Main Menu

See All Acoustic End-of-Line Test Systems See All DAQ and instruments See All Electroacoustics See All Software See All Transducers See All Vibration Testing Equipment See All Academy See All Resource Center See All Applications See All Industries See All Insights See All Services See All Support See All Our Business See All Our History See All Our Sustainability Commitment See All Global Presence

Main Menu

See All Actuators See All Combustion Engines See All Durability See All eDrive See All Production Testing Sensors See All Transmission & Gearboxes See All Turbo Charger See All Industrial electronics See All S&V Signal conditioner See All DAQ Systems See All Power Analyser See All S&V Hand-held devices See All High Precision and Calibration Systems See All Test Solutions See All nCode - Durability and Fatigue Analysis See All ReliaSoft - Reliability Analysis and Management See All Test Data Management See All DAQ Software See All Drivers & API See All Utility See All Vibration Control See All Acoustic See All Current / voltage See All Displacement See All Load Cells See All Pressure See All Strain Gauges See All Vibration See All Torque See All LDS Shaker Systems See All Vibration Controllers See All Power Amplifiers See All Accessories for Vibration Testing Equipment See All Training Courses See All Acoustics See All Asset & Process Monitoring See All Custom Sensors See All Data Acquisition & Analysis See All Durability & Fatigue See All Electric Power Testing See All NVH See All Reliability See All Smart Sensors See All Vibration See All Weighing See All Automotive & Ground Transportation See All Calibration See All Installation, Maintenance & Repair See All Support Brüel & Kjær See All Release Notes See All Compliance See All Our People

Main Menu

See All QuantumX See All LAN-XI See All SomatXR See All MGCplus See All CANHEAD See All Optical Interrogators See All GenHS See All API See All Microphone Cartridges See All Microphone Sets See All Microphone Pre-amplifiers See All Sound Sources See All Acoustic Calibrators See All Special Microphones See All Accessories for acoustic transducers See All Experimental testing See All Transducer Manufacturing (OEM) See All CCLD (IEPE) accelerometers See All Charge Accelerometers See All Rotating See All Non-rotating (calibration) See All Electroacoustics See All Noise Source Identification See All Environmental Noise See All Sound Power and Sound Pressure See All Noise Certification See All Industrial Process Control See All Structural Health Monitoring See All Electrical Devices Testing See All Electrical Systems Testing See All Grid Testing See All High-Voltage Testing See All Vibration Testing with Electrodynamic Shakers See All Structural Dynamics See All Machine Analysis and Diagnostics See All Dynamic Weighing See All Calibration Services for Transducers See All Calibration Services for Handheld Instruments See All Calibration Services for Instruments & DAQ See All On-Site Calibration See All Resources See All Software License Management

Learn how ReliaSoft software can help you facilitate the DfR process

Any product will fail when the stress experienced by the product exceeds its strength. In order to reduce the failure probability, we must reduce the interference between stress and strength. A structured process, such as the DfR process is needed in order to achieve this. This process can be adapted and customized based on your specific industry, your corporate culture and other existing processes within your company.

With ReliaSoft software products, we can help you bring a reliable product to market using a DfR process focused on designing out or mitigating potential failure modes prior to production release, based on an understanding of the physics of failure, testing to discover issues and statistical analysis methods for reliability prediction. DfR can open up many opportunities for companies who want to move beyond securing a basic offering to the marketplace to creating a true competitive advantage in which reliability plays a critical role for customer satisfaction.

Define the reliability requirements and goals for a product as well as the end-user product environmental/usage conditions. These can be performed at the system level, assembly level, component level or even down to the failure mode level.

Determining the usage and environmental conditions is an important early step of any DfR program. Companies need to know what it is that they are designing for and what types of stresses their products are supposed to withstand. The conditions can be determined based on customer surveys, environmental measurement, and sampling.

Using different allocation techniques, available and supported in ReliaSoft BlockSim software, you can determine the system reliability requirements that would be needed to achieve an overall reliability goal. Once the requirements have been defined, they must be translated into design requirements and then into manufacturing requirements.
During this stage, a clearer picture about what the product is supposed to do starts developing. It is important to understand how much change is introduced with this new product. A product can be an upgrade of an existing product, an existing product that is introduced to a new market or application, or a product that is not new to the market but is new to the company and could be introduced as completely new product. With more design or application changes, more reliability risks are introduced to the success of the product and company.

Using ReliaSoft XFMEA software, you can identify potential failure modes, assess the risk associated with those failure modes, prioritize issues for corrective actions and identify and carry out corrective actions to address the most serious concerns. A properly applied DFMEA takes requirements, customer usage and environment information as inputs and, through its findings, initiates and/or informs many reliability-centered activities.
It is highly important to estimate the product's reliability, even with a rough first cut estimate, early in the design phase. This can be done with estimates based on engineering judgment and expert opinion, simulation models, prior warranty and test data analysis from similar products/components using ReliaSoft Weibull++ software or with standard based prediction available in ReliaSoft Lambda Predict software. You can use common military or commercial libraries, such as MIL-217, Bellcore and Telcordia, to come up with rough MTBF estimates or to compare different design concepts when failure data is not yet available.
By this stage, prototypes should be ready for testing and more detailed analysis. This involves an iterative process where different types of tests are performed, the results are analyzed, design changes are made, and tests are repeated.

A wide array of tools is available for the reliability engineer to uncover product weaknesses, predict life and manage the reliability improvement efforts available in ReliaSoft Weibull++. With testing comes data, such as failure times and censoring times. Test results can be analyzed and its techniques to statistically estimate the reliability of the product and calculate various reliability-related metrics with a certain confidence interval. Such calculations can help in verifying whether the product meets its reliability goals, comparing designs, projecting failures and warranty returns. Additionally, using Weibull++'s Accelerated Life Testing module, you can cut down on the testing time, and by carefully elevating the stress levels applied during testing, failures may occur faster and thus failure modes are revealed more quickly.

A very important aspect of the DfR process also includes performing root cause analysis using XFRACAS software, which provides better understanding of physics of failure and can discover issues not foreseen by techniques used prior to testing (such as FMEA).

Using BlockSim's RBDs, you can model the overall reliability of the system, identify weak areas of the system, find optimum reliability allocation schemes, compare different designs and perform auxiliary analysis such as availability analysis. Fault tree analysis may be employed to identify defects and risks and the combination of events that lead to them.
During this stage, you need to make sure that the product is ready for high volume production. Statistical methods can be used to develop a test plan that will demonstrate the desired goal with the least expenditure of resources.

When reaching the manufacturing stage, the DfR efforts should focus primarily on reducing or eliminating problems introduced by the manufacturing processes. Manufacturing introduces variations in materials, processes, manufacturing sites, human operators, contamination, etc. The product's reliability should be reevaluated, and design modifications might be necessary to improve robustness. Continuous sampling of units for testing using ReliaSoft Weibull++ is highly desirable throughout manufacturing to estimate the reliability of the product and assess whether the reliability goal is still expected to be met.
Process FMEAs can be used to examine the ways the reliability and quality of a product or service can be jeopardized by the manufacturing and assembly processes. With ReliaSoft XFMEA’s Control Plans you can assure that all process outputs will be in a state of control.

The manufacturing process is also prone to deviations. Using Weibull++ to perform warranty analysis can be useful in preventing infant mortality failures, which are typically caused by manufacturing-related problems, from happening in the field. Deciding on the appropriate burn-in time can be derived from QALT and/or LDA. Also, manufacturability challenges might force some design changes that would trigger many of the DfR activities already mentioned.

Continuous monitoring and field data analysis are necessary to observe the behavior of the product in its actual use conditions and use the gained knowledge for further improvements or in future projects. In other words, you need to close the loop, review the successful activities as well as the mistakes, and ensure that the lessons learned are not lost in the process.

Are you and your organization ROI- and results-driven?


Here are some impressive results collected from engineers, from over 550+ companies across a wide spectrum of industry, who completed the Best Practices in Reliability survey report:

Increase in revenue growth
Reduction in failure modes
Reduction in development time

How can ReliaSoft help you further your reliability goals?

Further your reliability education

Gain experience using best-in-class software applications to facilitate and enhance your learning experience through extensive hands-on examples and real world case studies.

Get targeted help from our team

Make smarter decisions in the areas of design, development, testing, and asset management to support business decisions, maintenance, and help manage risk of your assets.

Improve reliability with the right tools

Discover a powerful range of solutions and save money with our DFR Suite, which is specifically designed for users focused on product design, test, and development.

Please fill out the below form to access the “Design for Reliability” video and PDF presentation