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Hardware & Software Techniques for Reliable Product Development

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This chapter covers various hardware and software techniques to ensure reliability in product development, including redundancy, component reliability, vendor assessment, safety considerations, and design methodologies.

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Hardware & Software Techniques for Reliable Product Development

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  1. Chapter 6 Product Development R. Fries

  2. Hardware & Software Techniques • Block diagram the system (Visio) • Consider Redundancy – active or standby • Active: failure of one parallel component - the second still works • Standby: failure of component – replacement • MTBF =mean time between failures = 1/λ • Active MTBF=3/(2λ) • Standby MTBF=2/λ

  3. Hardware/Software Cont. • Consider component reliability • Vendor assessment (Hx, failure, etc.) • Vendor audit (check facility) • Vendor evaluation (inspect incoming) • Vendor qualification (on-list?) • Consider component history – military & reliability groups, government info bases • Consider safety (FMEA, etc.)

  4. Hardware/Software Cont. • Consider component derating • Use 2 watt R in 1 watt situation, decrease failure rate >30% (T, humidity, P, V, I, friction, vibration) • Usage ratio = max stress/stress rating (.5-.9) • Goal is reliability! • Pacemaker example

  5. Hardware/Software Cont. • Safety margin must be considered • Safety margin=safety factor-1 • =(mean strength/mean stress)-1 • Elevator – safety margin~2 • Medical devices – Fries - .5 and up. • Load protection must be considered • Environment must be considered (see 112) • Product misuse – consider • Design for variation (6 sigma?)

  6. Software Engineering Management • Planning for safety (FDA!) • Planning for risk assessment • Planning for method • Waterfall • Incremental delivery • Spiral • Cleanroom • Code and fix, …

  7. Software Engineering Management • Choose design method • Top-down • Data driven • OOP • Language (Assembler/C++/Qbasic?etc.) • Testing • Requirements • Hazard Analysis!!! (FDA)

  8. Software Engineering Management • Requirements traceability (FDA) • Software architecture design • Well defined modules (logical) • Other vendor – standalone • Single purpose modules • Cohesion & coupling • Naming • Integration

  9. Structured/Unstructured Design Techniques • Computer/database assisted: • Ideation International IWB • TRIZ • Techoptimizer • Others… • Example done in class, another in text

  10. Structured/Unstructured Design Techniques • Axiomatic Design • Nam Suh, MIT • Requirements, design parameters, process variables, customer needs = vectors • Try to solve, disassociate functional requirements and design parameters • Highly mathematical • Acclaro Software

  11. Structured/Unstructured Design Techniques • Structured, step by step, 8 steps • Pahl and Beitz • Semistructured – Wilcox, Engineering Design for Electrical Engineers, Ulrich and Eppinger Product Design and Development

  12. Structured/Unstructured Design Techniques • Reverse engineering • Redesign • Etc.

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