Product Failure Rate Research Articles

Predictive technology in remote competitive product service markets

Competition for service of products between the original equipment manufacturer (OEM) and a fringe firm is studied using a sequential game-theory model. The OEM utilises predictive technology to reduce the product failure rate, and the fringe firm provides efficient service at a reasonable price. Because of market remoteness, the OEM is incapable of matching the local fringe firm’s service quality. The price of service offered by the two firms, the effective failure rate of the product when serviced by the OEM, and the fringe firm’s service quality drive the number of products in the service market. Further, the captive market segment for OEM service and the products’ failure rate as seen by each firm drive that firm’s service demand. In such a setting, the OEM invests in predictive technology that reduces the effective failure rate of the products serviced by it. We find predictive technology benefitting both the firms at higher failure rates, thus acting as a Pareto improvement while implying co-existence in such remote product service markets. We further find the OEM dominating the fringe firm with higher price and profits only when the OEM captive market segment is large.

Robust optimization design of low-cost spoke-type permanent magnet motors with auxiliary salient poles

Applying ferrite to spoke-type permanent magnet motors with flux-focusing ability is a low-cost process and can yield torque density comparable to that of rare-earth permanent magnet motors. To overcome the drawback of the high torque ripple associated with traditional spoke-type permanent magnet motors, a new rotor with auxiliary salient poles is proposed. These poles enhance the plasticity of the rotor and increase the number of optimized parameters. The multiobjective optimization method, which combines response surface analysis and multiobjective backbone particle swarm optimization algorithm, is used to improve the torque performance of the motor. The motor will inevitably be affected by uncertainties, such as errors and tolerances, during motor mass production. Therefore, the six sigma design method and Monte Carlo analysis method are combined for optimizing the robustness of the motor. A comparison of the pre- and post-optimization electromagnetic performance revealed that the proposed motor can effectively reduce torque ripple while increasing the output torque and significantly reducing the mass production failure rate of the motor. Finally, experimental results verify the accuracy and feasibility of the proposed new motor structure and its robust optimization design.

How common is new product failure and when does it vary?

This study aims to explore how common new product failure is in consumer packaged goods (CPG) categories and investigate the conditions in which the new product failure rate varies. This study analyzes 83,719 new stock-keeping units (SKUs), which were introduced over 8 years (2002–2009) across 31 CPG categories in the USA. Failure is the permanent cessation of sales, which is measured in consumer panel data. We find that one in four (25%) new SKUs are no longer bought 1 year later—a rate that increases to approximately 40% 2 years post-launch. New SKU failure was more likely for new launches that were introduced into higher revenue categories and by smaller share parent brands. Our findings can be used as a resource to aid marketing practitioners’ understanding regarding how common failure is for new CPGs and when there is greater associated risk.

An Agent-based Model for Flexible Customization in Product-Service Systems

Product-Service System (PSS) models offer an integrated service solution to create value for businesses. In the high-value manufacturing sector, value creation for maintaining market competitiveness and improving customer satisfaction is a challenging task. Designing an effective PSS solution depends on integrated service, and product requirements and constraints. Thereby, PSS contract decisions can be significantly influenced by customers’ requirements, and also product and service features. However, existing literature primarily focuses on the impact of service requirements on the PSS contract decisions. Moreover, the existing insights for PSS customization mainly consider hysteretic customer requirements rather than forecasting the requirements under product and service uncertainties. In this paper, an agent-based cost-benefit analysis simulation model is implemented for the PSS contract decisions context. Moreover, a sensitivity analysis is conducted on service costs. Additionally, the effect of product remaining life on service contract decisions is analyzed. The simulation model considers stochastic uncertainty to study PSS contracts customization. The presented model supports PSS customization process by providing a quantitative tool that measures contracts’ profitability as early as the requirement elicitation phase. Furthermore, the bottom-up nature of the model, and the integration of probabilistic uncertainties enhance the flexibility of PSS customization. A case study of PSS contract decision in the machine tool industry is considered for assessing the validity of the presented model. Studies on different forms of service uncertainty highlight that the product failure rate has the most influence on the profitability of a service contract. Moreover, the impact of product age on profitability in an availability-based contract is more significant compared to a spare-parts contract.

Idle Duration Prediction for Manufacturing System Using a Gaussian Mixture Model Integrated Neural Network for Energy Efficiency Improvement

Manufacturing activities dominate the energy consumption and greenhouse emissions of the industrial sector. With the increasing concerns of greenhouse gas (GHG) emissions and climate change in recent years, the significance of the performance in terms of sustainability of manufacturing has been gradually recognized by both academia and industry. Various researches have been implemented to analyze, model, and reduce the energy consumption of manufacturing activities toward sustainable manufacturing. In a typical manufacturing system with multiple machines and buffers, the state of a certain machine is not only determined by the machine itself, but also the states of the adjacent machines and buffers. Therefore, machines may be in idle states due to nonincoming part from the upstream section of the manufacturing system or noncapacity to hold the delivered part to the downstream section of the manufacturing system. Those idle machines consume energy without production if there is no appropriate energy control strategy. In this article, we focus on the reduction of the energy waste for those idle machines in a typical multi-machine and multi-buffer manufacturing system. A Gaussian mixture model (GMM) integrated neural network is proposed to predict the duration of the idle periods for the idle machines, during which optimal energy control action can be identified and implemented under the constraint of production throughput of the manufacturing system. A manufacturing system simulator is built to provide the training dataset including the information, such as production throughput, energy consumption, buffer content, and failure rate, to the proposed neural network. A numerical case study for a five-machine-and-four-buffer manufacturing system is conducted to validate the effectiveness of the proposed prediction model in terms of the energy waste reduction for the idle machines. Note to Practitioners —This article proposes a prediction model to forecast the idle duration of the manufacturing machines in a typical multi-machine and multi-buffer manufacturing system. With this predicted result, two concerns in energy control for the idle machine, i.e., throughput protection and energy consumption reduction, can be more accurately modeled in decision-making procedure. Optimal energy control actions under the constraints of throughput maintaining and energy saving can be identified and implemented considering different warmup energy consumption and warmup time of the machines to reduce the energy waste for those machines in idle states without any production and thus, improve the energy efficiency of the entire manufacturing system.

DETERMINANTS OF THE HALAL COSMETICS ADOPTION AMONG YOUNG CONSUMERS IN THE KLANG VALLEY

The global increase in young consumer population and purchasing power has created a new demand for halal cosmetics product development. In Malaysia, it is now the trend in the industry of cosmetics for local manufacturers to produce halal cosmetic products. As the market growth is rapid, the manufacturers of cosmetics are eager to dominate the market and come up with many product varieties in order to pursue and satisfy customers. However, most consumers are conscious of the ingredients used in the making of cosmetic products. While the introduction of new products may facilitate companies in gaining competitive advantage, the failure rate of local products is high. Therefore, the objectives of this study are to understand the relationship between product characteristics, social influence and individual innovativeness with halal cosmetics adoption among young consumers in the Klang Valley, Malaysia. The sampling of this study comprised 350 respondents using survey questionnaires that were distributed in shopping malls in the Klang Valley. In order to test the model, this study used the structural equation modelling (SEM) technique using partial least squares (PLS) with SmartPLS 3.2.8. The findings of this study show that there is a positive relationship between product characteristics, social influence and individual innovativeness towards halal cosmetics adoption among respondents. This study demonstrates that halal cosmetics adoption is increasing among young consumers. Therefore, cosmetics producers or marketers need to understand the behaviour of young consumers in order to ensure that failure rate can be minimised.

Coordinating an ExtendedWarranty Supply Chain under Increasing, Constant and Decreasing Product Failure Rates

A product typically exhibits three different failure rates across its lifetime: increasing, decreasing, or constant. This paper studies how the characteristics of failure rate impact the supply chain coordination for an extendedwarranty programinvolving a manufacturer and a retailer. Atwo-stage Stackelberg game is utilized to model the interaction between these two players. Two extended warranty channel structures are compared depending on whether the manufacturer or the retailer offers the warranty service. The analysis shows that the failure rate trend during the warranty period has different effects on the coordination of the service supply chain. When a product has an increasing or constant failure rate, the optimal length of extended warranty offered by the retailer is longer than that of the manufacturer, while the optimal length is shorter for a product with a decreasing failure rate. If a product during the warranty coverage has an increasing or constant failure rate, a longer extended warranty period will motivate customers to buy the product without the warranty, whereas more customers will buy both the product and the warranty if the product experiences a decreasing failure rate. It is concluded that, if the manufacturer and the retailer incur the same warranty service cost, the total profit in the supply chain is higher when the manufacturer offers the extended warranty. From the game participants’ perspective, the one which sells the extended warranty will obtain more profit.

Quality improvement of remanufacturing lift arm using six sigma methods in the heavy-duty industry in Indonesia: A case study

The high remanufacturing forecast reaching 160 billion dollars/year in the world of the equipment industry (heavy duty) is a promising business opportunity. However, the remanufacturing industry has a higher risk of product failure compared to original Equipment products. The remanufacturing of the heavy-duty industry in Indonesia in carrying out its production has a product failure rate of 834586,47 DPMO and is at 1.91 sigma with COPQ IDR 650,800,000.00 Six Sigma method is used in this research and is successful in reducing remanufacturing defective product for lift arm to 140762,5 DPMO, is at the level of 2.43 Sigma and COPQ IDR. 135,000,000.00 or decreased 78.71% from the previous condition.

Pengaruh Pemeliharaan Dan Pengendalian Kualitas Terhadap Tingkat Produk Gagal Di PT.Granesia (Studi Kasus Pada Divisi Produksi Buku Percetakan)

The product fails to be a product that cannot be categorized as a final product and is economically or technically irreversible so that it should be discarded or sold below the sale price of the final product, due to the factors affecting the failure Products are the maintenance and quality control factors to minimize product failure rates. Through this research the author intends to further analyze the maintenance and control of quality that affect the failure of failed products in PT. Granesia. The effectiveness of resources is crucial to face the various challenges of the company both internally and externally to maintain the quality of the product. Through increased ability employees are expected to obtain a competent workforce that will reduce the failure rate of products produced by the company. Therefore, the descriptive and Vericular methods become the author's choice with the subject of production division employees. The instrument is used through the validity and reliability test first. Data collection is carried out using a questionnaire distributed with 70 questionnaires. The statistical method uses the analysis path. The results of the descriptive research on the production division of PT. Granesia showed that maintenance is already good, the quality control assessed is good and the product level fail to be assessed low. The results of the verificative studies indicate that there is an influence on the maintenance and quality control of the production division of PT. Granesia. Based on the results The study showed that PT. Granesia maintenance significantly affects the product's level of failure. Quality control has significant effect on the failing product level. Quality maintenance and control are simultaneously influential.

Oxytocin injection quality in Ethiopia: a post-marketing surveillance study in public and private facilities across three regions

# Background The high prevalence of poor quality essential medicines in low and middle income countries (LMIC) presents considerable risks in terms of both health outcomes and economic cost. Oxytocin injection, the gold standard therapy for management of postpartum haemorrhage (PPH), presents a particular challenge in this area. Recent studies in India, Nigeria and DRC have identified product failure rates, in terms of low drug content, to be 41%, 74% and 80% respectively. Ethiopia bears a high burden of PPH with over 40% of maternal deaths being directly attributed to haemorrhagic causes. This study assessed the quality of oxytocin injection at points in the public and private supply chains to support national efforts to address PPH in Ethiopia. # Methods This study sampled oxytocin injection ampoules from 45 sites across Oromia, Afar regions and the administrative area of Addis Ababa. This included points along the public supply chain from the national point of entry for supplies through regional hubs to points of use (public and private facilities) in urban and rural areas. Collected samples were stored under refrigerated conditions until analysis for oxytocin content, known degradation products and microbiological quality. # Results Ninety-six percent of ampoules passed all tests, while two samples (4%) contained less than the specified oxytocin content. Both samples were collected from rural facilities in Afar, a remote, poorly resourced region with a very hot climate. All supplies collected were sourced from European stringent regulatory approved (SRA) suppliers and, where storage conditions could be determined, approximately 95% of samples were stored in the refrigerator at the time of collection. # Conclusions The study indicates that oxytocin injection in the selected regions is generally of high quality and being stored appropriately. The failed samples detected in Afar suggest challenges remain around maintenance of refrigerated storage in least resourced settings. These findings contrast with recent results in other African countries and support the joint World Health Organization (WHO)/United Nations Children Fund/United Nations Population Fund statement that the availability of high quality oxytocin injection at the point of use is dependent on procurement of supplies from manufacturers approved by WHO or SRAs and storage at 2-8°C throughout the supply chain.

Research on Assembly Technology of Complex Flexible Outcabin Motional Cable for Spacecraft

Based on the application of flexible cable assembly simulation analysis technology in complex flexible out-cabin motional cable assembly of spacecraft, the working environment and physical characteristics of flexible motional cable are analyzed, reasonable assembly constraints are planned, and cable assembly simulation analysis is described in detail. The research results not only ensure the accuracy and practicability of the design, but also reduce the assembly defects and product failure rate. The actual effect of cable assembly can be accurately judged, the product performance can be improved, the product development cycle can be saved, and the development cost can be significantly reduced.

Determination of the building products reliability parameters at different loads in a two-step mode

The reliability determination of building structures and their components in a two-step mode nowadays is a relevant task. The article studies the problem of determining the building structures and their components reliability performance in a two-step mode based on the results of the tests described. These tests were conducted as follows: the batch of products intended for test are first tested in the first mode, and then in the second mode. A certain moment of time for mode switching is selected randomly by a specified law. The product is then tested in the variable two-stage mode. During testing, moments of time of product operation in the first and second modes are registered. Two experimentation programs that differ in the way of mode switching are proposed: program tests and dynamic tests. Examples of the methodology application to the determination of the product failure rate were discussed. According to the results of theoretical and practical application of the proposed method, the way to determine the reliability parameters using different laws was suggested for application in structural analysis and construction products reliability assessment process.

New Method for Reduction of the Capacitor Leakage Failure Rate Without Changing the Capacitor Structure or Materials in DRAM Mass Production

In the development of dynamic random access memory (DRAM) with a device size of 20 nm or less, the leakage current of a capacitor with high-k dielectrics is one of the main factors causing the failure of a device. To reduce the failure rate of the device, we conducted experiments to reduce the boron impurities, which form defect sites in the dielectrics of the capacitor. The boron source flux was reduced during the deposition process of the capping layer after the formation of the capacitor, and the actual boron concentration in the capping layer was measured by an atom probe tomography. The leakage current characteristics of the samples were confirmed through the dielectric leakage failure test, which is a mass production test technique. In addition, the resistance failure test was performed to measure the risk of increased resistance. From these results, it was confirmed that the failure rate due to the leakage current of the capacitor decreased linearly with reduced boron concentration and the increase in failure rate due to the cell node resistance was negligible. In addition, the results show that the failure rate of mass-produced DRAM products can be significantly reduced without any change in the structure or materials of the capacitor. This is expected to contribute greatly to the development of DRAM with dimensions on the scale of 20 nm or less.

A Dynamic Failure Rate Forecasting Model for Service Parts Inventory

This study investigates one of the reverse logistics issues, after-sale repair service for in-warranty products. After-sale repair service is critical to customer service and customer satisfaction. Nonetheless, the uncertainty in the number of defective products returned makes forecasting and inventory planning of service parts difficult, which leads to a backlog of returned defectives or an increase in inventory costs. Based on Bathtub Curve (BTC) theory and Markov Decision Process (MDP), this study develops a dynamic product failure rate forecasting (PFRF) model to enable third-party repair service providers to effectively predict the demand for service parts and, thus, mitigate risk impacts of over- or under-stocking of service parts. A simulation experiment, based on the data collected from a 3C (computer, communication, and consumer electronics) firm, and a sensitivity analysis are conducted to validate the proposed model. The proposed model outperforms other approaches from previous studies. Considering the number of new products launched every year, the model could yield significant inventory cost savings. Managerial and research implications of our findings are presented, with suggestions for future research.

The afterlives of solar power: Waste and repair off the grid in Kenya

One neglected socio-cultural and political dimension to the rapid diffusion of solar power in Sub-Saharan Africa is the question of what happens when things fall apart. Investors in the small-scale renewable energy sector are increasingly concerned with the status of broken or non-functioning products and there is an emerging consensus around the need for centralised recycling systems as the solution to future flows of ‘solar waste’.But what does the afterlife of off-grid solar products look like from below? Grounded in anthropology, geography and economic sociology, this paper tracks the impact of off grid solar products through contexts of breakdown, repair, and disposal. Combining stakeholder interviews, a longitudinal survey of product failure rates in Kenya and ethnographic research at a repair workshop in the town of Bomet, we challenge narratives of energy transitions that fail to address the environmental consequences of mass consumption and present an alternative approach to solar waste embedded in cultures and economies of repair.

Determination of Factors and Quality Control of Car Painting Based on FMEA and SPC.V2

The global automotive industry demands world-class levels of product quality, productivity, and competitiveness as well as continual improvement. To achieve this goal, many vehicle manufacturers companies use quality control tools to improve the quality of the product with zero defects and highly satisfied to the customer. Nowadays, there are a lot of quality tools applied to solve the problem quickly but it’s still the fact to find out good and efficient solving way. The study emphasizes the identification of potential failure which failures may have encountered in the production process and it will lead to car scrap, rework and influence of the internal production and quality target. After the complete study of the manufacturing process and production data-failure causes, failure rate and data etc. FMEA discover the weak processes in the form of higher risk priority number in the manufacturing of the car painting process, which required reducing by identifying and implementing of the defects and this will improve the process quality of the painting surface of the car. To analysis, the improvement of the car surface defects SPC (Statistical Process Control) tools are more efficient where can easily visible the defects trends. SPC chart is chronological graphs of process data that are used in manufactures industries to help understand, control and improve the process and that although based on statistical theory area easy for practitioners to use and interpret. In order to orient goal of zero defects of the car, surface uses the PFMEA technique to prioritize the defects and statistically analyze the roots cause of the defect and control the defects through continues improvements process.

A Resource Sharing Mechanism for Sustainable Production in the Garment Industry

With the development of mass customization, the traditional garment production model needs to be optimized to have a more sustainable structure. To meet demand for flexibility, low-cost, and high-efficiency, an innovative resource sharing mechanism was proposed in this paper to form a new sustainable type of garment production. Different from the individual production in traditional models, the new mechanism involves resources being shared among various manufacturers. The tradeoff between positive and negative effects of the proposed mechanism is a key issue for sustainable production. In the present study, an overall sustainable index, integrating four production performance indicators, was defined on the basis of an Analytical Network Process to assess various production scenarios. According to the discrete-event simulation results of the different scenarios, we found that garment manufacturers could obtain comprehensive improvements in sustainable production by implementing the proposed resource sharing mechanism under the threshold of an increasing production failure rate.

An FPGA-based monitoring system for reliability analysis

Abstract Electronics density continue to increase which impacts the power density and thermal hot spots on the printed circuit boards. The reliability and prediction of the electronics failure rate is often related to the thermal stress induced during different operating conditions at the board. To get information about the environmental conditions and to assist in the prediction of a product's failure rate a monitoring system could be used. This paper presents a temperature monitoring function implemented in an FPGA using VHDL. The proposed system is composed of a number of temperature sensors together with a non-volatile MRAM memory for long-term storage. The solution offers a flexible system that could be scaled to an arbitrary number of sensors and be adapted to any FPGA or processor technology. To verify the concept, a climate chamber was used to simulate a number of different environmental settings followed by a reading of the data logged.

Failure rates of artificial dermis products in treatment of diabetic foot ulcer: A systematic review and network meta-analysis.

Diabetic foot ulcer (DFU) is a frequent complication in diabetic patients, occurring in up to 25% of those affected. Among the treatments available to clinicians, the use of bioengineered skin substitutes is an attractive alternative. Artificial dermis functions as a matrix, covering the wound and supporting healing and reconstruction of the lost tissue. This study was aimed at reviewing the use of five regeneration matrices (namely, Integra, Nevelia, Matriderm, Pelnac, and Renoskin) as reported by clinical trials. We searched Medline, Embase, ISI Web of Science, Scopus, and Cochrane Central Register of Controlled Trials databases for relevant studies. Risk of failure rates was analysed by relative risk ratio method and complete ulcer healing was studied using network meta-analysis. Thirteen studies (12 randomized clinical trials and one cohort study) were eligible for analysis. The network meta-analysis based on a single study for Matriderm and 12 studies for other products showed that Matriderm was statistically inferior in achieving complete ulcer healing, as compared to all other products combined. In the second phase analysis, which was limited to three studies using artificial dermis products, there was a 57% reduction in the risk of reepithelialization failure for DFU patients who used Matriderm or Pelnac, compared to those who used Pelnac with basic fibroblast growth factor spray or skin grafting. The data showed an overall low failure rate suggesting that these bioengineered skin products provide a suitable support and microenvironment for healing of DFUs with low ulcer recurrence rates. This systematic review with meta-analysis highlights the pressing need for more studies investigating the safety, efficacy and failure rates of regeneration matrices in the treatment of DFUs.

Warranty pricing with consumer learning

We consider a problem in which a firm dynamically prices a product and its warranty service over time. Consumers can learn about the reliability of products based on warranty prices. A firm’s optimal product and warranty pricing policies are characterized. We find that a warranty should be priced lower than the marginal warranty service cost, which implies that warranty sales will not generate profits directly. However, offering a modest warranty still benefits the firm’s overall profits. We also show that consumers’ beliefs and the firm’s warranty policy converge in the long run. In a steady state, either a fraction of consumers will purchase a warranty or no consumer will purchase a warranty. Comparative statics analysis is conducted to show how factors such as a firm’s warranty service cost, consumers’ learning speed, and the heterogeneity of consumers’ handling costs determine consumers’ beliefs, the firm’s warranty policy and profitability in a steady state. Lastly, we note that a firm benefits from consumer learning by hiding the information about the true product reliability only when the true product failure rate is relatively high.