Applied Reliability for Industry 3

Abdelkhalak El Hami is Full Professor of Universities at INSA-Rouen-Normandie, France. He is the author/co-author of several books and is responsible for several European pedagogical projects. He is a specialist in fluid structure interaction and problems of optimization and reliability in multi-physical systems.David Delaux is Reliability Director at Valeo and Reliability Senior Expert. An Honorary Visiting Professor at Bradford University, UK, he is also a national auditor/assessor at COFRAC (ISO 17025), President of the European Campus of Statistics Statistical Analysis For Industry (SAFI), Expert for the European Innovation Council and President of the association ASTE. He is also the former President of the European Reliability Environmental Confederation (CEEES).Henri Grzeskowiak is a Technical Expert at Matra BAe Dynamics and MBDA (missile). He is also an auditor at COFRAC, Head of Department of Environmental Engineering (Matra & MBDA) as well as former President of the Standardization Committee for Mechanical & Climatic Environment (DGA) and of the association ASTE (France) and CEEES (Europe).

• Foreword xiPhillipe EUDELINEPreface xiiiAbdelkhalak EL HAMI, David DELAUX, Henri GRZESKOWIAKChapter 1 Durability Approach: Applied to a Vehicle Lighting Control System 1Medoune NDIAYE and Caroline RAMUS-SERMENT1.1 Introduction 11.2 Example of a vehicle lighting control system 21.2.1 Risks and reliability requirements 31.2.2 From failure modes to failure mechanisms 31.2.3 From failure mechanisms to physical damage factors 51.2.4 From physical damage factors to mission profiles or customer usage 61.2.5 From failure mechanisms to component part strength distribution 71.2.6 Resistance distribution chart 111.2.7 Proposal and study of a validation plan using the stress–strength method: various real-world examples 141.3 Conclusion 191.4 References 19Chapter 2 Structural Diagrams to Validate the Reliability of Mechanical Components 21Paul SCHIMMERLING2.1 Introduction 212.2 Choice of methods 222.2.1 Criteria selection 222.2.2 Four basic methods 232.2.3 An applied example: the validation of disc brake pads 242.3 Feasibility study on the four methods 252.3.1 Animation principle 252.3.2 Comparison of Weibull laws under testing and in service 252.3.3 Comparing degradation under testing and in service 282.3.4 Stress–strength method 302.4 Conclusion 342.5 References 35Chapter 3 How to Put an Efficient Methodology to Design Innovative Products in Place 39Claire SCHAYES, Ludovic NGAVOUKA and Eric MANOUVRIER3.1 Introduction 393.1.1 Reliability 393.1.2 Variability 403.1.3 “Lean Six Sigma” 403.1.4 Quality according to the “Lean Six Sigma” approach “is conforming to requirements” 413.2 Dfss 423.3 Dmaic 463.3.1 Introduction to DMAIC 463.3.2 Why launch DMAIC projects? 463.4 Feedback 503.4.1 Feedback on the define phase 503.4.2 Feedback on the measure phase 503.4.3 Feedback on the analyze phase 513.4.4 Feedback on the innovation phase 523.4.5 Feedback on the control phase 533.4.6 Can DMAIC be customized? 543.5 How to design a reliable welding process with control over the design of experience? 573.6 Definition of the objectives 583.6.1 Determining the study space 593.6.2 Building the DOE 653.6.3 Conducting the tests 663.6.4 Analyzing the results 673.6.5 Process optimization 683.6.6 Validation 693.7 Big Data and process? 693.8 Conclusion 743.9 Appendix 1: example of an ANOVA study 743.10 Appendix 2: studying the variability of cycle times 793.11. Appendix 3: example for the use of traditional statistics in Big Data 873.12 References 90Chapter 4 Reliability Study of the High Electron Mobility Transistor (HEMT) 91Abdelhamid AMAR, Bouchaïb RADI and Abdelkhalak EL HAMI4.1 Introduction 914.2 HEMT technology 924.3 HEMT thermal modeling 944.4 Reliability methods 964.4.1 Reliability study 964.4.2 Calculating the probability of failure 974.5 Thermo-reliability coupling 1014.6 Calculating HEMT reliability 1024.7 Conclusion 1034.8 References 103Chapter 5 Warranty Cost 107David DELAUX5.1 Introduction 1075.1.1 The evolution of the warranty 1075.1.2 The warranty cost 1085.2 Warranty and reliability 1115.2.1 Qualitative analysis 1115.2.2 Quantitative analysis 1125.3 Reliability estimation models 1135.3.1 Parametric, non-parametric and other models 1135.3.2 Mixed models 1145.3.3 Advantages and disadvantages 1165.4 New models for estimating reliability from warranty costs 1175.4.1 Assumptions 1175.4.2 Definition of the transition between “random” and “wear-and-tear” phases 1205.4.3 New operational reliability model for the “random” phase 1255.4.4 New operational reliability model for the “wear-and-tear” phase 1255.5 Applied automotive case studies 1265.6 Conclusion 1285.7 References 128Chapter 6 Reliability Evaluation of a Luxury Watch Product: Application of the Stress–Strength Method to a Mechanical Component 135Matthieu SALLIN and Anthony PONCET6.1 Introduction 1356.2 Presentation of the watch and its case study 1366.2.1 The mechanical watch 1366.2.2 Case study of the barrel spring 1376.2.3 Identification of failure modes and damaging factors 1376.3 Evaluation of the customer usage profile 1386.3.1 Classifying usage typologies 1386.3.2 Statistical quantification of usage 1396.4 Characterizing experimental reliability 1406.4.1 Performance of failure tests 1406.4.2 Evaluation of the accelerated lifetime law 1416.4.3 Constructing the law of resistance 1426.5 Reliability evaluation of customers 1436.5.1 Reliability calculation using the stress–strength method 1436.5.2 Transformation of the stress profile 1446.5.3 Numerical application to the barrel case study 1466.6 Conclusion 1476.7 References 148Chapter 7 RBDO of the High Electron Mobility Transistor 149Abdelhamid AMAR, Bouchaïb RADI and Abdelkhalak EL HAMI7.1 Introduction 1497.2 Description of the HEMT technology 1517.3 Electrothermomechanical modeling of HEMT 1527.3.1 Electrothermal modeling of HEMT 1527.3.2 Thermomechanical modeling of HEMT 1547.4 Reliability methods 1567.5 Reliability analysis of HEMT 1567.6 Reliability optimization of systems 1587.6.1 The classic RBDO approach 1587.6.2 The hybrid RBDO approach 1597.7 HEMT reliability optimization using the hybrid RBDO approach 1607.7.1 Description of the optimization problem 1607.7.2 Results and discussion 1607.8 Conclusion 1617.9 References 162List of Authors 167Index 169Summaries of other volumes 171