Reliability Data Analysis for Corrective Design
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Solution Overview
Problem
Current methods are inadequate for addressing time-in-service reliability concerns of complex system components, such as those in automotive or aircraft systems, as they fail to provide timely identification and corrective design solutions for components with constant or increasing failure rates, which negatively impact long-term customer satisfaction and brand perception.
Innovation Solution
A method involving remote customer databases to collect service data, analyze failure rates, determine failure modes, and develop corrective designs based on established benchmarks, allowing for proactive design improvements before new components go into service.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high mileage reliability data is compiled and analyzed using traditional methods, then reliability concerns can be identified, but the time required makes tailoring corrective design solutions to empirical data impractical
Solution Approach 1:
The patent applies preliminary action by establishing performance criteria and benchmarks before reliability data compilation is complete. The system proactively defines design solutions and performance targets in advance, allowing corrective design to be tailored to empirical data as it becomes available, rather than waiting for complete data analysis before initiating design improvements
Solution Approach 2:
The patent implements feedback by continuously monitoring extended time-in-service performance data and using this information to refine and update performance criteria and corrective design solutions. The system creates a closed-loop process where reliability data feeds back into performance criterion establishment, enabling ongoing improvement of design solutions based on actual field performance
2Reliability
If extended time-in-service performance is monitored to improve reliability, then customer satisfaction and loyalty improve, but warranty expenses increase due to more identified defects
Solution Approach 1:
The patent applies preliminary action by establishing performance criteria and corrective design solutions before failures occur in the field. By proactively identifying potential reliability concerns through performance monitoring and implementing design corrections in advance, the system prevents failures that would otherwise result in warranty claims, thereby reducing warranty expenses while maintaining improved reliability
Solution Approach 2:
The patent converts the potentially harmful effect of identifying more defects (which increases warranty expenses) into a benefit by using the identified reliability concerns to drive corrective design improvements. The system transforms warranty data and performance monitoring information into actionable design corrections that prevent future failures, ultimately reducing warranty costs while improving product reliability
Data Source
AI summary
The present invention comprises a method determining a corrective design for a system component exhibiting time-in-service reliability concerns. The method comprises the steps of establishing a plurality of remote customer databases for collecting service data for a system component, receiving at a centralized database during a predetermined period of time at least one parameter representative of a failure rate for the system component based at least in part on the service data and determining if the at least one parameter represents a system component defect. When the at least one parameter represents a system component defect, the method includes determining at least one failure mode of the system component based at least in part on the at least one received parameter and determining a corrective design for the system component based at least in part on the at least one failure mode.