BE Analytic collaborate with Product development companies to meet their Reliability Engineering requirements and take care of Analysis and Testing Solutions

RAMS
BE Analytic works for all or any phase of product life cycle to improve the product reliability and meet all industry specific requirements/ compliance and also help to compete well in the market. Our customized reliability analysis /test solutions help you in design improvements, faster product release, and better service and enhanced customer satisfaction. Our expert reliability team will unify with your product development team and form a group to perform all required reliability & safety analysis right from concept phase to in-service phase of the product life cycle.

Reliability, Availability, Maintainability and Safety analysis is a cross functional team, which works for different engineering domains like Aerospace, Auto/ Rail, Energy (Gas Turbine, Wind, Solar), Medical, home appliance, security devices and process industry.

BE Analytic is willing to collaborate with Product development companies/ Engineering services companies to meet their Reliability Engineering requirements, most of the companies are good in their core design activities but may not be having a dedicated team to take care of Reliability Analysis Solutions and Reliability Testing Solutions.

Most of the analysis does not need a reliability person to travel onsite (client location), it can be done being in offshore, and thereby cutting costs at the same time achieving targeted reliability, availability, maintainability and safety (RAMS) goals.

BE Analytic is “One Stop Shop” when it comes to Reliability Engineering, we provide Training, Consulting & Project execution (onshore & offshore) and Reliability Engineering software sales. We are authorized distributor of ITEMSOFT in India. ITEMSOFT is World Leader in Reliability, Safety & Risk Assessment Software.
Reliability Analysis Solutions
Reliability Engineering Training
We conduct instructor led corporate training programs in every aspect of Reliability, Availability, Maintainability & Safety Engineering. Syllabus of the courses can be chosen by customer from list of generic courses offered by us like Introduction to Reliability, CRE syllabus prep program, Design for Reliability or customer can request for a customized trainings depends on their needs. The courses are designed for practicing Design engineers with course duration vary from 1 to 5 days depends on the course.
For a detailed training proposal, please mail us your requirement at
corp.training@beanalytic.com
  • MTBF requirements/ Goal Setting
    Reliability metric is an inherent characteristic of any product. It is one of the important Design aspect during the process of product development. It is reference for selecting the best concept / configuration. As it will also effect the total life cycle cost of the product. Goal setting can be done in different formats, like as a MTBF (Mean Time Between Failure) or Reliability at a particular time or failure rate or even Annualized Failure Rate (AFR). This is not a mere number or goal setting is not a straight forward calculation, it requires competitor assessment, vendor assessment, bench marking, if it is a new product, then we may even go for internal and external surveys to meet the customer expectation and to set a right goal. Goal will also have different other constraints like, availability of funds for the project, resources, time and technology. Sometimes, during goal setting, failure definition also added.
  • Reliability Program Plan
    Once the goal setting is completed, we have to realize the goal at the end of the product development and this should be evaluated over every phase of product development life cycle. Reliability Program Plan is a document which describes what to do at different phases of product development to achieve the target reliability and noting down the pitfalls or identifying the lessons learned.
    The Reliability Program Plan is prepared early in the product development, a proper Reliability plan will consider the continuous evaluation and improvement of Reliability, Maintainability and Availability metrics and go hand in hand with design process. To evaluate and improve Reliability, there are many different analysis and techniques available, but all may not be required to perform. Reliability plan will select and document the right kind of task, tools, techniques & testing methods by considering the industry type, which are very specific to the product under development. This will also spell the project schedules for each phase and analysis with necessary resources and skills set required.
    The reliability tasks prescribed in program plan needs to be achievable with the available skill set within the organization, or organization has to add tasks in order to bring in expertise, like look for training or even outsource certain activities.
  • Reliability Allocation
    In today’s scenario of complex systems, it is crucial to translate system reliability requirements into detailed specifications for the multiple subsystems /components that make up the system, the process of translating System Goals to subsystem/component level targets is called Reliability Allocation, hence each subsystem owner/designer will be given a goal to achieve, hence designer is obliged to consider reliability equally with other system parameters such as weight, cost, and performance characteristics. The Reliability goal is not just for hardware items, but should also considers software subsystem; it should be done by balancing the hardware and software requirement among them. Balancing is act of bringing approximate relative equality of development time, importance of subsystem in the configuration, complexity, risk, or to the minimization of overall development cost. Sometimes, allocation will also consider Maintainability, availability and duty cycle as constraints. If the allocated Reliability requirements for a system cannot be achieved using available technology, the allocation has to be reassigned or it can be achieved by selection of right parts/material, redundancy, derating, change of technology or manufacturing process would help.
    apportionment method; c) AGREE apportionment method; d) Feasibility of objective method; e) Dynamic programming approach; f) Minimum effort algorithm; g) Boyd apportionment method
  • Fmea/ Fmeca
    Failure Modes and Effects Analysis / Failure Modes, Effects and Criticality Analysis is bottom up approach. FMEA is very useful tool to identify potential failure modes (hardware design deficiencies) and knowing their effects on the system. The FMEA results can either be qualitative or quantitative. FMEA is started in the early phase i.e in concept phase and it is continually updated in subsequent phases. The final FMECA will be carried out for critical design review. FMEAs can be useful for improving design and safety; it can also be used for better maintenance planning (process FMEA for RCM).
    FMECAs can take many forms, but at the core, these analyses are used to study a particular system and determine how that system can be modified to improve overall reliability and to avoid failures.
Some of the widely used Standards:
  • Military Standard - MIL-STD-1629a
  • British Standard - BS 5760 Part 5
  • International Standard - IEC 61508
  • International Standard - ISO 26262
  • International Standard - ISO 9000
Inputs:
  • Bill Of Materials
  • System Description
  • System Architecture or 2D/3D models

Output:
  • FMEA/FMECA Report will contain worksheet with all potential failure modes with respective criticality numbers and their corresponding effects over different levels of the system.
  • FMES report contains summary of failure effects and respective modes which are leading to those effects.
  • Failure effects and severities traced through to system hierarchy
  • Criticality Vs Severity plots, identifying top severity or criticality items in the design

Reliability Prediction
It is one of the most common analyses done by Reliability Engineer, Reliability prediction can be done for Electronics/Hardware components, Mechanical equipment and software as well. The common metric used very widely is MTBF or Mean Time Between Failure. (It became more controversial as well). Using this, it is possible to calculate Reliability or Unreliability over a period operating/ mission time. It will be useful to take decisions during initial product development like checking which concept is better, calculating the approximate spares, weak components in the system, deciding the layout of the system. It will also help the designer to understand the impact of different stresses like temperature, environment, electric etc on the system. These results will also go as input to FMECA and RBDs.

Electronics/Hardware Reliability Prediction:
There are several standards available to perform Reliability prediction, most widely used standard is MIL 217Fn2. Failure rates/MTBF are calculated using two methods of reliability prediction – Parts Count Analysis and Part Stress Analysis. The final result is based on the roll-up of all the component failure rates.
Other than MIL 217, BE Analytic is capable of doing Reliability Prediction as per Telcordia SR 332 Issue 3, IEC 62380 (RDF), 217Plus.
Most equipment failures are precipitated by stress. When applied stress exceeds the inherent strength of the part, either a serious degradation or a failure will occur. To assure reliability, equipment must be designed to endure stress over time without failure.
Design stress parameters must be identified and controlled. Parts and materials must be selected which can withstand these stresses. Derating is the selection and application of parts and materials so that the applied stress is less than rated for a specific application

BE Analytic can perform derating analysis as per below standards
  • NAVSEA TE000-AB-GTP-010
  • MIL-HDBK-1547
  • MIL-STD-975M (NASA)
  • NAVAIR-AS-4613 Class A
  • NAVAIR-AS-4613 Class B
  • NAVAIR-AS-4613 Class C

Mechanical System Reliability can be predicted by two ways, one is using NPRD 2011 data base to find the part failure rates and rolling up the results to subsystem and then to system level.

Another approach is using NSWC model, unless like other approaches using a failure rate data, NSWC model defines failure of mechanical equipment depend upon its application, loading, operating conditions utilization rates and the way you maintain it. Moreover, mechanical failure rates do not follow a constant failure rate distribution (exponential). Models developed in the handbook are based upon

Identified failure modes and their causes. Empirical Equations were derived for each failure mode from design and published experimental data. From these equations the failure rate per hour or per cycle is determined. Limitations of the models are also presented in the Handbook.

Inputs required:
  • BOMs
  • System Architecture/ Circuit Drawings
  • System Description document
Analysis Output (Prediction & Derating)
Failure rate and MTBF (Mean Time Between Failure) for electronic parts and equipment. Analysis will generates system, subsystem and component level failure rates and their corresponding MTBF. Report will contain,
  • Failure rate over temperature
  • Failure rate over environment
  • Failure rate over stress
  • MTBF for component/ PCS and System level
  • MTBF over temperature
  • MTBF over environment
  • MTBF over stress
  • Unavailability
  • What if analysis (Pareto analysis)
  • Non operating MTBF/Failure rate or also called Shelf Life
  • Derating Analysis report
  • Reliability/ Unavailability over a period of operating time.
Reliability Block Diagrams Analysis (RBD Analysis)
A Reliability Block Diagram is a pictorial representation of the system using blocks and connections and these blocks logically connected Reliability wise, it may not be the actual physical representation. RBDs are used to calculate the Reliability, Availability and maintainability on large and complex systems. While performing Reliability prediction, we assume all components are in series and component failures follow Exponential distribution (Constant failure rate), but RBDs avoid these two assumptions, it represents actual system configuration as per failure definition and it will not restrict to use Constant failure rate, each block can be connected in series, parallel and more complex scenarios like Stand by models with mixed series parallel models, also it allow us to use different distribution (as per their actual behavior) for each component/sub system. Hence, the estimations done using RBDs are more accurate and close to the real time scenarios. The analysis can also be extended to find the importance factors of each block in the system and optimum allocation of Reliability to attain the system Reliability target.



Inputs required:
  • System Architecture
  • System Functional Description
  • Block or component Failure Rates

Output:
  • Reliability, availability and Maintainability (MTTR) reports both steady state and time profile.
  • Importance Ranking
  • Optimal Reliability Allocation
  • Time profile Graphs

Fault Tree Analysis (FTA)
“To Design Systems that work correctly We often need to understand and correct how they can go wrong”
By: Dan Goldin, NASA Administrator, 2000

The above statement is particularly true when we are performing analysis like FMEA & FTA. These two analyses are more of failure analysis.

FTA is a top down approach; it is an event oriented analysis both for Hardware and software failures besides allowing the consideration of operational errors, human errors, maintenance errors and environmental influences on the system.FTA uses failure frame of reference.

It is basically a deductive approach which is used to identify relationships between an undesired system event (top event) to all sub system failure events that may contribute to its occurrence. It starts with top event and descending system level to more detailed level of sub systems and component levels. It allows calculating Reliability or probability of failure at each sub tree level. This makes fault tree analysis more useful. This tool is also used for accident investigation or RCA.

It provides risk assessment by cut sets and probability calculations of events, which can be validated against the standard or allowed risk probability levels. FTA identifies safety critical components and allows measuring the design changes. Further studies will ensure checking of common mode failures.

Inputs required:
  • PRA/ FHA documents or list of top events
  • System functional description
  • FMEAs
  • System architecture
  • Basic Event Probabilities

Output:
  • Reliability, availability calculations.
  • Cut sets
  • Common Cause failure report
  • Uncertainty Report at each Gate and tope event.

System Safety Assessment (SSA)
The System Safety Analysis is a report comprises of different safety analysis activities in the life cycle; this can be split up into the following, all these phases integrated well with the product development life cycle.

FHA: Functional Hazard Assessment (addressing hazard identification and preliminary risk analysis)
PSSA: Preliminary System Safety Assessment (analyzing the contribution and interaction of the subsystems to system hazards)
SSA: System Safety Assessment (assessing the results of design and implementation, ensuring that all safety requirements are met)

During the above three phases of safety analysis one or more of the methodologies or techniques will be used and if required updated throughout the life cycle, those techniques includes.

  • Fault Tree Analysis (FTA)
  • Markov Analysis (MA)
  • FMEA/ FMES
  • Common Cause Analysis (CCA)
    4.1 Zonal Safety Analysis (ZSA)
    4.2 Particular Risk Analysis (PRA)
    4.3 Common Mode Analysis
  • Dependency Diagram (DD)
  • Event Tree Analysis (ETA)

MSG-3
“The MSG-3 (“Maintenance Steering Group”) is a decision-logic process for determining by reliability principles the initial scheduled maintenance requirements for new aircraft and/or engines.

The process identifies each Safety Significant Item (SSI) and applies a function, failure, failure effects and causes analysis on each using Failure Modes Effect Analysis (FMEA). Damage to an SSI is considered possible from accident, environment or fatigue. MSG-3 output is used as the basis for an MRB Report which, when agreed by the NAA involved, will set the principles for each MRO to develop a Maintenance Schedule for a particular aircraft type.

  • Maintainability Analysis
  • Life Data Analysis
  • Warranty Analysis
  • FRACAS
  • Integrated Logistic Support / Logistic Support Analysis – ILS/LSA

Reliability Testing Solutions
  • Reliability Test plan development
  • Accelerated Life Testing (ALT)
  • Reliability Growth Testing (RGT)
  • Reliability Demonstration Test (RDT)
  • Highly Accelerated Life Testing (HALT)
  • Highly Accelerated Stress Screening (HASS)
  • Environmental Testing