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Modelling infant failure rate of electromechanical products with multilayered quality variations from manufacturing process

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  • Yihai He
  • Linbo Wang
  • Zhenzhen He
  • Xun Xiao

Abstract

The optimisation of product infant failure rate is the most important and difficult task for continuous improvement in manufacturing; how to model the infant failure rate promptly and accurately of the complex electromechanical product in manufacturing is always a dilemma for manufacturers. Traditional methods of reliability analysis for the produced product usually rely on limited test data or field failures, the valuable information of quality variations from the manufacturing process has not been fully utilised. In this paper, a multilayered model structured by ‘part-level, component-level, system-level’ is presented to model the reliability in the form of infant failure rate by quantifying holistic quality variations from manufacturing process for electromechanical products. The mechanism through which the multilayered quality variations affect the infant failure rate is modelled analytically with a positive correlation structure. Furthermore, an integrated failure rate index is derived to model the reliability of electromechanical product in manufacturing by synthetically incorporating overall quality variations with Weibull distribution. A case study on a control board suffering from infant failures in batch production is performed. Results show that the proposed approach could be effective in assessing the infant failure rate and in diagnosing the effectiveness of quality control in manufacturing.

Suggested Citation

  • Yihai He & Linbo Wang & Zhenzhen He & Xun Xiao, 2016. "Modelling infant failure rate of electromechanical products with multilayered quality variations from manufacturing process," International Journal of Production Research, Taylor & Francis Journals, vol. 54(21), pages 6594-6612, November.
    • Handle: RePEc:taf:tprsxx:v:54:y:2016:i:21:p:6594-6612
    DOI: 10.1080/00207543.2016.1154215
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    Cited by:

    1. Yang, Xiuzhen & He, Yihai & Liao, Ruoyu & Cai, Yuqi & Ai, Jun, 2022. "Integrated mission reliability modeling based on extended quality state task network for intelligent multistate manufacturing systems," Reliability Engineering and System Safety, Elsevier, vol. 223(C).
    2. Milia Habib & Farouk Yalaoui & Hicham Chehade & Iman Jarkass & Nazir Chebbo, 2017. "Multi-objective design optimisation of repairable -out-of- subsystems in series with redundant dependency," International Journal of Production Research, Taylor & Francis Journals, vol. 55(23), pages 7000-7021, December.
    3. J. Piet Hausberg & Kirsten Liere-Netheler & Sven Packmohr & Stefanie Pakura & Kristin Vogelsang, 2019. "Research streams on digital transformation from a holistic business perspective: a systematic literature review and citation network analysis," Journal of Business Economics, Springer, vol. 89(8), pages 931-963, December.

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