Reliability oriented key quality characteristics driven integrated built-in reliability activity chain and approach for manufacturing process

Abstract

Product reliability is determined at the design phase and built into the product through manufacturing process. To effectively implement reliability activities at each stage, reliability data in product life cycle is integrated with KQC (key quality characteristics), and the concept of R-KQC (reliability-oriented KQC) is proposed. Based on the R-KQCs, this study presented an integrated Built-in reliability (BIR) approach to ensure that the product reliability formed losslessly conforms to the reliability goal determined in the design phase. First, the connotations of BIR and BIR-oriented RQR (manufacturing system Reliability, manufacturing process Quality, and product Reliability) chain are proposed by considering the evolution mechanism of product reliability in the life cycle driven by the R-KQCs. Second, a product BIR activity chain consisting of plan, synthesis, and improvement based on R-KQC is presented by the BIR-oriented RQR chain. Third, an R-KQC-driven BIR assurance technology framework based on the BIR activity chain is proposed, and a product reliability modeling considering the deviation of R-KQCs is established based on the framework. Finally, the validity of the proposed approach is verified using the reliability assurance for an automobile engine cylinder head as an example.