DFR, Design for Reliability Training

DFR, Design for Reliability Training Course by Tonex

DFR, Design for reliability training provides the tools and techniques required to design reliability in a system early in its life cycle. Such designing ensures reliable performance and mission success.

DFR is an effective tool to save the costs of fixing the reliability issues in a fielded system by designing reliability upfront.

DFR, design for reliability training course will cover all the details of designing reliability process, the value added by achieving the goal, and real-life scenarios and example to get hands-on practicing.

TONEX DFR Training Features

DRF training course is delivered in a fun, interactive, and dynamic form. It includes several hands-on activities, group activities, and labs. Applicants have the option of bringing their sample work into the class or use the real-life examples our instructors will provide to practice applying what they have learned during the lecture.

Design for Reliability (DfR) training is a structured training program or course aimed at educating professionals, engineers, and designers on principles, methodologies, and best practices related to designing and validating products or systems with high reliability. The goal of DfR training is to equip individuals with the knowledge and skills necessary to create reliable and durable products that meet customer expectations and industry standards.

The key aspects typically covered in DfR training programs:

1. Reliability Engineering Fundamentals: This includes an introduction to reliability concepts such as failure modes and effects analysis (FMEA), fault tree analysis (FTA), reliability prediction models, reliability testing methods, and statistical analysis techniques used in reliability engineering.
2. Design Principles: DfR training focuses on teaching design principles that enhance product reliability, such as designing for robustness, designing for manufacturability (DFM), designing for testability (DFT), and designing for sustainability.
3. Risk Assessment: Participants learn how to assess and manage risks associated with product reliability, including identifying potential failure modes, analyzing their impact, and developing risk mitigation strategies.
4. Materials Selection: Understanding the properties and behaviors of different materials is crucial in designing reliable products. DfR training often covers topics related to material selection, including material properties, compatibility, aging, and degradation mechanisms.
5. Testing and Validation: DfR training includes guidance on designing effective reliability tests, establishing reliability targets, conducting accelerated life testing, interpreting test results, and validating product reliability before launch.
6. Failure Analysis: In-depth knowledge of failure analysis techniques is essential for identifying root causes of failures and implementing corrective actions. DfR training may cover failure analysis methods such as root cause analysis (RCA), failure modes and effects criticality analysis (FMECA), and failure reporting, analysis, and corrective action systems (FRACAS).
7. Quality and Compliance: Participants learn about quality management systems, regulatory requirements, standards (e.g., ISO 9001, ISO 13485), and industry best practices related to reliability, quality control, and compliance.
8. Lifecycle Considerations: DfR training often emphasizes considering reliability throughout the product lifecycle, from conceptual design and development to manufacturing, operation, maintenance, and end-of-life disposal or recycling.
9. Case Studies and Best Practices: Real-world case studies, examples of successful reliability design implementations, and best practices from various industries are often included in DfR training to provide practical insights and enhance learning outcomes.

Topics Include:

• DFR module
• Planning for Reliability
• Analysis, goal setting/metrics, & program plan module
• Reliability modeling and prediction module
• Design for availability (DoA)
• Thermal analysis module
• FMECA
• FTA
• DoE
• Human engineering
• Warranty analysis
• Critical parts management
• Design for extreme conditions
• Highly Accelerated Life Test (HALT)
• Reliability demonstration
• RCA
• Highly Accelerated Stress Screen (HASS)
• Restriction on Hazardous Substances (RoHS)
• Subcontracted engineering and reliability
• Mechanical reliability
• Software reliability

Which Industries Could Benefit from DFR Training?

• Oil and Gas
• Electronics Design
• Communications
• Automotive
• Aerospace Engineering
• Military
• Chemical Plants
• Transportation
• Manufacturing

Audience

DFR, design for reliability training is a 3-day course designed for:

• Reliability engineers
• Practical engineers
• Production supervisors and managers
• Product design engineers
• Quality team personnel
• Project managers
• Project engineering managers
• System engineers
• Maintenance engineers and managers
• Safety engineers
• Engineering personnel
• Risk Specialists
• Maintenance strategists
• Plant Inspectors

Learning Objectives

Upon the completion of DFR, design for reliability training, attendees are able to:

• Understand the process and procedures of each phase of life cycle.
• Gain detailed knowledge of designing reliability.
• Understand the concepts of reliability.
• Apply the right tools where is needed.
• Ensure all the requirements are met.
• Understand RAM concepts including processes, procedures, and tools of each stage of the life cycle.
• Understand and apply reliability engineering design approaches.
• Apply proper analysis to develop design.
• Use redundancy when is needed.
• Understand mathematics of reliability
• Discuss “critical reliability” items.
• Define reliability goals, metrics, plans, and schedule.
• Monitor and enhance to estimate the reliability related costs.
• Establish processes to monitor reliability development.
• Assist production and supply chain personnel to develop their reliability strategy.

Course Modules

Overview and Introduction

• Reliability engineering definition
• RAM concepts
• Mission success
• Reliability Engineering principles
• Reliability Engineering planning and business practices
• Goals and objectives
• Systems engineering lifecycle
• Mission categories and man-rating

Define Reliability Goals & Targets

• Establishing system level reliability requirements and goals
• Allocating reliability requirements and goals
• Understanding and quantifying end-user environmental and usage conditions

What are “Critical Reliability” Items?

• Key reliability risks
• Baseline reliability performance
• Conducting functional analysis on the key risks

Reliability Lifecycle Phases

• Pre-Phase A
• Phase A
• Phase B
• Phase C
• Phase D
• Phase E
• Phase F

Reliability Engineering Design Approaches

• Design for reduced risk
• Design for extreme environments
• Design to eliminate failure modes.
• Design for fault tolerance
• Design for fail-safe
• Design for early warning of failures
• MM/OD survivability

Fundamental Reliability Mathematics

• Basic probability concepts and probability distributions
• Principles of life data analysis
• Explanation of confidence intervals
• Basics of system reliability analysis

Analyzing Reliability

• Using FMEA’s on key reliability risks
• Design Review Based on Failure Modes (DRBFM)
• Applying physics of failure for reliability predictions and system modeling
• Developing a reliability improvement plan

Quantifying and Improving Reliability Methods

• Design of Experiments (DOE)
• Test Designs/Plans
• HALT/HASS (Qualitative ALT)
• Failure (Root Cause) Analysis
• Design Review Based on Test Results (DRBTR)
• Life Data Analysis
• Accelerated Life Testing (Quantitative ALT)
• System Reliability Analysis and Modeling (RBD, FTA)
• Reliability Growth
• Supplier Reliability

Applying Analysis to Drive the Design

• Perform Reliability Analysis
• RAM Simulation and modeling (Discrete Event Modeling)
• Fault Tree Analysis
• FMEA/CIL
• Worst case Analysis
• Parts Stress
• Single Event Upset/Effects Analysis
• Radiation Effects
• Thermal Analysis
• Structural Analysis
• Common Cause Failure Analysis
• Success Tree Analysis
• Parts and Materials
• GIDEP and NASA Alerts
• Flight Rules, Trade-offs, work-around, and other tools
• Human engineering/ Human Factors

Failure Modes and Effects Analysis Review

• Definition of FMEA
• Advantages of FMEA?
• Why can FMEA be applied?
• Who should conduct an FMEA?
• FMEA requirements, steps & data components
• The summary report

Fault Tree Analysis Review

• Definition of FTA
• Advantages of FTA
• When an FTA can be applied
• FTA procedures
• How to analyze the fault tree data
• Related analysis

Validate Reliability

• Reliability demonstration test design
• Field reliability predictions (warranty predictions)
• Achieved reliability performance.
• Volume manufacturing and/or supplier control plan
• Monitor and control reliability.

Reliability Testing

• Development (discovery) testing
• Reliability qualification testing
• Accelerated life testing
• Manufacturing testing

Factory Audit (Reliability QA)

• Warranty Forecasting and Analysis
• FRACAS
• Communicate, Update and Maintain Knowledge Items

Mechanical Reliability Assessment – Parts and Systems

• Definition and purposes
• Steps in making an analysis
• Parts analysis techniques
  • Failure data analysis
  • Empirical models
  • Mechanical stress/strength interference method
  • Surrogate data
• System-level analysis
  • RBDs
  • Simulation
  • Parts count

Reliability Allocation

• Modeling and trade studies
• Gap Analysis

Trending System Reliability During Operation

• Trend assessment
• Point process
• Confidence interval determination

Maintaining Reliability through Production and Operation

• Production and operation impacts on reliability
• Production concerns
• Quality of production
• Supplier selection and management
• Designing for maintainability
• Reliability information systems
• Developing a maintenance program of corrective and preventive actions

DFR, Design for Reliability Training