Applied Reliability for Industry 3

Foreword xi
Phillipe EUDELINE

Preface xiii
Abdelkhalak EL HAMI, David DELAUX, Henri GRZESKOWIAK

Chapter 1 Durability Approach: Applied to a Vehicle Lighting Control System 1
Medoune NDIAYE and Caroline RAMUS-SERMENT

1.1 Introduction 1

1.2 Example of a vehicle lighting control system 2

1.2.1 Risks and reliability requirements 3

1.2.2 From failure modes to failure mechanisms 3

1.2.3 From failure mechanisms to physical damage factors 5

1.2.4 From physical damage factors to mission profiles or customer usage 6

1.2.5 From failure mechanisms to component part strength distribution 7

1.2.6 Resistance distribution chart 11

1.2.7 Proposal and study of a validation plan using the stress-strength method: various real-world examples 14

1.3 Conclusion 19

1.4 References 19

Chapter 2 Structural Diagrams to Validate the Reliability of Mechanical Components 21
Paul SCHIMMERLING

2.1 Introduction 21

2.2 Choice of methods 22

2.2.1 Criteria selection 22

2.2.2 Four basic methods 23

2.2.3 An applied example: the validation of disc brake pads 24

2.3 Feasibility study on the four methods 25

2.3.1 Animation principle 25

2.3.2 Comparison of Weibull laws under testing and in service 25

2.3.3 Comparing degradation under testing and in service 28

2.3.4 Stress-strength method 30

2.4 Conclusion 34

2.5 References 35

Chapter 3 How to Put an Efficient Methodology to Design Innovative Products in Place 39
Claire SCHAYES, Ludovic NGAVOUKA and Eric MANOUVRIER

3.1 Introduction 39

3.1.1 Reliability 39

3.1.2 Variability 40

3.1.3 "Lean Six Sigma" 40

3.1.4 Quality according to the "Lean Six Sigma" approach "is conforming to requirements" 41

3.2 Dfss 42

3.3 Dmaic 46

3.3.1 Introduction to DMAIC 46

3.3.2 Why launch DMAIC projects? 46

3.4 Feedback 50

3.4.1 Feedback on the define phase 50

3.4.2 Feedback on the measure phase 50

3.4.3 Feedback on the analyze phase 51

3.4.4 Feedback on the innovation phase 52

3.4.5 Feedback on the control phase 53

3.4.6 Can DMAIC be customized? 54

3.5 How to design a reliable welding process with control over the design of experience? 57

3.6 Definition of the objectives 58

3.6.1 Determining the study space 59

3.6.2 Building the DOE 65

3.6.3 Conducting the tests 66

3.6.4 Analyzing the results 67

3.6.5 Process optimization 68

3.6.6 Validation 69

3.7 Big Data and process? 69

3.8 Conclusion 74

3.9 Appendix 1: example of an ANOVA study 74

3.10 Appendix 2: studying the variability of cycle times 79

3.11. Appendix 3: example for the use of traditional statistics in Big Data 87

3.12 References 90

Chapter 4 Reliability Study of the High Electron Mobility Transistor (HEMT) 91
Abdelhamid AMAR, Bouchaib RADI and Abdelkhalak EL HAMI

4.1 Introduction 91

4.2 HEMT technology 92

4.3 HEMT thermal modeling 94

4.4 Reliability methods 96

4.4.1 Reliability study 96

4.4.2 Calculating the probability of failure 97

4.5 Thermo-reliability coupling 101

4.6 Calculating HEMT reliability 102

4.7 Conclusion 103

4.8 References 103

Chapter 5 Warranty Cost 107
David DELAUX

5.1 Introduction 107

5.1.1 The evolution of the warranty 107

5.1.2 The warranty cost 108

5.2 Warranty and reliability 111

5.2.1 Qualitative analysis 111

5.2.2 Quantitative analysis 112

5.3 Reliability estimation models 113

5.3.1 Parametric, non-parametric and other models 113

5.3.2 Mixed models 114

5.3.3 Advantages and disadvantages 116

5.4 New models for estimating reliability from warranty costs 117

5.4.1 Assumptions 117

5.4.2 Definition of the transition between "random" and "wear-and-tear" phases 120

5.4.3 New operational reliability model for the "random" phase 125

5.4.4 New operational reliability model for the "wear-and-tear" phase 125

5.5 Applied automotive case studies 126

5.6 Conclusion 128

5.7 References 128

Chapter 6 Reliability Evaluation of a Luxury Watch Product: Application of the Stress-Strength Method to a Mechanical Component 135
Matthieu SALLIN and Anthony PONCET

6.1 Introduction 135

6.2 Presentation of the watch and its case study 136

6.2.1 The mechanical watch 136

6.2.2 Case study of the barrel spring 137

6.2.3 Identification of failure modes and damaging factors 137

6.3 Evaluation of the customer usage profile 138

6.3.1 Classifying usage typologies 138

6.3.2 Statistical quantification of usage 139

6.4 Characterizing experimental reliability 140

6.4.1 Performance of failure tests 140

6.4.2 Evaluation of the accelerated lifetime law 141

6.4.3 Constructing the law of resistance 142

6.5 Reliability evaluation of customers 143

6.5.1 Reliability calculation using the stress-strength method 143

6.5.2 Transformation of the stress profile 144

6.5.3 Numerical application to the barrel case study 146

6.6 Conclusion 147

6.7 References 148

Chapter 7 RBDO of the High Electron Mobility Transistor 149
Abdelhamid AMAR, Bouchaib RADI and Abdelkhalak EL HAMI

7.1 Introduction 149

7.2 Description of the HEMT technology 151

7.3 Electrothermomechanical modeling of HEMT 152

7.3.1 Electrothermal modeling of HEMT 152

7.3.2 Thermomechanical modeling of HEMT 154

7.4 Reliability methods 156

7.5 Reliability analysis of HEMT 156

7.6 Reliability optimization of systems 158

7.6.1 The classic RBDO approach 158

7.6.2 The hybrid RBDO approach 159

7.7 HEMT reliability optimization using the hybrid RBDO approach 160

7.7.1 Description of the optimization problem 160

7.7.2 Results and discussion 160

7.8 Conclusion 161

7.9 References 162

List of Authors 167

Index 169

Summaries of other volumes 171