "ore and more products are being ad!ertised by

their reliability ratings, such as their failure rate, mean time

between failures ;"T$

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&ow co%plexit! a''ects te reliabilit! o' series euip%ent.

u%ber o' co%ponents in

series

In*i+i*ual co%ponent reliabilit!

. .

#uip%ent reliabilit!

%55 33:35= 33:5%=

&5 33:0= 30:'=

55 33:5= 3:%&=%,555 33:5%= 35:(1=

%5,555 35:(1= '-:03=

%55,555 '-:03= 5:5%=

"easons $or "eliabilit! #ngineering Progra%s

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' 7mplement an integrated reliability engineering and product

assurance program in purchasing, engineering, research,

de!elopment, manufacturing, 4uality control, inspection,

testing, pac9aging, shipping, installation, start up, operation,

field ser!ice, and performance feedbac9, ta9e correcti!eactions where!er and whene!er indicated, and incorporate the

correct, complete, and comprehensi!e reliability and

maintainability specifications into all of these company

acti!ities that come in contact with the product from birth todeath:

pplications n* Bene'its

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' Study the types of failures experienced by parts, components,

products and systems and recommend design, research, and

de!elopment efforts to minimize these failures:

' +stablish what failures occur at what time in the life of an

e4uipment and be prepared to cope with them:

' Determine the time2to2failure distribution of parts,

components, products, and systems:

' Study the effects of age, mission duration, application and

operation stress le!els on reliability:

' *redict the reliability of e4uipments, products, and systems to

see if the established goals can be met:


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' 7ndicate areas in which design changes would be most

beneficial from the reliability impro!ement and cost reduction

point of !iew:

' *ro!ide a basis for comparing two or more designs and for

choosing the best from the reliability point of !iew:

' +!aluate the amount of redundancy present in the design:

' +stimate the re4uired redundancy to achie!e the

specified reliability:

' Conduct failure modes, effects, and criticality analyses to

identify areas which should recei!e concentrated design,

research, and de!elopment effort:


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' *inpoint areas where research and de!elopment money can best be

spent:

' *ro!ide guidelines for critical reliability design re!iews:

' *ro!ide guidelines for manufacturing processes and techni4ues:

' #elp pro!ide guidelines for 4uality control practices:

' #elp pro!ide guidelines for !alue engineering practices:

' #elp pro!ide guidelines for human factors engineering practices:

' +stablish no2charge 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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How complexity afects system reliability !"

Number o#

critical

components

$n%ivi%ual component reliability

. . .

System reliability%5 33:33= 33:35= 33:55=%55 33:35= 33:5%= 35:(1=

&5 33:0= 30:'= 00:10=

55 33:5= 3:%&= -5:-(=

%,555 33:5%= 35:(1= '-:00=

%5,555 35:(1= '-:03= >5:%=

%55,555 '-:03= >5:%= >5:%=

./It is assu0ed that a'' critica' co0&onents are re'iabi'it wise inseries"

Co%plexit! o' Pro*ucts

&

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T(an+#

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QM ZG528-L1.ppt

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