Robust Design Methodology for Reliability Exploring the Effects of Variation and Uncertainty

by Bergman, Bo; de Mare , Jacques; Svensson , Thomas; Loren, Sara

• ISBN13: 9780470713945
• ISBN10: 0470713941
• Edition: 1st
• Format: Hardcover
• Copyright: 2009-09-28
• Publisher: Wiley

Summary

The contributions of Exploring Unreliability and Its Countermeasures aim to address reliability problems in a constructive manner and offer a comprehensive design theory for reliability utilizing robust design methodology and six sigma frameworks. They advocate testing for robustness in the early stages of product design development, and consider varying uncertainties that are sometimes inherent in model assumptions for design solutions but which should not affect the system solution. Many companies today utilise design for Six Sigma (DfSS) for strategic improvement of the design process but often these initiatives do not explicitly describe the reliability perspective; this book explains how reliability design can relate to and work with DfSS and illustrates this with vivid illustrations from real - world problems. Advocates a new approach to reliability thinking that addresses the design process and proneness to failure in the design phase via sensitivity to variation management. Includes contributions from both academics and industry practitioners with a broad scope of expertise, including quality science, mathematical statistics and reliability engineering. Takes the innovative approach of promoting the study of variation and uncertainty as a basis for reliability work. Includes case studies and illustrative examples from real-world problems that translate the theory into practice

Author Biography

Bo Bergman has held the post of SKF professor at the Department of Quality Sciences at Chalmers University of Technology, Sweden since 1999. From 1983 to 1999 he was Professor of Quality Technology and Management at Linköping University, where he was responsible for the creation of education and research in the quality field, and previous to this he held varying engineering and managerial positions in the fields of reliability, quality and statistics at Saab Aerospace. His research interests cover wide areas of quality of both a quantitative and a qualitative nature. He has authored more than 50 papers in international scientific journals and has authored and co-authored a number of books — including new, completely revised English versions of Quality from Customer Needs to Customer Satisfaction and Six Sigma; the Pragmatic Approach.

Jacques Demaré has held the post of Professor of Mathematical Statistics at Chalmers University of Technology since 1999. The focus of his work has been on both chemical and mechanical applications and he is currently working with statistical methods for material fatigue in co-operation with the Swedish National Testing and Research Institute. At Chalmers he has also worked in different ways to bring the mathematical and engineering disciplines closer together.

Thomas Svensson is a research engineer at the Technical Research Institute of Sweden (SP). He obtained his PhD in Fatigue Life Prediction in Service — A Statistical Approach in 1996, and is a member of the editorial board of Fatigue and Fracture of Engineering Materials and Structures.

Table of Contents

Preface

Acknowledgements

About the Editors

Contributors

Methodology

Introduction

Background

Failure Mode Avoidance

Robust Design

Comments and Suggestions for Further Reading

References

Evolution of Reliability Thinking - Countermeasures for Some Technical Issues

Introduction

Method

An Overview of the Initial Development of Reliability Engineering

Examples of Technical Issues and Reliability Countermeasures

Discussion and Future Research

Summary and Conclusions

References

Principles of Robust Design Methodology

Introduction

Method

Results and Analysis

Discussion

Conclusions

References

Methods

Including Noise Factors in Design Failure Mode and Effect Analysis (D-FMEA) - A Case Study at Volvo Car Corporation

Introduction

Background

Method

Result

Discussion and Further Research

Summary

References

Robust Product Development Using Variation Mode and Effect Analysis

Introduction

Overview of the VMEA Method

The Basic VMEA

The Enhanced VMEA

The Probabilistic VMEA

An Illustrative Example

Discussion and Concluding Remarks

Appendix: Formal Justification of the VMEA Method

References

Variation Mode and Effect Analysis: An Application to Fatigue Life Prediction

Introduction

Scatter and Uncertainty

A Simple Approach to Probabilistic VMEA

Estimation of Prediction Uncertainty

Reliability Assessment

Updating the Reliability Calculation

Conclusions and Discussion

References

Predictive Safety Index for Variable Amplitude Fatigue Life

Introduction

The Load-Strength Reliability Method

The Equivalent Load and Strength Variables

Reliability Indices

The Gauss Approximation Formula

The Uncertainty Due to the Estimated Exponent ß

The Uncertainty Measure of Strength

The Uncertainty Measure of Load

The Predictive Safety Index

Discussion

Appendix

References

Monte Carlo Simulation versus Sensitivity Analysis

Introduction

Transfer Function

Example from an Industrial Context

Highly Nonlinear Transfer Function

Total Variation for Logarithmic Life

Conclusions

References

Modelling

Model Complexity Versus Scatter in Fatigue

Introduction

A Statistical Model

Design Concepts

A Crack Growth Model

Partly Measurable Variables

Conclusions

References

Choice of Complexity in Constitutive Modelling of Fatigue Mechanisms

Background

Questions

Method

Empirical Modelling

A Polynomial Example

A General Linear Formulation

A Fatigue Example

References

Interpretation of Dispersion Effects in a Robust Design Context

Introduction

Dispersion Effects

Discussion

References

Fatigue Damage Uncertainty

Introduction

Fatigue Review

Probability for Fatigue Failure - Safety Index

Computation of E [D(T) k] and V [D(T) k]

Non Gaussian Loads - Examples

References

Widening the Perspectives

Background

Additional Engineering Perspectives on Reliability

Organizational Perspectives on Reliability

Industrialization of Robust Design Methodology

Adoptions of Fatigue Reliability Methodology

Learning for the Future

References

List of Abbreviations

Index

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