Specifying Reliability

Designs are usually based upon specifications, which define the problems
the designer must overcome. Where the specification is deficient, it is
possible that the unspecified parameter or feature will be traded against
when compromises are needed. This is accepted for features which are
deterministic, such as weight, size and input and output parameter
values. It is more difficult t9o specify non-deterministic features such as
appearance and reliability. It is relatively easy to assess a design for
conformance with deterministic features, or even for appearance. The
inherent reliability of a design is not as easily apparent, since it depends
upon external factors such as load cycles, the environment in which it will
be used, manufacturing quality etc.

In order to ensure reliability does not suffer, the requirement must be

specified. The reliability specification must contain:

1. A definition of failure related to the product’s function. The definition

should cover all failure modes relevant to the function.

2. A full description of the environments in which the product will be

stored, transported, operated and maintained.

3. A statement of the reliability requirement, and/or a statement of

failure mode and effects which are particularly critical and which
must therefore have a very low (or zero) probability of occurrence.
The reliability specification may be a separate document, or it may
be covered in the range of other specifications (design, test,
maintenance etc.)

Do not write vague requirements such as ‘as reliable as possible’,

‘high reliability is to be a feature of the design’, or ‘the target
reliability is to be 99%’.

Do not write unrealistic requirements. ‘Will not fail under the

specified operation conditions’ is a realistic requirement in many
cases. However, an unrealistically high reliability requirement for,
say , a complex electronic equipment will not be accepted as a
credible design parameter, and is likely therefore to be ignored.

Definition of failure

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The failure criteria must be unambiguous. Failure should always be
related to a measurable parameter or to a clear indication. A seized
bearing indicates itself clearly, but a leaking seal might or might not
constitute a failure, depending on the leak rate, or whether or not
the leak can be rectified by a simple adjustment. Defects such as
changes in appearance or minor degradation that do not affect
function are not usually relevant to reliability.

There will be subjective variations in assessing failure, particularly

when data are not obtained from controlled tests. Failure data from
repairs carried out under warranty might differ from data on the
same equipment after the end of the warranty period, and both will
differ from data derived from a controlled reliability demonstration.

Environmental specifications

The environmental specifications must cover all aspects of the many

loads and other effects that can influence the product’s strength or
probability of failure. Without a clear definition of the conditions
which the product will face, the designer will not be briefed on what
he is designing against. The environments to be covered must
include handling, transport, storage, normal use, foreseeable
misuse, maintenance and any special conditions.

Stating the reliability requirement

The reliability requirement should be stated in a way which can be

verified, and which makes sense relative to the use of the product.
The simplest requirement is to state that no failure will occur under
the stated conditions. Levels of reliability less than unity can be
stated as a success ratio, or as a life.

Reliability specifications based on life parameters must be framed in

relation to the appropriate life distributions. Two common
parameters used are MTBF, when a constant failure id assumed, and
B –life related to Weibull life distributions. MTBFs should not be
specified if a constant failure rate assumption cannot be justified.

Specified life parameters must clearly state the life characteristic,

eg the life of a switch or DVD player cannot be usefully stated as a
number of hours. The life must be related to the duty cycle (in these
cases, switch reversals and frequency, sequencing operations and

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frequency, operating cycles on play, switch on/off etc). The life
parameter may be stated as some time-dependent function eg
miles travelled, switching cycles, load reversals, or it may be stated
as time, with a stipulated operating cycle.