Reliability Model Augmentation Using Component Compatibility Data
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Solution Overview
Problem
Current methods for predicting the reliability and determining maintenance plans for complex products with multiple components are inadequate, as they often rely on general models that fail to account for unique component interactions, leading to premature failure or excessive maintenance costs.
Innovation Solution
A method that uses manufacturing data and compatibility rules to augment reliability models for individual products, determining the compatibility of components and generating customized maintenance plans based on their specific performance characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If general reliability models are used for all products, then manufacturing complexity is reduced and ease of manufacture is improved, but reliability prediction accuracy deteriorates and premature failures increase
Solution Approach 1:
The patent segments the reliability modeling process by dividing products into individual components and creating separate reliability models for each component based on its specific manufacturing data, rather than using a single general model for the entire product. This segmentation allows for more accurate reliability predictions while maintaining manufacturing efficiency.
Solution Approach 2:
The patent applies local quality by tailoring reliability models to specific components and their unique manufacturing characteristics. Each component receives a customized reliability model that reflects its specific manufacturing data, ensuring that reliability predictions are locally optimized for each component rather than using a uniform approach.
2Productivity
If component compatibility is not evaluated, then manufacturing process is simpler and productivity is improved, but product reliability deteriorates due to defective component pairings
Solution Approach 1:
The patent implements preliminary action by evaluating component compatibility during the manufacturing assembly process, before the product reaches the customer. Compatibility rules are applied to assess whether paired components will work together reliably, allowing defective pairings to be identified and corrected before deployment.
3Reliability
If unit-specific reliability models are created for each product, then reliability prediction accuracy is improved and premature failures are reduced, but device complexity and data processing requirements increase
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting reliability model parameters based on specific manufacturing data for each component. The system modifies model parameters such as degradation rates and failure probabilities to reflect the actual manufacturing characteristics of individual components, enabling accurate unit-specific reliability predictions.
Data Source
AI summary
A method of augmenting a reliability model for a manufactured product includes receiving a product attribute identifying a product, receiving a first component attribute and a second component attribute, and receiving first manufacturing data and second manufacturing data, the first manufacturing data comprising manufacturing data associated with the first component and the second manufacturing data comprising manufacturing data associated with the second component. The method can include applying a set of compatibility rules to the first manufacturing data and the second manufacturing data, determining pairing data from the application of the set of compatibility rules to the first manufacturing data and the second manufacturing data, obtaining a reliability model of products including the product, augmenting the reliability model based on the pairing data, and performing one or more actions with the augmented reliability model.