Reliability Basics

Introduction

• Reliability of a unit is the probability that

the unit will perform its intended function
adequately for a given period of time
under the stated operating conditions or
environment.

2
Introduction

• The reliability definition stresses four elements

namely:

• Probability,
• Intended function,
• Time, and
• Operating conditions.

• Reliability is primarily associated with the

design.
3
Introduction

• Quality of a device is the degree of conformance

to applicable specifications and workmanship
standards.

• Quality is not concerned with the elements of

time and environment.

• Quality is associated with the manufacturer.

4
Introduction

• Equipment which has undergone all

quality tests may not necessarily be more
reliable.

• Reliability is the ability of the unit to

maintain its quality under specified
conditions for a specified time.

5
Introduction

• The intended function of the device is

related to the quality.

• Environmental conditions such as

temperature, humidity, vibrations, etc.,
affect the quality and in turn cause the
failure of the unit under operation.

6
Introduction

• Any change in the operating parameters

might also cause failures.

• One can build a reliable complex system

using less reliable elements, but it is
practically impossible to construct a good
quality system from poor quality elements.

7
Causes of Failures and Unreliability
• The specific causes of failures of components and
equipment in a system can be many. Some are known
and others are unknown due to the complexity of the
system and its environment.

• Poor design (component or system)

• Wrong manufacturing techniques
• Lack of total knowledge and experience
• Complexity of equipment
• Poor maintenance policies, and
• Human errors etc.
8
Designing for Higher Reliability

• A number of techniques are available to enhance

the system reliability. Some of the important
methods are:

• Parts improvement method

• Effective and creative design
• System simplification
• Use of over-rated components
• Redundancy, and
• Maintenance and repair.

9
Designing for Higher Reliability
• A few examples of systems where redundancy is
extensively used are:
• Interconnected power systems
• Protective systems for nuclear reactors
• Aircraft propulsion systems
• Satellite communication systems
• Ignition systems for rocket engines
• Temperature control systems for space vehicles,
and
• Data-processing systems etc.

10
Reliability Definitions
Reliability is a time dependent characteristic.

• It can only be determined after an elapsed time

but can be predicted at any time.

• It is the probability that a product or service will

operate properly for a specified period of time
(design life) under the design operating
conditions without failure.
11
Reliability Definition

The probability that a component or a system will consistently perform its intended or
required function for a given duration continuously, intermittently or on demand under
stated conditions without failure.

If quality is performance to specs at t = 0,

Then reliability is performance to specs at t > 0,
i.e. quality over a period of time

An Item’s intrinsic reliability is defined by the design.

Reliability Definition

This brings to focus the following five aspects of the definition

1. Reliability by definition is a probability.

2. The intended or required function should be clearly specified along with the
performance criteria.

3. The acceptable degradation in performance criteria should be specified quantitatively,

which will be a part of the failure definition.
Reliability Definition

4. The duration or usage needs to be specified.

5.The operational environment under which the product or component is expected to

operate needs to be specified.
It will include all external and internal conditions (such as temperature, humidity,
radiation, magnetic and electric fields, shock vibration, etc.) either natural or man
made, or self-induced, that influence the form, operational performance, or survival of
an item.
What is a failure ?

Failure is defined as the lack of ability of a component, equipment, sub

system, or system to perform its intended function at the required
performance level.
Other Measures of Reliability

Availability is used for repairable systems

• It is the probability that the system is

operational at any random time t.

• It can also be specified as a proportion of time

that the system is available for use in a given
interval (0,T). -

12
Other Measures of Reliability
Mean Time To Failure (MTTF): It is the average
time that elapses until a failure occurs.
It does not provide information about the distribution
of the TTF, hence we need to estimate the variance
of the TTF.

Mean Time Between Failure (MTBF): It is the

average time between successive failures.
It is used for repairable systems.
13
fit): inability f(t) I
= F(t)
t
&

-
F(t) (
=

f(t) dt =-RCt)
0

f(t)
R(t 0) 1
RC4
= =

dt
=

R(t 0) 0
=
=

tea:
ft) at
F(t) 1 RCt) 1
1
= -
= -

MTTF
t
= ftdt=
-It RI=- tRCl+Rdt
R(0) 0
=

R(t)dt
=0 +
!
MTTF GRI)
=
dt
Mean Time to Failure: MTTF

 
MTTF   tf (t )dt   R(t )dt
0 0

1 n
MTTF   ti
n i 1

1
2 2 is better than 1?
R(t)

1 Time t
0
14
Median, Mode
First moment:Mean,

second moment:0,82

I
(t -y)2 f(t)dt
=

MTTF

=
(t2 7 M M2) fCtdt
+

MTTF2 f(t)]dt
ftdtul
-

=1tf() 2t-MTTF. f(t)

-
+

MTTF

-It ftdt-2. MTTF

(fat + NTTE

j"
Eftdt-MTTE
=
Mean Time Between Failure: MTBF

15
Median Time to Failure
• Median time to failure represents the median value
of the failure data.
• 50% of the components under operation would
have failed or only 50% of the component would
survive by this time.

• It divides the distribution into two halves, with 50%

of the failures occurring before the median time to
failure and 50% occurring after the median value.
16
Criticisms on Reliability Engineering
• Inevitable Uncertainty in results
• Lack of data
• Modelling problems
• Assumptions and boundaries
• Lack of standardization

17
The Reliability Function

• The reliability function can be derived

using the definition of the cumulative
distribution function (CDF).

• Let the times to failure of a component is

a random variable (T), then from our
definition of the CDF, the probability of a
unit failing by time t is given by:
18
The Reliability Function
t
F (t )  P(T  t )   f (t )dt for 0  t  
0

• Since this function defines the probability

of failure by a certain time, we could
consider this the unreliability function.

• Subtracting this probability from 1 will

give us the reliability function.
19
The Reliability Function
• The reliability function gives the probability of
success of a unit undertaking a mission of a
given time duration.

• To show this mathematically, we first define the

unreliability function Q(t), which is the
probability of failure or the probability that our
time to failure is in the region of 0 and t. This is
the same as the CDF.

20
The Reliability Function
t
Q(t )  F (t )   f (t )dt for 0  t  
0

21
The Reliability Function

• Reliability and
unreliability are the Q(t )  R(t ) 1
only two events
being considered, R(t )  1  Q(t )
t
and they are
 1   f (t )dt
mutually exclusive: 0
hence, the sum of 
these probabilities is R(t )   f (t )dt
equal to unity. t

22
The Reliability Function
dF (t ) dR(t )
f (t )  
dt dt


 f (t )dt  1
0

0  F (t )  1
0  R(t )  1
F (0)  0 Lim F (t )  1
t 

R(0)  1 Lim R(t )  0

t 

23
24
= 1 dF(t)
dt
RCt]

=- dRCH
RCt) at
Life Characteristic Curve
(Bath Tub Curve)
Early Failures
Increasing
Constant Failure
Failure Rate Failure Rate Rate

start of
E
life or
design
mission time
(t 0) =
Time

1. Early failure region (infant mortality) or

Burning period

2. Useful life region (constant failure rate)

3. Wear out region (increasing failure rate)

25
dist. -(t/y)B
B 1:exponential
(t) B > 1:R(t) C
=

(z)
=

single parameter
-

f(t) Reliability
=

decreasing
const. Hazard
rate
failure rate
increasing

F(t) 1
=
-
e-(t/y)B ↓
out region
wear

-
(t)B BC1:increasing
RCt)
rate
Ex: Normal, log-normal dist.

decreasing,failure
RCt e
=

B 3.5
=
B 2.5
=

infant mortality region

*
f(t)
(z) - (t)
=

F(t) 1
=
-
e-(t/y)B
R(t)
-
(4y)B
e
=

dist.
B 1:exponential
=

single parameter
const. Hazard
rate

-(t/y)B
B > 1:R(t) C
=

decreasing Reliability
failure rate
increasing
↓
wear out region
dist.
..
2(t)
E-FCt) t: ERC). tt)
=
EX: Normal,
B 3.5 =
log-normal
B 2.5
=

RCt)
BC1:increasing rate
decreasing,failure
infant mortality region
Life Characteristic Curve
(Bath Tub Curve)
• The region (1) suggests that no item be used
unless it has survived this period. Some of the
reputed manufacturers sell only those components
which have survived this period.
• The region (2) is useful life period where hazard
rate is governed by chance failure and is fairly
constant.
• The region (3) indicates that the component
should be replaced or scrapped.

26
Phase I Phase II Phase III

Characterized Decreasing failure Constant failure rate Increasing failure

By rates Useful Life rate
Infant Mortality, Wear out
Burn in

Caused By Manufacturing Environment, Fatigue,

defects, Random Loads, Corrosion,
welding flaws, cracks, Human error, Ageing,
defective parts, friction,
Poor quality control, cyclical loading
contamination,
poor workmanship

Reduced By Burn-in testing, Redundancy, Excess Derating,

screening, quality strength Preventive
control, Acceptance Proper Maintenance Maintenance, Parts
testing practices Replacement.
27
Repairable and Non-Repairable

Another measure of reliability is availability (probability

that the system provides its functions when needed).
Maximum Reliability level

With R
epairs
Reliability

No Rep
airs

Time