VDA

Quality Management
in the Automotive Industry

Reliability Management

rd
3 Edition 2000
Reliability assurance
for car manufacturers
and suppliers

Reliability Management

rd
3 Edition 2000

Verband der Automobilindustrie e.V. (VDA)

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so that any possible faults can be corrected.

Referenced standards
The extracts from standards identified with their DIN number and issue date
are reproduced with the permission of the DIN Deutsches Institut für Nor-
mung e.V. (German Institute for Standardization).

The version with the latest issue date is definitive for the use of the
standard, which can be obtained from the publishers Beuth Verlag GmbH,
10772 Berlin.

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3
ISSN 0943-9412

Copyright 2000 by

Verband der Automobilindustrie e.V. (VDA)

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4
Preface
nd
The demand for the 2 Edition of this volume has confirmed that the
interest in practical presentations of reliability activities in the automotive
industry continues. Thus, after 15 years, the desire arose to revise the
volume again and to include the activities in the product development
process in a meaningful way in order to achieve high product reliability. This
lead to a comprehensive study of a product life cycle from pre-development
to disposal.
rd
The 3 Edition produced two volumes. Volume 1 describes the reliability
management over a product life cycle. It particularly targets managers and
those responsible for project management, who have to make sure that the
reliability methods are incorporated into the various phases of the project
process. It was only logical that Volume 2, which describes the reliability
methods and tools, received a structure similar to that of Volume 1. Here,
nd
the procedures and examples of the 2 Edition of the volume were
thoroughly revised and extended. Volume 2 provides experts in the works
with a manual they can use in their every day work offering practical
examples and methods to be applied.
th
In its meeting on the 25 of November 1999, the VDA Committee „Quality
Management in the Automotive Industry” has generally agreed to the
rd
publication of the 3 Edition of the book “Reliability assurance for car
manufacturers and suppliers” in two volumes.

We would like to thank those companies and their employees involved in

rd
activities regarding this 3 Edition for their cooperation:

BMW Group Robert Bosch GmbH

DaimlerChrysler AG Mannesmann Sachs AG
Ford-Werke AG Hella KG – Hueck & Co.
Institut für Maschinenelemente Filterwerk Mann+Hummel GmbH
Universität Stuttgart
BERU AG
Audi AG
VDO Adolf Schindling AG
MAN Technologie AG WABCO Fahrzeugbremsen
TRW Occupant Restraint
Systems GmbH
Volkswagen AG

5
6
List of contents Page

Preface 5

1 Introduction 9
1.1 Why reliability management? 9
1.2 Quality - Reliability - Safety 12

2 Introduction and explanation 14

2.1 Working towards reliability during projects 14

3 Project-related reliability management 20

3.1 Milestone 0 Completion of pre-development 21
3.2 Milestone A Project inquiry/contract 24
3.3 Milestone B Approval for Rough Development 27
3.4 Milestone C Approval for detailed development 36
3.5 Milestone D Approval for detailed planning - Production process 47
3.6 Milestone E Approval for plant procurement 52
3.7 Milestone F Approval for serial production 56
3.8 Milestone G Product Review 59
3.9 Milestone H Model discontinuation/disposal 66

4 Index 72

5 Appendix 75

7
8
1 Introduction

1.1 Why reliability management?

Reliability management has always been of great importance with regard to

quality assurance measures of product development. Reason for that is the
fact that product nonconformities which are first identified by the customer
lead to significantly higher costs for corrective action than if they are
recognized prior to start of production – a long known fact! However, not
only costs are affected, the manufacturer’s image and levels of customer
satisfaction can also suffer. From this point of view, investment in
preventive work approaches for quality assurance is necessary. Thereby,
reliability assurance is an integral part of the product development process
prior to start of serial production. Legal regulations, such as the product
safety law in Europe, as well as the American standards must be complied
with. Any company will compare its products to those of the competition and
in the end, component/subassembly reliability must be adjusted to fit the
entire working life of the vehicle.

Within the scope of the current discussion regarding EU-wide extension of

guarantees to two years, the reliability work on our products is of
advantage. The application of reliability methods is very helpful to find
customer-oriented solutions that contribute to the reduction of repair and
material costs in car maintenance. For commercially used cars, another
aspect is that each failure and unplanned workshop stay limits the
availability and thereby reduces the economic efficiency of the vehicle for
the operator.

In consideration of the car manufacturer’s customer care efforts, all

systematic attempts to improve the level of safe usage are therefore very
important.

9
Figure 1 demonstrates the relationship of motives and tasks in reliability
management. Those who wish to apply the reliability work process properly
in their organization need convincing facts to advocate the increased
application of reliability methods. They require

− clear reasons
− a quick summary of methods
− retouch work expenditure that can be calculated
− no surprises for new production runs
− easy decision making
− costs that can be planned and achieved (including guarantee and fair
play costs)
− no delays

This manual claims to fulfill these expectations and wants to show that
properly applied reliability management concerns the entire organization. It
reduces development periods, contributes to product innovations and
promotes customer-oriented reliability.

10
 Motives Tasks

Image
• Positive purchasing
criteria
• A solid customer base
trusts the manufacturer

Innovation
• Transparency in the
project
• Comparison with
predecessor models
• Quality assurance • Market observation
during product
• Comparison of
development
competitiveness
Reliability • Estimating reliability
• Bench performance
Management test
Budget • Endurance test
• Product observation
• Control/Reduction of
• Field analysis
guarantee costs
• Damage analysis
• Reduction of change
costs

Marginal conditions
• Product liability and
safety
• Duty to observe the
market
• Environmental
regulations
• Guarantee period
- Long-term
behaviour
- Service life
- Post-guarantee
period
Early warning effects

Figure 1: Reliability Management: Motives and tasks

11
1.2 Quality - Reliability - Safety

The terms quality and reliability are often used as synonyms in day to day
language. For a better understanding, these terms will be explained again
repeating the definitions used. These two terms are supplemented by the
term “safety”.
Quality:
The definition of the DIN EN ISO 8402 is:
"The entirety of characteristics (and characteristic values) of a unit with
respect to its suitability to fulfill defined and expected requirements.”
To the customer, the quality of a product is the fulfillment of his requests.
He expects certain characteristics of the product and that the product is
ready and suitable for its use.
Reliability:
According to DIN 55 350, reliability is a subset of quality:
"Reliability is the part of quality in respect of the behavior of the unit during
or after set time periods under defined conditions of application."
Reliability strongly emphasizes the time aspect of quality. According to this
definition, the following details are needed to describe it:
• Failure modes
• Wear and tear
• Time period (Time in use, distance covered)

If the functional reliability is described quantitatively using probability, the

following statement results (VDI 4001 Sheet 2):
"Reliability is the probability that the unit observed does not fail during a
defined time period under given functional and environmental conditions."
Safety:
The standards do not offer a uniform definition. Similarly to reliability, safety
can be defined as follows in accordance with T. Pfeifer (Quality
Management § 2.2.2, ISBN 3-446-18575-8):
"Safety is the probability that the unit observed does not pose any danger
during a certain period of time (under defined operational conditions).”
In summary, it can be said: A product can be regarded as reliable if its
failures during its operational life are rare, and is safe if no functions and
failure modes pose any danger to mankind and environment.

12
Safety is again differentiated into two groups:
• Passive safety: The functions do not represent any
danger
• Active safety: Failure situations are controlled by
minimizing danger

The three terms ‘quality, reliability and safety’are therefore connected and
built on each other. They form a pyramid with quality as its base and body,
and safety as its peak. The different terms are not to be seen as contrasts
but as a unit. (Figure 2).

Safety

Reliability

Quality

Figure 2: Quality, reliability and safety as an integrated unit

13
2 Introduction and explanation

2.1 Working towards reliability during projects

Target group:

The explanations and comments of the following sections target those

persons involved in the tasks and contents of reliability management.

Contents on reliability management are explained and their scheduled

integration within the project process is demonstrated to management
(company leadership, project management), as well as to employees
dealing with certain sections.

Approach and aim:

The approach is to present the work contents of reliability management in

accordance with the project schedule.

This procedure enables the user to work on his project activities with
respect to reliability management in the form of a checklist.

The presentations and terms for a project schedule are taken from the VDA
series “Quality management in the automotive industry”, Volume 4, Part 3:
“Quality assurance prior to start of serial application”. The phases “Project-
independent pre-development” and “Production and use” have been added
or supplemented, compare Figure 3.

14
Task fields
Pre- Project-
develop- independent
ment pre-
developmen
t

Conception

Product development and

verification

Planning and verification of

production process

Product inspection
from the customer’s
perspective

Procurement of
production resources

Production and use

Continuous improvement process

0 A B C D E F G H

End of Project Approval Approval Approval Approval Approval Product Model

pre- inquiry/ for rough for for for for serial Review discontinu
deve- contract develop- detailed detailed procuremen productio -ation/dis-
lop- ment of develop- planning t and manu- n posal
ment product ment of of facture of
and product productio production
process n process resources

Milestones

Figure 3: Task fields and milestones in accordance with VDA

Volume 4.3

15
The task and work contents for reliability management are repeated for
every milestone (O-H), here: X, and are structured as follows:

x.1 Explanatory comments

x.2 Tasks regarding reliability work
x.2.1 Management tasks
x.2.2 Qualitative technical work approach
x.2.3 Quantitative technical work approach
x.2.3.1 Targets
x.2.3.2 Data basis and correlation
x.2.3.3 Technical simulation
x.2.3.4 Reliability assessment
x.2.3.5 Testing
x.2.3.6 Status
x.3 Reliability work with suppliers

The presentation of each milestone takes place initially in the form of a

summary, which is followed by a detailed description.

Aim of the following explanations is to provide the user with useful and
timely advice for project-related activities. Using the basic question:

WHO is to do WHAT, by WHEN and WHY?

The work contents regarding the reliability management are described per
milestone.

The checklist shown in Part: 5 Appendix provides assistance with the

processing of the tasks per milestone. Thereby, work contents and current
status can be documented.

Note:

The tasks concerning reliability in production including planning are

not discussed in detail as there is comprehensive literature available
regarding the subject of “safe processes” for production tools and
production processes.

16
Brief description of work contents:

x.1 Explanatory comments

WHAT is to stand/to be supplemented/to be done WHERE and by

WHEN?

x.1.1 Milestones represent project-dependent checkpoints fixed in time.

At these points in time, the respective project progress is
reviewed to identify deficiencies, if applicable, and to introduce
corrective actions, if necessary.

x.1.2 Phases describe the work contents in certain overlapping time

periods, compare Figure 3.

x.1.3 Design levels represent possible sub-groups of the product and

are described in Table 1.

x.1.4 Project documents, which incorporate the definition/specifications

of the tasks concerning reliability, are structured according to the
project process.

x.1.5 Technical documentation contains further necessary details.

x.1.6 Personal resources describe the employees required to perform

the tasks.

17
Design levels
System Subsystem Component Subassembly Piece part

Vehicle
Car body

Power train
Motor

Clutch

Gear
Case
Bearing cover
Drive shaft

Sealing ring

System – FMEA
Effect Failure Cause

Design – FMEA
Effect Failure Cause

Table 1: Examples for design levels

18
x.2 Tasks for reliability work

WHO is to do WHAT, by WHEN and WHY?

This main section describes in detail the scope of the tasks for the reliability
work. The contents of the task fields emerge in correspondence to the
project phases. The reference column shows cross-references to the
relevant sections of the VDA Volume 3, Part 2 (“Reliability methods and
tools).
A differentiation is made between the qualitative and quantitative work
approach.
x.2.1 Management tasks
In this section, the basic tasks in the individual project phases are
explained.
x.2.2 Qualitative technical work approach
In the qualitative work approach, the basic work methods and
their incorporation into the project process with regard to time are
stated.
This also includes the planning approach.
x.2.3 Quantitative technical work approach
The quantitative work approach describes the detailed targets
within the individual project phases. This approach is subdivided
into targets, data basis, risk calculation, technical simulation,
testing and status.
x.3 Reliability work with suppliers

WHO is to do WHAT, by WHEN and WHY?

If external suppliers are involved in the projects, they must be incorporated

into the reliability work. The resulting work scopes and requirements at the
interfaces are, where relevant, explained at the end of each milestone
description.
The tasks related to the individual milestones are repeated in the following
text within a related checklist and subsequently described in more detail.
With regard to the technical work approaches of the suppliers, the same
conditions apply as for the expert departments of the car manufacturers.

19
3 Project-related reliability management

The examined milestones O-H are subdivided into:

• Explanatory comments
• Reliability management tasks
• Reliability work with suppliers

The reference column contains the respective reference to volume

“Reliability methods”.

20
3.1 Milestone 0
Completion of pre-development

0 A B C D E F G H
Milestone Completi- Project Approval Approval Approval Approval Approval Product Model dis-
on of pre- inquiry/ For rough for detailed for detailed for plant for serial Review continuation/
develop- contract develop- develop- planning procure- production disposal
ment ment ment ment

Explanatory comments

0.1.1 Milestone · 0
0.1.2 Phase · Project-independent
predevelopment
0.1.3 Design level · Components
0.1.4 Project documentation · Drawings
0.1.5 Technical documents · ---
0.1.6 Personnel resources · Design engineers

0.2 Tasks for reliability work Reference

0.2.1 Management tasks · Within the scope of this phase,
normally no project-integrated
reliability work takes place. How-
ever, the foundation for the reliabi-
lity work must already be laid at
this point within the scope of pre-
development/research. Within the
scope of feasibility studies/analy-
sis, reliability should already be
considered.
0.2.2 Qualitative technical work approach
· see Milestone C.2.2
0.2.3 Quantitative technical work approach
0.2.3.1 Targets · Establish reliability data regarding 3.1
innovative components; compari-
son with base data
0.2.3.2 Data basis and correlation · Establish reliability risks of
innovations
0.2.3.3 Technical simulation · ---
0.2.3.4 Reliability assessment · ---
0.2.3.5 Testing · ---
0.2.3.6 Status · ---

0.3 Reliability work with suppliers

21
0.2 Tasks for reliability work

0.2.1 Management tasks

---

0.2.2 Qualitative technical work approach

See C.2.2

0.2.3 Quantitative technical work approach

0.2.3.1 Targets

Establish reliability data regarding innovative components;

compare to base data

As early as the pre-development phase, statements must be made

whether the innovative concept being targeted fulfills the basic
company targets (see A.2.1) with respect to reliability or whether
risks or improvement potentials, especially in comparison to the
predecessor model, still exist.

For this, project-independent reliability targets are needed for each

respective design level, which are based on the company targets
and the data of the proceeding models.

Approaches for targets are:

• Legal requirements
• Company’s ACTUAL-status
• Competition status
• Customer expectations

Generally, all targets and statements are based on the measured

reliability variables and parameters available within the
organization (see B.2.3.1).

22
0.2.3.2 Data basis and correlation

Establish reliability risks of innovations

In this early phase, a statement regarding reliability can only be

made by testing. Therefore, use is normally made of estimations
in comparison to the concept of the predecessor model and,
above all, theoretical methods of reliability predictions are relied
upon.

Components/characteristics relevant to safety are to be identified.

For these, quantitative risk analyses should, if possible, already
have been carried out at this point. For less critical scopes,
qualitative Design-FMEAs are recommended for the identification
of failure modes.

0.2.3.3 Technical simulation

---

0.2.3.4 Reliability assessment

---

0.2.3.5 Testing

---

0.2.3.6 Status

---

23
3.2 Milestone A
Project inquiry/contract

0 A B C D E F G H
Milestones Completi- Project Approval Approval Approval Approval Approval Product Model dis-
on of pre- inquiry/ for rough for detailed for detailed for plant for serial Review continuation/
develop- contract develop- develop- planning procure- production disposal
ment ment ment ment

A.1 Explanatory comments

A.1.1 Milestone ·
A: Project inquire/contract
A.1.2 Phase Design ·
A.1.3 Design level System ·
A.1.4 Project documentation ·
Specification (Complete vehicle)/
Target catalogue
A.1.5 Technical documentation · ---
A.1.6 Personnel resources · Project engineers

A.2 Tasks for reliability work Reference

A.2.1 Management tasks · Define market position regarding 3.1.2

reliability through company
management.
A.2.2 Qualitative technical work approach
---
A.2.3 Quantitative technical work approach
A.2.3.1 Targets · ---
A.2.3.2 Data basis and · ---
correlation
A.2.3.3 Technical simulation · ---
A.2.3.4 Reliability estimation · ---
A.2.3.5 Testing · ---
A.2.3.6 Status · ---

A.3 Reliability work with suppliers

24
A.2.1 Management tasks

Define market position regarding reliability through company

management

By means of the project contract, the company management

determines the framework for reliability targets. This creates the
operative reliability targets for the complete vehicle and its
components in the subsequent phase.
In order to be able to establish the technical targets for product
reliability (see B.2.1 and B./C.2.3.1), the importance of quality and
reliability within the company and for the individual project, as well
as the significance of reliability in relation to other product
characteristics must first be described. Legal requirements and
safety functions always have highest priority. It is also important
what customer requirements regarding reliability exist for the
respective product and what market position the company wants
to achieve.
This means, for example, that a company that puts quality
leadership in the foreground must also define higher reliability
targets than an organization favoring cost leadership.
It is also important that it becomes clear which priorities are given
to reliability under these aspects in comparison to other
performance characteristics, how demanding the chosen reliability
targets can be set and which resources are required and
ultimately available to achieve the set targets. The degree of
innovation, cost aspects, vehicle weight and time pressures are to
be brought in line with reliability.
It has to be considered, that the interest in the subject of reliability
reaches right to the level of comfort. Here especially, the stated
customer expectations play an important role. They can be
established using varied methods and analyses, e.g. classic
market research, benchmark analyses and customer surveys.
Customer expectations again depend on the market, brand
image, target group and state of the art technology.

25
 Prior to the development of the new product, important framework
conditions emerge which influence reliability targets:
• Competition analysis: Main competitor, strategies of the com-
petitors, possibilities for cooperation
• Product positioning: Customers, brand image, existing pro-
duct range
• Market: Sales area, country-specific positio-
ning, market volume and growth, legal
regulations
• Economic efficiency: Cost targets
• Global product Functionality, reliability, comfort, hand-
requirements: ling, visual impact etc.
• Production concept: Production site, logistics concept,
adjustment to predecessor product

A.2.2 Qualitative technical work approach

---
A.2.3 Quantitative technical work approach
---
A.2.3.1 Targets
---
A.2.3.2 Data basis and correlation
---
A.2.3.3 Technical simulation
---
A.2.3.4 Reliability estimation
---
A.2.3.5 Testing
---
A.2.3.6 Status
---

26
3.3 Milestone B
Approval for Rough Development

0 A B C D E F G H
Milestone Completi- Project Approval Approval Approval Approval for Approval Product Model dis-
on of pre- inquiry/ for rough for detailed for detailed plant pro- for serial Review continuation/
develop- contract develop- develop- planning curement production disposal
ment ment ment

B.1 Explanatory comments

B.1.1 Milestone · B: Approval for rough development

B.1.2 Phase · Design
B.1.3 Design level · System
B.1.4 Project documentation · Performance specification
(Complete vehicle)
B.1.5 Technical documents · Design instructions
B.1.6 Personnel resources · Design engineers, project
engineers, Controlling, Purchase

B.2 Tasks for reliability work Reference

B.2.1 Management tasks · Define quality goals for reliability 3.1.1

through company management
· Establish financial expenditure for
reliability work
· Plan scope of tasks for reliability
· Propose reliability methods
B.2.2 Qualitative technical work approach
· Perform strengths and 3.1.2
weaknesses analysis
B.2.3 Quantitative technical work approach

B.2.3.1 Targets · Define quantitative reliability targets 3.2

for system and subsystem and
document in detailed performance
specifications/supplier agreements
B.2.3.2 Data basis and correlation · ---

B.2.3.3 Technical simulation · Describe interfaces and CAE-

models at component level
B.2.3.4 Reliability estimation · Set up system model for reliability

B.2.3.5 Testing · ---

B.2.3.6 Status · ---

B.3 Reliability work with suppliers

· Carry out reliability planning

27
B.2.1 Management tasks

Establish quality goals for reliability through company

management

The company management defines the requirements for the

vehicles derived from the framework conditions (see A.2.) in the
customer’s works and, derived from that, the reliability targets
(see also B.2.3.1).

In this context, an important role is played by the company’s

strategies on:
• Servicing: Intervals, scope
• Warranty: Parts, time period, good will
• Recycling: Detailing of disassembly, compliance
with legal regulations
• Life cycle cost: See VDA Volume 3.2

Estimate financial expenditure for reliability work

In this section, the financial expenditure required to achieve the

reliability targets must be made clear.

The estimation is necessary in order to be able to make the

financial resources available for the subsequent project phases. It
must become clear that the achievement of the reliability targets
involves costs that must be stated and considered in the budget
planning at an early stage.

In this early project phase, the financial estimation can be carried

out using a relative approach. Hereby, reference is made to
defined total costs.

This way, e.g. the expenditure for measures ensuring quality

(quality costs) can be derived from the relation to turnover, 5-10%,
depending on the sector and extent of production.

In relation to that, the expenditure for the reliability work can be

estimated as a percentage of the total project costs.

28
A similar approach is to quote the expenditure for reliability as a
percentage of the predicted guarantee costs in relation to the
quality costs identified.

Basis of this procedure is the knowledge of the cost situation of

previously completed projects.

The relative approach for cost estimation is, however, not always
applicable for strategic targets of the company management, such
as:
• Improvement of image,
• Best in class,
• Fulfillment of customer expectations,
• Stronger customer commitment

Here, a strategic approach is required. In this case, company

management must provide the costs in accordance with the
strategic importance that has been apportioned.

Hereby, the budget specifications (cost targets) or first results

from the benchmark analyses for the strategic targets are to be
considered.

Plan scope of tasks for reliability

The existing quality plans of similar products in the company

(from the master plan up to the detailed inspection and test
specification), external and internal standards and regulations
form the basis for the task scopes.

For the approval for rough development, the tasks for the
reliability work must be planned individually for the project and
binding milestones must be established accordingly.

Thereby, the particularities of the respective project are to be

adjusted to the standard processes and solutions are to be
identified and agreed for bottlenecks, especially with respect to
deadlines and resources.

29
 Propose reliability methods

As the classic approach using matured design methods and

procedures, such as
• performance specification,
• calculation with established loads,
• proved design guidelines,
• early testing,

alone is no longer sufficient to ensure high product reliability,

additional analytic reliability methods must be applied.

These quantitative and qualitative methods help to establish or

predict reliability and its optimization.

While the quantitative calculation methods provide direct fre-

quency or probability values (base statistics, probability theory),
the qualitative methods establish possible defects and failures,
including their effect, based on the planned and systematic proce-
dure.

In this early project phase, the preventive and analytical approach

of this method is defined in its basis and instructions ensure the
continuous documentation of all activities regarding reliability.

This is the task of the company management and/or project

management.

It is the task of the specific departments to select and apply the

methods available in a targeted manner.

30
B.2.2 Qualitative technical work approach

Perform strengths and weaknesses analysis

The strengths and weaknesses analysis aims to create an

understanding of the customer’s expectations within the company
thereby ensuring the long-term competitiveness of the
organization. Part of the customer expectations relates to the
reliability of the product. This manifests itself in:
• Guarantee period
• Breakdown statistics
• Complaint statistics
• Benchmarks
• Competition analyses

The strengths and weaknesses analysis refers mainly to the

system and subsystem levels (compare Table 1). It compares the
results of the ACTUAL-analysis to the DESIRED-status and to the
specified company targets. The deviations show the weaknesses
of the system analyzed, which are then weighted and prioritized
according to their importance for the company. With regard to the
weak points, the result then contains:

• a description of the weak point

• a description of possible effects on the product and the
company
• a classification of the need for measures to implement
corrective actions
• proposals for corrective actions

These form the basis for the qualitative and quantitative reliability
analyses.

31
B.2.3 Quantitative technical work approach

B.2.3.1 Targets

Determine quantitative reliability targets for systems and

subsystems and document in detailed performance
specifications/supplier agreements

For the approval for rough development, targets for the complete
vehicle and the next system level are necessary which will
subsequently be broken down by the individual departments to
component, part and failure mode level. They will be described as
requirements in performance specifications and supplier
agreements.

Dependent on the effects of failures for the customer (with regard

to safety, breakdowns, limitations to use, etc.), different reliability
targets result for varying systems (e.g. brake, radio).

Complaint frequencies are normally parameters, which are related

to the distance covered or time in use (see VDA Volume 3.2), for
example from the guarantee or breakdown statistics. To
determine the targets, the environmental and marginal conditions
for use must be exactly defined. The same applies for the
required functional scopes as these form the basis for the
reliability requirements.

To establish the connection between the reliability information

from the product development process and the targets gained
from field data, it is helpful to have a measuring and parameter
system available. Only then is it possible to predict the feasibility
of the agreed or specified reliability targets during the course of
the project with sufficient accuracy.

Such systems for reliability are currently not available in

companies, however, they are gaining in importance considering
decreasing error rates and therefore a greater difficulty for
statistical verification within the project.

32
 Some comments regarding necessary requirements are therefore
made in the following:
The system should
• consider all relevant reliability data (compare G.2.3.2),
• be detailed across all constructive levels and indicate deficits
or problems,
• allow reliable statements regarding variance comparisons in
the development, as well as in the production and utilization
phase.
Type and significance of the available information differ
substantially across the project and product phase. Therefore, it
is, in most cases, impossible to make a comprehensive statement
using just one parameter (such as degree of innovation, number
of identified or processed technical problems, etc.).
Only the connection of all relevant information sources to one
logical parameter system will provide a universal evaluation tool
across project and production phases and various decision levels
requiring detailed information for analysis or strongly condensed
presentations.

B.2.3.2 Data basis and correlation

---

B.2.3.3 Technical simulation

Describe interfaces and CAE-models at component level

A description of the interfaces of all components with neighboring
functions (e.g. input and output signals, forces, etc.) and the
surrounding environment (e.g. temperature, forces, electric
tension, etc.) is required in all physical dimensions to establish the
requirements, loads and capacities. These result in the influences
for individual components relevant to reliability as a basis for the
test parameters of the reliability testing and for the CAE-models
required in the future.

The detailed development can thereby be performed in a more

targeted manner. With the help of the CAE-modeling, critical
influences can be selected and subjected to a more detailed
analysis.

33
 The input parameters for the reliability system model and the
qualitative analyses (see B, C, D, E 2.3.4) are the same critical
influences.

In the project, the space and the expenditure must be held

available which the departments require to carry out this work
systematically. Verification of systematic work is to be requested
from the project manager.

B.2.3.4 Reliability estimation

Set up system model for reliability

With the knowledge of the interface requirements and capacities

of the components, the failure probabilities of the components can
now be estimated.

In order to determine the reliability or failure probability of the

complete vehicle from this, all individual probabilities are to be
considered and connected in a system model.

Calculation programs must be made available in this project

phase through purchase or internal preparation.

In terms of content, the modeling for this milestone is to be

roughly established at the level of the complete vehicle and to be
tested with existing data of individual components (from e.g. risk
analyses of standard components, field data of the predecessor,
etc.).

B.2.3.5 Testing

---

B.2.3.6 Status

---

34
B.3 Reliability work with suppliers

Carry out reliability planning

In the design phase, the car manufacturer has first discussions

with the (pre-) selected supplier regarding necessary reliability
assurance measures. An open and trusting cooperation brings
advantages for both sides, e.g. a smooth start for new serial
products. Required measures to achieve reliability assurance are
performed by both the customer and the supplier and are adjusted
to each other.

The customer must inform the supplier in a timely, sufficient and

clear manner with respect to the reliability requirements. The
supplier has the duty to address any identifiable information
deficiencies immediately and of his own accord.

Normally, this information exchange will refer to the design level

components, subassemblies and parts (performance
specification, agreements). Thereby, higher level implies greater
reliability responsibility for the supplier.

System suppliers with design responsibility will therefore perform

activities that were formerly executed by the car manufacturer.
Those reliability activities that will, according to mutual agreement,
be taken over by the supplier will also be incorporated in his
project schedule.

Occasionally, reliability requirements derived from a predecessor

product are already available to the manufacturer at this stage. In
that case, they also have to be described qualitatively and
quantitatively in the performance specifications and notified to the
supplier. In other cases, the determination of reliability
responsibilities and methods will only be possible at a later project
phase (see C.2.3). However, the supplier should always request
these special performance specifications.

35
3.4 Milestone C
Approval for detailed development

0 A B C D E F G H
Milestones Completi- Project Approval Approval Approval Approcal Approval Product Model dis-
on of pre- inquiry/ for rough for detailed for detailed for plant for serial Review continuation/
develop- contarct develop- develop- planning procure- production disposal
ment ment ment ment

C.1 Explanatory comments

C.1.1 Milestone · C: Approval for detailed development

C.1.2 Phase · Product design and verification
C.1.3 Design level · Subsystems
C.1.4 Project · Specifications
documentation
C.1.5 Technical · Design instructions, design documents
documents
C.1.6 Personnel · Design engineers, project engineers,
resources Controlling, Purchase

C.2 Tasks for reliability work Reference

C.2.1 Management tasks · Determine financial expenditure for
reliability; describe use of resources
C.2.2 Qualitative · Perform strengths and weaknesses 3.1.2
technical work analysis; translate findings into action
approach · Perform classification analysis
4.2.1
. Perform System-FMEA for subsystems
4.2.2
C.2.3 Quantitative technical work approach
C.2.3.1 Tasks · Define quantitative reliability targets for 3.2.2
components and document in detailed
performance specifications/supplier
agreements
C.2.3.2 Data basis and ---
correlation
C.2.3.3 Technical · Complete CAE-modeling for simulation
simulation analysis
C.2.3.4 Reliability estimation · Improve reliability system model
C.2.3.5 Testing · Specify testing principles 3.2.1
C.2.3.6 Status · ---

C.3 Reliability work with suppliers

· Define and agree quantitative reliability
targets and verification procedures, as well
as qualitative methods (in QAA)
· Establish performance specifications for
components and subassemblies

36
C.2.1 Management tasks
Determine financial expenditure for reliability work and
describe use of resources
The financial expenditure estimated in the preceding step must be
specified in detail for this milestone. Basis for this is the
requirement for:
• personnel,
• equipment,
• internal/external services.
By specifying the required bench performance test, verification
procedures, test conditions and duration, resources can be
determined and thus the financial expenditure can be described.
The functional and environmental conditions must be stated and
defined in the performance specification.

C.2.2 Qualitative technical work approach

Perform strengths and weaknesses analysis and transfer
findings into action
The measures resulting from the strength/weakness analysis are
broken down to design level ‘Components’, e.g. motor, and are
included as targets in the qualitative and quantitative reliability
analyses.
Perform classification analysis
The classification analysis as a decision making tool for
management serves to determine the depth of analysis for
components and lower design levels. This, in turn, determines the
resulting expenditure of the qualitative and quantitative reliability
procedures.
The procedure for the classification analysis is shown in Figure 4.
The decisive criteria for this are:
• degree of severity
• complexity
• degree of innovation
• experience
and are detailed in the following.

37
 Increasing degree of severity

Medium degree of High degree of Critical degree

Low degree of severity
severity severity of severity

yes yes
High High
complexity? complexity?

no no

High yes High yes High yes

innovation? innovation? innovation?

no no no

yes Fleet yes Fleet

experience? experience?

no no

Prepare summarizing Describe Prepare qualitative Detailed qualitative and

assessment of the experiences from analysis of safety quantitative safety and
inconveniences for existing models and evaluation and reliability reliability assessment
the user justify comparability update

Increasing analytical depth

Figure 4: Classification analysis

38
The degree of difficulty differs with respect to the effects of an
operational failure as described in Table 2.

Degree of Description Part Example Consequence

severity for the customer

Critical In case of an Passive or Steering or Accident

operational active safety wheel
failure, there is part; part with suspension
a direct danger DrsA* defect, tire
to life and limb damage, break
for vehicle users system defect,
or other road airbag defect
users

High Extensive Risk part; Part Jamming of Breakdown with

damage to the with DrsA* piston, catalyst immediate stay
vehicle, damage at the workshop
environment or
violation of a
law must be
expected.

Medium Main function Standard part Battery failure, Breakdown with

(transport) is not tearing of the V- repair at site;
fulfilled. belt, loss of immediate stay
internal coolant at the workshop
required
(Emergency
service)

Low Result is a Standard part Artificial interior Unplanned stay

reduction of lighting, radio at the workshop
functionality for failure
the comfort
functions or a
redundancy
function

= DrsA: Documents requiring special archiving in accordance with VDA Volume 1,

2nd Edition

Table 2: Definition of the four degrees of severity

The complexity is determined by the number of interlinked

functions and their interactions.

39
 The degree of innovation is assessed according to the following
criteria:
• Innovative development
• New design
• New materials
• New production procedures
• Different operating conditions
• No similar products available

The classification analysis is based on the experiences and

results of other pre-analyses, such as:
• System analysis and functional analysis
• QFD (Quality Function Deployment)
• Risk analysis
• Fault Tree and Event Tree Analysis
• Analysis of predecessor systems

For safety parts, a full reliability assessment with qualitative

analyses and quantitative specifications of the reliability
parameters has to be carried out. For components and functional
influences, which cannot be reliably determined, the criteria for a
failure with safe ending or survival must be applied after several
operational periods (Factor 2-4).

As can be seen from the diagram, qualitative and quantitative

reliability analyses (e.g. System-FMEA) are to be carried out for
systems and components with a high degree of innovation.

Perform System-FMEA for subsystems

The FMEA, System- and Design-FMEA (compare Table 1), is an

indispensable tool of any structured design process. Due to the
high demands on the product (e.g. low failure quota) with high
complexity at the same time, a systematic assessment of the
possible system failures based on the functional links must be
carried out. Interfaces with the system environment also have to
be tested.

This can be done in the form of a System-FMEA (see VDA 4, Part

2) which, at this stage, will provide a preliminary result.

40
 The first steps are executed:
1- System elements and system structure
2- Functions and functional structures
3- Fault analysis (Failure mode, cause, effect)
4- Risk assessment

The System-FMEA changes into the Design-FMEA (e.g.

subassemblies) at the lower system levels. The transition is
smooth.

The system elements with their structure and functions in

connection with the interplay of the system elements and the
external marginal conditions are input. The functional analysis can
be presented in form of a table, tree structure and affinity diagram
or function block diagram.

The possible main failure events at system level which are to be

considered when processing the next level, as well as the preliminary
risk analysis identifying failure mode fields and an action plan are
output.

C.2.3 Quantitative technical work approach

C.2.3.1 Targets
Define quantitative reliability targets for components and
document in detailed performance specifications/supplier
agreements

As a result of the risk and classification analyses at system level,

those functional links between the component with high reliability
relevance emerge.

On this basis,
• the interface requirements (functional and environmental
conditions) are defined,
• the detailed reliability targets at component level are derived
and
• documented in detail as targets in the performance
specifications and supplier agreements.

The marginal conditions specified by legislation, market and

customer requirements always form the basis for establishing the
targets and respective protection procedures. It has to be
41
 considered that these do not stay the same from project to project
but change continuously due to competitive and social
requirements.

Today’s reliability requirements for a complete vehicle, mean

extremely low failure and complaint frequencies at component
level, see also PPM targets (C3).

C.2.3.2 Data basis and correlation

---

C.2.3.3 Technical simulation

Complete CAE-modeling for simulation analyses

Basis of a meaningful calculation is the full modeling with

quantitative description of the parameters. In this phase of the
project, the respective data is only available in form of rough
estimates:

Target values are known for the complete vehicle and detailed
field data regarding the predecessor model is available for
individual components, however, the functional interface
description in connection with the component performance
specifications are only in development.

Even the system analyses to be performed (FMEA, amongst

others) only provide initial individual information.

A prompt and precise specification of the data is however

prerequisite to determine the critical stress situations in simulation
analyses in time.

Points of emphasis in the analysis of the following detailed

development must be adjusted to these results.

42
C.2.3.4 Reliability estimation
Improve reliability system model

The existing reliability information can only provide a basic

structure (compare C.2.3.3) which needs to be completed with the
help of estimations in order to become a comprehensive model.

Within the interplay of test, analysis, simulation and design, the

description of requirements and capacities becomes more and
more complete.

The progressing knowledge regarding the reliability of the

individual components allows a refinement of the system model
and provides increasingly precise statements for the reliability
forecast of the complete vehicle.

C.2.3.5 Testing
Specify test principles

The known critical operating status and that established in the

model are now included in the specification of the testing
principles which, in the end, are aimed at reducing the failure
frequencies.

The definition of the basic testing procedure is necessary at this

point in time, so that the detailing of the test plan can be carried
out in the subsequent phase.

The project-specific results must be analyzed and form the basis

for testing.

In addition to this, standard processes for testing have emerged in

the companies from experiences and targets. Considering the
incomplete state of knowledge in this project phase, these cannot
be ignored.

C.2.3.6 Status
---

43
C.3 Reliability work with suppliers
Define quantitative reliability targets and agree verification
procedures, as well as qualitative methods (in QAA)

The reliability targets of the car manufacturer are often notified to

the supplier by formulating them as requirements. This can
happen, e.g. in form of Quality Assurance Agreements (QAA)
which are accepted and signed by both parties and thus have
contractual character. Such agreements contain the following
important points:
• The clear and full description of the required reliability,
• The specification of the reliability characteristics and
DESIRED-values to be fulfilled and
• The application of specified reliability analysis methods.

Thus, in this phase of product development, an intensive

exchange of information (e.g. field data) between the car
manufacturer and the supplier is also necessary with respect to
reliability to ensure the required quality of the series already in the
pre-project phase. The suitable reliability methods will be
determined by both partners.

Establish performance specifications for components and

subassemblies

The car manufacturer establishes performance specifications

for the two highest design levels (compare Table 1). He thereby
creates the basis for reliability requirements for the supplier
regarding the component and subassembly levels. So now, for
example, the reliability requirements for the vehicle or car body,
running gear and power train can be broken down to components
such as motor and gear or subassemblies, e.g. gearbox casing.

The reliability tests, as well as other reliability requirements, are

normally defined in the specifications for supplied products.

44
The customer has to provide the time schedule and the applicable
wear and tear/load for the tests to be performed on serial supply
in the form of test specifications.

The required measuring and test equipment, as well as testing

devices are to be agreed between customer and supplier.

Car manufacturers principally include reliability requirements in

their zero-defect philosophy within the scope of their quality
strategies for supplied parts.

In this respect, the common PPM-targets offer an approach for

components and subassemblies, i.e. only a few faulty units, with
respect to one million units supplied, are accepted. The PPM-
targets are defined as so-called “delivery quality” at 0 km and/or as
field failures within a certain period of time, in which the vehicle is
already with the customer.

Other reliability requirements can be, e.g.:

• Failure per vehicle depending on time in use or distance
covered,
• Complaint frequency for parts, aggregates or vehicles up to a
certain time in use or distance covered (long-term target)

These reliability targets for suppliers are to be specified in the

development phase and to be documented in the performance
specifications, as well as in drawings and technical terms of
delivery.

One possibility for verifying the completeness of reliability

data is the checklist shown in Table 3. It helps car manufacturers
and suppliers to review whether all aforementioned data generally
needed regarding reliability requirements is complete.

45
 Evidence
Drawing,
Data complete (Performance)
Cont. yes no specification etc.
No. Data required
1 Reliability requirements
- Reliability characteristic
- Description/Definition „Failure“
- Description failure distribution
D.: t0, t 1, t 10, b)
2 Specification of reliability test
2.1 Test specification
– time schedule
- wear and tear required
2.2 Measuring and test equipment, testing
device
- The same test equipment, testing device
- Agreement concerning differing
measuring and test equipment
- Agreement concerning differing testing
devices
3 Comparison: Measuring and test
results/field data
- Field data available
- Agreement concerning the data transfer
to supplier
4 Other

Table 3: Checklist for verification of completeness of

required reliability data

46
3.5 Milestone D
Approval for detailed planning - Production process

0 A B C D E F G H
Milestones Completi- Project Approval Approval Approval Approval Approval Product Model
on of pre- inquiry/ for rough for detailed for detailed for plant for serial Review discontinu-
develop- contract develop- develop- planning procure- production ation/
ment ment ment ment disposal

D.1 Explanatory comments

D.1.1 Milestone · D: Approval for detailed planning

Production process
D.1.2 Phase · Product development and
verification
D.1.3 Design level · Components
D.1.4 Project documentation ---
D.1.5 Technical documents · Design instructions, design
documents
D.1.6 Personnel resources · Design engineers, project
engineers

D.2 Tasks for reliability work Reference

D.2.1 Management tasks · ---
D.2.2 Qualitative technical work approach
· Carry out System-FMEA for 4.2.2
components
· Establish fault tree analysis 4.2.3
D.2.3 Quantitative technical work approach
D.2.3.1 Tasks · ---
D.2.3.2 Data basis and · Evaluate test data, state current 5.3
correlation ACTUAL-reliability; determine
reliability growth 5.5
D.2.3.3 Technical simulation · ---
D.2.3.4 Reliability estimation · Simulate reliability data with known 4.3.4
components
D.2.3.5 Testing · Determine test plans and reliability 5.2
test programs
D.2.3.6 Status · Provide evidence that the reliability
targets can be achieved

D.3 Reliability work with suppliers

47
D.2.1 Management tasks

---

D.2.2 Qualitative technical work approach

Carry out System-FMEA for components

The System-FMEAs are carried out at component level. Potential

failures are identified.

Establish fault tree analysis

The fault tree analysis (DIN 25424) is particularly suitable when a

significant failure event - such as the failure of the braking effect
or unsuccessful starting of the vehicle – with all its ramifications of
possible causes is to be assessed at system level.

The following steps are executed:

• Determination of the undesired event and failure criteria
• System analysis
• Determination of the component’s failure modes
• Preparation of the fault tree (top-down procedure in contrast to
bottom-up in the FMEA)
• Evaluation of the fault tree

The logical links of the undesired event with the failures of the
parts system and subassemblies are presented with the following
aims:
• Systematic identification of all possible failure combinations
• Establishing of reliability parameters, such as failure probability
or availability: for this, the relevant reliability parameters for the
fault tree input must be determined.

48
 Beside the OR-link used in the FMEA, AND-links and inversions
can be shown which provides advantages compared to other
procedures. The fault tree analysis can be used in a descriptive
and calculating form. The final step is the evaluation with the
following results:

• Listing of all failure combinations that result in an undesired

event.
• Establishing the most critical failure combination that results in
the undesired event.
.
• Evaluating the frequency with which the undesired event
occurs.

Corrective actions must be specified for the most critical failure

combinations with the respective failure causes. These can be
further processes in the FMEA.

D.2.3 Quantitative technical work approach

D.2.3.1 Targets

---

D.2.3.2 Data base and correlation

Evaluate test data; present current ACTUAL-reliability

As the results gained from hardware analysis are still incomplete

at this stage, all information from analyses, system models and
similarity assessments with known components is to be used.

This way, the current reliability status can be illustrated in com-

parison to the target.

In case of nonconformities, targeted measures are to be identi-

fied.

49
 Determine reliability growth

The test with hardware (“qualification/improvement of prototypes”)

often shows that in this phase the reliability of complex systems
lies way below the predicted value. The failure causes are to be
identified by means of systematic analysis and corrective actions
are to be provided. The achieved reliability improvement must be
constantly followed to monitor the approximation towards the
specified values. Thereby, a measure for the effectiveness of the
reliability program is gained and corresponding calculations
regarding the reliability level to be expected can be carried out.

The concept of Reliability Growth Management (RGM) is suitable

for planning, monitoring and visualizing reliability during
development (see VDA Volume 3, Part 2, Chapter 5.5).

D.2.3.3 Technical simulation

See D.2.3.4

D.2.3.4 Reliability estimation

Simulate reliability data with known components

Parallel to the preparation and improvement of the CAE-models,

suitable programs must be provided which enable the link
between the physical simulation (CAE) and the probability
calculation for reliability.

These calculations can be used to optimize the component

reliability by varying the input quantities. For this, all data from
hardware tests and results of qualitative analyses are used.

50
D.2.3.5 Testing

Specify test plans and reliability test programs

Reliability targets, results of the reliability analysis and the current

project status determine the test plan which contains the detailed
programs for reliability testing with all conditions to be fulfilled
(loads, environmental conditions, quantities).

Small sample sizes and short time spans require the application
of acceleration methods. For a summary of the various methods
see VDA Volume 3.2, Chapter 5.4.

D.2.3.6 Status

Provide evidence that reliability targets can be achieved

To be able to start the detailed planning of the production

process, a statement by all affected departments regarding the
achievability of the targets is required for the present product
concept. Any necessary concept changes must be identified
here.

This also applies to the reliability targets.

This does not mean, that the targets need to be achieved by this
stage, but that it is verified that the achievement of the targets
through agreed measures within the remaining development
period is guaranteed.

In the subsequent project phases, the verification is to be

constantly updated until the achievement of the targets for serial
application is confirmed.

If necessary, the concept of Reliability Growth Management

(RGM) is to be applied for planning, monitoring and visualizing
reliability during development (see VDA Volume 3.2, Chapter. 5).

51
3.6 Milestone E
Approval for plant procurement

0 A B C D E F G H
Milestones Completi- Project Approval Approval Approval Approval Approval Product Model dis-
on of pre- inquiry/ for rough for detailed for detailed for plant pro- for serial Review continuation/
develop- contract develop- develop- planning curement production disposal
ment ment ment

E.1 Explanatory comments

E.1.1 Milestone · E: Approval for plant procurement

E.1.2 Phase · Product development and
verification
E.1.3 Design level · Components, subsystem
E.1.4 Project documentation · ---
E.1.5 Technical documents · Design instructions, design
documents
E.1.6 Personnel resources · Design engineers, project
engineers

E.2 Tasks for reliability work Reference

E.2.1 Management tasks

E.2.2 Qualitative technical work approach
· Carry out System- and Design- 4.2.2
FMEA (components and
subsystems); minimize failure
modes
E.2.3 Quantitative technical work approach
E.2.3.1 Tasks · ---
E.2.3.2 Data basis and correlation · ---
E.2.3.3 Technical simulation · ---
E.2.3.4 Reliability estimation · Carry out forecasting 5.6
5.4.3
4.3.4
E.2.3.5 Testing · Carry out reliability tests at the test 5.4
benches (loads) and in driving
mode
E.2.3.6 Status · Complete reliability verification for
partial scopes

E.3 Reliability work with suppliers

· Run tests on supplier samples

52
E.2.1 Management tasks

---

E.2.2 Qualitative technical work approach

Carry out System- and Design-FMEA (subsystems and

components); minimize failure modes

The System-FMEAs and Design-FMEAs are carried out at the

lower design levels (bottom-up). Potential faults are identified and
through respective measures their causes are eliminated, the
probability of their occurrence reduced, the probability of their
identification increased or the effects lowered.

The optimization process starts at high-risk priority values. Potential

faults with high ratings within the individual parameters are to be
treated and evaluated separately.

A target for the maximum risk priority value to be achieved in the

next phase is established.

E.2.3 Quantitative technical work approach

E.2.3.1 Tasks

---

E.2.3.2 Data base and correlation

---

E.2.3.3 Technical simulation

---

53
E.2.3.4 Reliability estimation

Carry out forecasting

Based on the hardware tests and the improved model

calculations, more and more precise calculations to forecast the
overall reliability of the vehicle in the customer’s use are possible.

E.2.3.5 Testing

Carry out reliability tests at test benches (loads) and in

driving mode

The test program must provide test statements for the final
optimization loop for this phase and the confirmation of the target
achievement in the following phase.

E.2.3.6 Status

Complete reliability verification for partial scopes

When releasing to plant procurement, it must be ensured that no

basic reliability problems can occur which would require the
changing of the production concept.

The statements made based on the mathematical simulations

must therefore be verified with the help of evidence gained from
hardware tests in accordance with the agreed test program and,
therewith, provide the starting points for the “final polish”,
guaranteeing the achievement of the targets by the start of series.

54
E.3 Reliability work with suppliers

Carry out tests on supplier samples

During the product development phase prior to Approval for plant

procurement and, if required, even in the previous phase,
reliability-relevant tests are carried out on samples/prototypes at
the supplier and car manufacturer. Prior to that, the partners
agree who will perform which inspections and tests. The supplier
will often carry out bench performance tests, if necessary with
acceleration effect while the car manufacturer already obtains first
field data through prototype testing (endurance tests). Samples
and prototypes must already fulfill important functional reliability
requirements while reliability requirements oriented towards the
production process can normally not be evaluated yet.

When reliability problems occur during testing or in the field,

improvement measures must be established quickly. For this, the
available information, test and field data, as well as rejected parts
are to be exchanged objectively. It is useful for the customer and
supplier to jointly examine the damages.

55
3.7 Milestone F
Approval for serial production

0 A B C D E F G H
Milestones Completi- Project Approval Approval Approval Approval Approval Product Model dis-
on of pre- inquiry/ for rough for detailed for detailed for plant for serial Review continuation/
develop- contract develop- develop- planning procure- production disposal
ment ment ment ment

F.1 Explanatory comments

F.1.1 Milestone · F: Approval for serial production

F.1.2 Phase · Product development and
verification
F.1.3 Design level · Subsystem, system
F.1.4 Project documentation · ---
F.1.5 Technical documents · Design instructions, design
documents
F.1.6 Personnel resources · Design engineers, project engineers

F.2 Tasks for reliability work Reference

F.2.1 Management tasks · ---
F.2.2 Qualitative technical work approach
· Update System- and Design-FMEA 4.2.2
F.2.3 Quantitative technical work approach
F.2.3.1 Tasks · ---
F.2.3.2 Data basis and correlation · ---
F.2.3.3 Technical simulation · ---
F.2.3.4 Reliability estimation · ---
F.2.3.5 Testing · ---
F.2.3.6 Status · Verify achievement of reliability
targets

F.3 Reliability work with suppliers

· Carry out tests on suppliers’first
samples

56
F.2 Tasks for reliability work

F.2.1 Management tasks

---

F.2.2 Qualitative technical work approach

Update System- and Design-FMEA
Based on the measures implemented for risk elimination or
reduction, all FMEAs are updated at all levels and the new risk
priority figures are reviewed with regard to their target
achievement. If necessary, additional loops are performed at
individual points to minimize risks.
The fault tree analyses carried out previously are revised and
newly evaluated based on the measures performed.

F.2.3 Quantitative technical work approach

F.2.3.1 Targets
---

F.2.3.2 Data base and correlation

---

F.2.3.3 Technical simulation

---

F.2.3.4 Reliability estimation

---

F.2.3.5 Testing
---

F.2.3.6 Status
Verify achievement of reliability tasks
The affected departments are responsible for ensuring that the
specified reliability targets are achieved or, in case of deviations,
the degree of target achievement is documented.

57
F.3 Reliability work with suppliers

Carry out test on suppliers’first samples

In this phase, where first samples are produced and tested, the
supplier normally verifies compliance with most of the reliability
requirements during first sample testing. If this cannot be realized
for certain reliability characteristics, e.g. due to insufficient testing
time or no possibility for testing, then a mutual agreement has to
be made accordingly. Thus, a date by which the supplier will
provide the missing results can be agreed. However, it is often
also agreed that the customer will test special reliability
requirements for the supplied product within the scope of the
overall vehicle inspection (e.g. summer or winter test).

Critical reliability-relevant findings obtained from these tests can,

at this stage, still be included in the inspection and test plans for
serial production at the supplier.

58
3.8 Milestone G
Product Review

0 A B C D E F G H
Milestones Completi- Project Approval Approval Approval Approval Approval Product Model dis-
on of pre- inquiry/ for rough for detailed for detailed for plant for serial Review continuation/
develop- contract develop- develop- planning procure- production disposal
ment ment ment ment

G.1 Explanatory comments

G.1.1 Milestone · G: Product Review

G.1.2 Phase · Manufacture and use
G.1.3 Design level · System
G.1.4 Project documentation · ---
G.1.5 Technical documents · Production evaluation
G.1.6 Personnel resources · Design engineers, quality
engineers, customer service
engineers

G.2 Tasks for reliability work Reference

G.2.1 Management tasks · Ensure field observation and 7.2.1 7.2.2
technical support of series
G.2.2 Qualitative technical work approach
· Revise System-FMEA and fault 4.2.2
tree analysis 4.2.3
G.2.3 Quantitative technical work approach
G.2.3.1 Tasks · ---
G.2.3.2 Data basis and correlation · Evaluate field data 7.3.1, 7.5
· Analyze correlation test/field data 7.6, 8.2
8.3
G.2.3.3 Technical simulation · ---
G.2.3.4 Reliability estimation · ---
G.2.3.5 Testing · Determine or use reliability tests
accompanying production
G.2.3.6 Status · ---

G.3 Reliability work with suppliers

· Review reliability characteristics
during serial production

59
G.2.1 Management tasks

Ensure field observation and technical support of series

Ensure reliability support in the series

The companies must have knowledge of the complaint

characteristics and field data of their products on the market. In
order to obtain this field data, the organizational, financial and
personnel framework is to be established in customer support.

The product safety law from 1997 obliges the companies to

monitor the market, i.e. to continue to monitor the products after
their introduction to the market (“Product monitoring duty”).

With the help of the analytical field data, the predicted reliability
can be compared and the targets for subsequent products can be
improved.

The customer service ensures that the field information (data,

parts) is made available to the responsible (analyzing)
departments.

G.2.2 Qualitative technical work approach

Revise System-FMEA and fault tree analysis

Based on the experience and knowledge from the field results, the
System-FMEAs and fault tree analyses are reworked and the risk
priority figures are revised. If the targets are exceeded,
redevelopment and rework of individual components is carried out
during serial production.

The results will also be considered for new developments.

G.2.3 Quantitative technical work approach

G.2.3.1 Tasks

---

60
G.2.3.2 Data base and correlation

Evaluate field data

Analyze correlation test/field

Only in the product application phase is it possible to compare the

predicted failure behavior with the actual failure behavior in the
field. This allows the correlation between test and field data to be
examined.

Comparison criteria here are e.g. service life characteristics.

Distance covered, time in use, number of load changes, number
of applications etc.

The comparison of the ACTUAL/DESIRED-data serves to

introduce suitable corrective actions in case of significant
nonconformities.

Primary reliability estimation data is required for the prognosis, as

well as the feedback customer => manufacturer.

Depending on the object and motive of analysis, differing data

sources can be used (see Table 4: Reliability data).

With regard to the form of application, the data of the varying

information systems can be divided into data types:

1. Master data
= Data with product-specific information, e.g.:
Manufacturer
Production site
Date of manufacture
Equipment or design details: Model, type etc.
Batch no.

61
 2. Event data
= Data regarding failure behavior and frequency, e.g.:
Service life characteristic: Time in use, distance covered,
number of load changes, or similar operating conditions
(Area of application for differing markets)
Symptomatology
Dates: Commissioning, repair, repeated repairs, type of
damage, component causing the damage

3. Reference quantities
= Data for comparison in statistical analyses and risk
estimations, e.g.:
Production figures
Sales figures
Registration figures
Spare parts sales

62
 Data source Object/motive for analysis Data type
Guarantee data/parts Vehicles within their Master data
through sales guarantee period Event data
Damage analysis by
Quality Assurance
Field assessments/tests Preventive parts assessment Master data
and damage analysis by in case of concrete Event data
Quality Assurance suspicions
Test bench data from Comparison bench Master data
development, laboratory performance parameter/ Event data
service life characteristic
Field
Test/ confirmation run Pilot/Pre-production vehicle Master data
data from development, Event data
damage analysis by
Quality Assurance
Complete vehicle life Vehicles outside the Master data
cycles of leasing guarantee period Event data
companies, fleet owners Long-term behavior,
damages without guarantee
claims (e.g. damages from
accidents as potential cause
for consequential damages)
Breakdown statistics of Breakdown; Event data
ADAC, ACE Frequency/cause
Main examinations Focus of complaints Event data
TÜV-Report, DEKRA regarding older vehicles
Market research, surveys, Consumer Event data
observation, experiment by behavior/intentions,
service providers establishing performance
capability
Complaints to third parties Complaints outside the Event data
through KBA, specific customer/manufacturer
media, e.g. Internet relationship
Product monitoring duty
Production data of Registration of volume Reference
controlling product lines fluctuations in production quantities
Spare parts data from Spare parts sales/stocks Reference
central store, sales quantities
centers
Sales figures from the Market-specific differences Reference
sales and marketing quantities
department
Outline/environmental Registration figures, vehicle Reference
data from the Federal stocks quantities
Statistical Office, KBA

Table 4: Reliability data

63
G.2.3.3 Technical simulation

---

G.2.3.4 Reliability estimation

---

G.2.3.5 Testing

Determine or use reliability tests accompanying production

Tests accompanying production can be subdivided into tests

within the framework of series monitoring and tests on production
process control.

While in the first case evidence has to be provided that the targets
for the product are complied with by means of law, valid standards
or company guidelines, the test results, in the second case, are
used to control the running production process.

Production-accompanying statements regarding the current

reliability status can be obtained with the help of service life
characteristics of components/subassemblies resulting, e.g. from
bench performance tests. This allows the reliability target to be
checked in the form of a product/subassembly review (product
audit).

If, based on field observations, modifications to improve compo-

nents/subassemblies have to be incorporated, the effectiveness of
measures is to be verified using accelerated tests.

Beside the specification of functional and marginal conditions, the

target to carry out the tests until the defined limits are reached is
decisive for testing.

G.2.3.6 Status

---

64
G.3. Reliability work with suppliers

Review reliability characteristics during serial production

After start of serial production, the supplier has to ensure that the
agreed reliability characteristics are subjected to a regular series
review. The production and testing devices are also to be
monitored in a regular, sufficient and provable manner.

If possible, it should be agreed in the supply contract that the

supplier gets access to the customer’s field data – if available.
Especially when supplied parts fail at the end user, the supplier
has the right to get all field information, insofar as the customer
has knowledge of it.

65
3.9 Milestone H
Model discontinuation/disposal

0 A B C D E F G H
Milestones Completi- Project Approval Approval Approval Approval Approval Product Modell dis-
on of pre- inquiry/ for rough for detailed for detailed for plant for serial Review continuation/
develop- contract develop- develop- planning procure- production disposal
ment ment ment ment

H.1 Explanatory comments

H.1.1 Milestone · H: Model discontinuation/disposal

H.1.2 Phase · Manufacture and use
H.1.3 Design level · System
H.1.4 Project documentation · ---
H.1.5 Technical documents · ---
H.1.6 Personnel resources · Design engineers, quality
engineers, customer service
engineers

H.2 Tasks for reliability work Reference

H.2.1 Management tasks · Verify analysis of field data at 7.2.1
disposal companies 7.2.2
7.2.3,
7.3.1
7.3.2
7.3.3
7.3.4
H.2.2 Qualitative technical work approach
H.2.3 Quantitative technical work approach
H.2.3.1 Tasks ---
H.2.3.2 Data basis and correlation · Evaluate field data of customer 7.2.1
service and disposal 7.2.2
· Analyze correlation test/field 7.5
7.2.3
7.3.1
7.3.2
7.3.3
7.3.4
7.6
H.2.3.3 Technical simulation · ---
H.2.3.4 Reliability estimation · ---
H.2.3.5 Testing · ---
H.2.3.6 Status · ---

H.3 Reliability work with suppliers

· Exchange reliability data 7.2.2

66
H.2.1 Management tasks
Verify analysis of field data at disposal companies
Also after model discontinuation, complaint characteristics/field
data must be known in the use phase and be available for
analysis. Customer service must verify this.
The findings of the disposal companies can be a valuable data
source and thus helpful support when establishing the failure
behavior of components. Therefore, agreements, which clarify the
organizational and personnel-related conditions, must be made
with the appointed disposal companies at an early stage. As per
agreement, the disposal companies must be able, upon request,
to carry out reliable data collections of the service life
characteristics for selected components (subsystems).

H.2.2 Qualitative technical work approach

---

H.2.3 Quantitative technical work approach

H.2.3.1 Tasks
---

H.2.3.2 Data base and correlation

Evaluate field data of customer service and disposal
Analyze correlation test/field data
Specifically in this phase where the products show increased time
in use and distances covered, the knowledge of the failure
behavior and field data is of great importance. With their
knowledge, the reliability targets for new products can be stated
more precisely. The customer service data, as well as the data of
the disposal companies can be used to carry out comparison
calculations or correlation between test and field data. For
evaluation, it must be ensured that the data material contains at
least the master and failure data, compare G.2.3.2. The reference
quantities may, if necessary, be researched and supplemented at
a later stage in accordance with the defined task.

67
H.2.3.3 Technical simulation
---

H.2.3.4 Reliability estimation

---

H.2.3.5 Testing
---

H.2.3.6 Status
---

H.3. Reliability work with suppliers

Exchange reliability data

For effective reliability work, a supplier also needs information

regarding damages or complaints at the customer, in addition to
the reliability requirements.

Especially in the production and use phase, an exchange

relationship is established between car manufacturer (customer),
supplier and consumer with regard to information exchange, as
shown in Figure 5. Here, the car manufacturer presents the
center of the information cycle. All partners must ensure this
necessary information flow is maintained.

68
 Supplier

Ve
Fe
u.

rs
rtig
a.

uc
g

h
.
Development

Quality Assurance

Information cycle
Car manufacturer
and supplier

Quality Assurance

Development
M btei

Ve
Fe

at lg

rs
A
u.

er .
rtig

uc
a.

ial

h
g

-
.

Information cylce Information cycle

Supplier and consumer Supplier and consumer
Car manufacturer
(Customer)

Customer service

Information cycle
Car manufacturer
and consumer

Customer
(Workshop)

Figure 5: Information flow of reliability data

69
 Information cycle car manufacturer/customer

The car manufacturer maintains the connection to the customer

via his customer service and – incorporating the experience of
suppliers - provides him with essential information regarding:

• permissible wear and tear

• servicing
• repair
• instructions for proper use.

The workshop provides the car manufacturer’s customer service

with information from the field regarding:
• complaints
• actual wear and tear and operating conditions
• difficulties during servicing and repair

The information passed on by the customer service is evaluated

in the respective departments of the car manufacturer.

The results are used to check the reliability requirements

established for own productions and supplied goods.

Information cycle car manufacturer/supplier

In case of reliability problems with supplied parts within the

running series, the quality assurance of the supplier is normally
addressed. In special cases, the design department is also
consulted. The field data processed by the customer service is
normally notified to the customer. As previously agreed, the
complaint data from the field is available in the form of original
values or evaluations, but should, if possible, contain details on
actual wear and tear.

70
The supplier has provisions within the scope of his quality system
which allow him, in close coordination with the car manufacturer,
to process field complaints from the running series quick and
effectively and to eliminate their causes.

Information cycle customer/supplier

This information cycle represents the exception rather than the

norm, e.g. for particularly specialized suppliers with their own
customer service (electric car equipment) or component supplier.

If the supplier has his own field data, this information must also be
submitted to the car manufacturer and vice versa.

71
4 Index

Accident ................................... 39 Detailed planning ............... 47, 51

Benchmark ................... 25, 29, 31 Effects ................................ 39, 53
Bench performance test ..... 55, 64 Error rate .................................. 32
Breakdown .................... 32, 39, 63 Event data .......................... 62, 63
Breakdown statistics .......... 31, 63 Event tree analysis ................... 40
Budget ................................ 28, 29 Experience ........ 37, 40, 43, 60, 70
CAE-Model ................... 27, 33, 50 Failure .................... 30, 45, 48, 53
Classification ............................ 31 Failure behavior ................ 61, 62
Classification analysis 36, 37, 38, Failure conditions ..................... 13
40, 41
Failure data .............................. 67
Competition analysis .......... 26, 31
Failure modes ........ 13, 48, 52, 53
Complaint characteristics ....60, 67
Failure probability ............... 34, 48
Complaint frequency .... 32, 42, 45
Fault tree analysis 47, 48, 49, 57,
Complaint statistics .................. 31 59, 60
Complexity .................... 37, 39, 40 Field data 32, 34, 42, 44, 46, 55,
59, 60, 61, 66, 67, 70, 71
Correlation ....... 16, 59, 61, 66, 67
Field observation .......... 59, 60, 64
Costs ........................ 9, 10, 28, 29
FMEA ......... 40, 42, 48, 49, 53, 57
Cost leadership ........................ 25
Functional analysis ............ 40, 41
Customer expectations 25, 29, 31
Guarantee ................................ 28
Danger ......................... 12, 13, 39
Guarantee period ..................... 63
Degree of innovation 25, 33, 37, 40
Image ....................................... 25
Degree of severity .............. 37, 39
Improvement of image ............. 29
Design-FMEA 40, 41, 52, 53, 56,
57 Innovation .................... 10, 21, 23
Design guideline ...................... 30 Life-Cycle-Cost ........................ 28
Design level 17, 18, 22, 35, 37, 44, Loads ..................... 30, 51, 52, 54
53
Marginal conditions 32, 41, 42, 64
Detailed development ........ 36, 42
Market ................................ 26, 60
72
Market observation .................. 60 Quality costs ..................... 28, 29
Master data ........................ 61, 63 Quality leadership ..................... 25
Measuring and test equipment 45, Quality plan .............................. 29
46
Recycling ................................. 28
Milestones 15, 17, 29, 47, 52, 56,
Reference quantity ....... 62, 63, 67
59, 66
Reliability 5, 12, 13, 14, 16, 17,
Model discontinuation ............. 66
19, 21, 22, 24, 25, 26, 27,
Performance specification 27, 30, 28, 29, 30, 31, 32, 34, 36,
35, 37, 45, 46 37, 43, 44, 47, 50, 51, 56,
57, 59, 60, 64, 67
Personnel resources ................ 17
Reliability estimation .... 16, 34, 61
Plant procurement ............. 52, 54
Reliability growth ................ 47, 50
PPM-targets ....................... 42, 45
Reliability management 9, 11, 14,
Probability of identification ...... 53
16
Probability of occurrence ......... 53
Reliability requirement .. 32, 35, 42,
Product audit ............................ 64 45, 46, 55, 58, 68, 70
Product development 15, 36, 47, Reliability target 25, 27, 28, 32,
52, 56 41, 44, 51, 57
Product development process 5, 9, RGM ................................... 50, 51
32
Risk analysis ................. 34, 40, 41
Product positioning .................. 26
Risk calculation ....................... 19
Product safety law .................... 60
Risk part ................................... 39
Project contract ........................ 25
Risk priority figure ........ 53, 57, 60
Project-independent pre-
Rough development ........... 27, 29
development ...... 14, 15, 21
Safety ........................... 12, 13, 32
Project phases ................... 19, 28
Safety function ......................... 25
Project process .................. 14, 19
Safety part .......................... 39, 40
Production ....... 14, 15, 16, 59, 63,
66, 68 Serial application ...................... 56
QFD ......................................... 40 Servicing ............................ 28, 70
Quality .................... 12, 13, 14, 25 Specification ............................. 46
Quality assurance agreement .. 44 Standard part ........................... 39

73
Strengths and weaknesses Test data ............................ 47, 49
analysis ........ 27, 31, 36, 37
Testing ............ 16, 19, 30, 43, 51,
Subassembly review ................ 64 54, 58, 63, 64
Supplier agreement ...... 27, 36, 41 Testing principles ............... 36, 43
Supplier sample ................. 52, 55 Test parameter ......................... 33
System analysis ........... 40, 42, 48 Test program ................ 47, 51, 54
System-FMEA 36, 40, 41, 47, 48, Testing devices ............ 45, 46, 65
59, 60
Test instructions ........... 29, 45, 46
System model reliability ..... 27, 34
Use of resources ................ 36, 37
Targets ..................................... 41
Weak point ................................ 31
Task fields ................................ 15
Wear and tear ......... 12, 45, 46, 70
Technical support of series 51, 59,
Workshop stay ........................... 9
60

74
5 Appendix

Example of a checklist

The following pages show an example of a checklist as it could be used as

a tool for the planning and status of reliability activities, especially by the
project manager.

The checklist is meant as an encouragement to companies to establish their

own forms. However, it is also possible to use it as shown if the required
project-specific activities, corresponding to the necessary extent of produc-
tion, are ticked off in the left column.

75
Project: Project manager: Page 1
Date: of 3

Checklist for reliability (R) activities

Tick off required activities Executed/Comments Status
Milestone 0:
• Determine R-data for innovations
• Establish or estimate R-risks for innovations
Milestone A
Project inquiry/contract:
• Define R-positioning amongst competition
Milestone B
Approval for rough development:
• Determine R-targets, R-task scopes, R-
budget and propose R-method
• Carry out strengths and weaknesses
analysis
• Define quantitative R-targets for system and
subsystem level in performance
specifications and supplier agreements
• Establish technical simulation model at
component level
• Establish R-system model
• Carry out R-planning with supplier for
purchased parts
Milestone C
Approval for detailed development:
• Determine financial and personnel-related
expenditure for R
• Describe use of resources
• Break down to component level the
measures to be taken as a result of
strengths and weaknesses analysis
• Perform classification analysis
• Carry out System-FMEA for subsystems
• Define quantitative R-targets for component
level in performance specifications and
supplier agreements
• Improve R-System model

Key not yet approx. 25% approx. 50% approx. 75%

started finished finished finished finished

76
Project: Project manager: Page 2
Date: of 3

Checklist for reliability (R) activities

Tick off required activities Executed/Comments Status
• Complete technical simulations
• Specify testing principles
• Agree quantitative R-targets, verification
procedures and methods with supplier
Milestone D
Approval for detailed development:
• Carry out System-FMEA for components
• Perform fault tree analysis
• Evaluate test data
• Demonstrate current ACTUAL-R
• Establish reliability growth (RGM)
• Establish probability calculations for R
(Basis: test results and analysis)
• Determine test plans and program
• Provide verification for achievability of R-
targets
Milestone E
Approval for plant procurement:
• Perform System- and Design-FMEA on
components, subassemblies and minimize
failure modes
• Predict overall R of the vehicle
• Carry out bench performance and driving
mode tests
• Complete R-verification for partial scopes
• Carry out tests on supplier samples

Key not yet approx. 25% approx. 50% approx. 75%

started finished finished finished finished

77
Project: Project manager: Page 3
Date: of 3

Checklist for reliability (R) activities

Tick off required activities Executed/Comments Status
Milestone F
Approval for serial production:
• Update all FMEAs at all construction levels
and test if new reliability priority figure
achieves targets
• Revise and newly evaluate fault tree
analyses
• Verify achievement of R-targets
• Perform test on suppliers’first samples
Milestone G
Product Review:
• Ensure field observation and technical
support of series regarding R
• Analyze field data and compare to R-
prognosis
• Revise all FMEAs and fault tree analyses
based on field results
• If the field results deviate from the targets,
introduce rework of individual components
in serial production
• Provide field results for new development
• Analyze correlation between test and field
data
• Determine and apply R-tests accompanying
production
• Make field data available to the supplier,
where required
• Ensure regular series review at the supplier
Milestone H
Model discontinuation/disposal:
• Secure and evaluate field data at disposal
companies
• Analyze correlation between test and field
data from disposal companies
• Incorporate supplier into the information
cycle of the R-data

Key not yet approx. 25% approx. 50% approx. 75%

started finished finished finished finished

78
VDA FORMS
FIRST SAMPLE TEST REPORT – new version (1998)
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79
Quality Management in the Automotive Industry
The latest revisions of the published VDA volumes regarding ‚Quality
Management in the Automotive Industry (QAI)‘can be found on the internet
under http://www.vda-qmc.de.

Orders can also be made directly from the VDA homepage.

Order:
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80