DS/ETC

Testing Handbook

Process Instruction “Reliability Growth Management (RGM)”

Printed versions of this process instruction are only valid on the date of printout.

Language English
Category Process instruction
Number PI-02.07.01
Topic Reliability Growth Management (RGM)
Author Valentin Licht
Status Published
Date 11/2009
Version 2.0

Signatures
Name, first name Date Signature
Created by Valentin Licht 23.11.2009 gez. Licht
Checked by Martin Mangold 23.11.2009 gez. Mangold
Approved by Dieter Eppinger 23.11.2009 gez. Eppinger

Contents
PROCESS INSTRUCTION “RELIABILITY GROWTH MANAGEMENT” (RGM)”................................ 1
Signatures .......................................................................................................................................................... 1
Contents ............................................................................................................................................................. 1
Task / Purpose ................................................................................................................................................... 1
Changes from Previous Version....................................................................................................................... 2
Scope of Application ......................................................................................................................................... 2
Process Input ..................................................................................................................................................... 2
Measuring Process Performance ..................................................................................................................... 2
Process Output .................................................................................................................................................. 2
Process – Process Instruction ........................................................................................................................... 2
1. Responsibilities ........................................................................................................................................... 2
2. Scope of application.................................................................................................................................... 3
3. Period of use ............................................................................................................................................... 3
4. Test planning............................................................................................................................................... 3
5. Specification of a target growth curve ........................................................................................................ 3
6. Endurance test evaluation........................................................................................................................... 3
7. Proof of the reliability ................................................................................................................................. 4
8. Status of the RGM process .......................................................................................................................... 5
Procedure in Case of Deviations ...................................................................................................................... 5
Attachments....................................................................................................................................................... 5
Links................................................................................................................................................................... 5
Documents which refer to this Process Instruction ........................................................................................................ 5

Task / Purpose
Reliability Growth Management (RGM) is the standard procedure for the evaluation of the testing at DS.
The procedure is applied during testing in order to determine and document the proven reliability, the reliability
growth and the testing progress.

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Changes from Previous Version

No. Item Date Responsible
1 Extensively modified (see especially 2.11.2009 Valentin Licht
Process-Process Instruction, 7. Proof of
the Reliability
2
3
4

Scope of Application
See DS System Manual Chapter 2.2.

Process Input
The following data and documents are input values for the RGM process:
 Life time distribution (Weibull exponent)
 Data from validation tests (running times, failures, repairs)
 Failure values for the failure modes (failure weighting)

Measuring Process Performance

The measurement of the process performance occurs using the reliability characteristic B10 and the failure
tracking
 The reliability characteristic B10 and the failure mode specific failure numbers and failure weightings
are evaluated on a project-specific basis. Countermeasures for the correction of failure modes are
documented.
 The reliability characteristic B10 is calculated periodically (typ. monthly).

Process Output
The following data, parameters and documents are the output parameters of the RGM process:
 Achieved reliability characteristic B10 as function of the testing effort (total test time)
 Documentation of the failure mode specific failure numbers,, the related failure values and the
associated improvement measures

Process – Process Instruction

1. Responsibilities
 The decision about application of the RGM process is made by the responsible testing center in
agreement with the component or system development. An appropriate comment is made in the proving
sheet
 The RGM process is carried out at the testing center responsible for the testing
 DS/ETM is responsible for further development of the methods and user software

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2. Scope of application
The RGM method is applied for the evaluation and documentation of validation tests:
 Standard and base line products without an existing platform
 PE, EE Application is mandatory
 AE Tests of AE projects must be included in the RGM evaluation of the PE or EE testing
 A Not relevant
 Subsequent PE of the same product family, which is derived from an existing platform (base line
products, design optimizations concerning fuel-critical markets)
 Tests of such projects are included in the RGM evaluation of the platform.

3. Period of use
 The RGM process is applied for validation tests beginning with the B sample phase.

4. Test planning
 The test planning is documented in the proving sheet [5].
 Two tests are provided for validation.
 If failures occur in testing, counter measures must be specified and verified in testing. Two tests of the
final design must be past for the validation.

5. Specification of a target growth curve

A target growth curve is specified as standard of comparison for the reliability growth. The target growth curve
is the aimed progress of the proven B10 life time with the total test time. Represented in a logarithmic scaled
figure the target growth curve is a straight line, which is characterized by a B10 start value, a B10 target value
and the total testing time needed to achieve the target value.
 B10 start value Derived from the results of preliminary tests or from experience with
similar products
 B10 target value Project specific B10 target value (cf. section 7)
 Total testing time Estimated cumulative testing time to achieve the B10 target value
The target growth curve is to specify so, that the slope of the straight line in the logarithmic scaled figure is
between 0.3 and 0.6 (empirical value for complex systems).

6. Endurance test evaluation

Validation tests with comparable load form the basis for testing.
Periodically during testing (e.g. each quarter, month, week) the currently achieved reliability is determined from
the achieved total testing time and the number of failures. The results are compared with the target growth curve.
Failures are evaluated as follows:
 An improvement measure for the type of failure does not exist,
or has not yet been introduced in the test a=1
 The failure mechanism has been clarified, an improvement measure
has been found or can be transferred from experience with similar
products and the improvement measure has been introduced in the test a = 0.5
 The effectiveness of the improvement measure has been proven reliably
in new tests a=0
All failure must be considered in the evaluation, even if the running time to the failure is greater than the B10
target value.

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If after completion of the endurance test heavy wear is detected by visual inspection, this has to be evaluated
as a failure, even if the functional test was passed without problems.

The failure assessment (failure values) is performed by the responsible testing center and confirmed by
the relevant DS development department. Objections must be clarified. If this is not possible, the responsible
testing center decides about the failure assessment.
The data are evaluated by a two-parameter Weibull distribution with b = 1.5.

7. Proof of the reliability

All failure modes must be solved (a=0) for the proof of the reliability.
An exception is possible, if a failure mode occurs only after long test times. It must be shown than, that the
failure mode specific load collective until failure exceeds in the validation tests the expected load collective until
end of mission time in field. The comparison of the load collectives must be proven and documented.
If a statistical reliability proof is required additionally, the following B10 life time targets must be met at least
 FIE - On-HW:

PC LD MD HD
Duty Class
1 2 2+ 3 4 4+ 5 5+

B10 Target 800 h 1000 h 1200 h 1500 h 2000 h 2500 h 3000 h 3000 h

 FIE - Off-HW Agricultural/Industrial:

Duty Class 1 2 3 4 4+ 5 5+

B10 Target not defined 2000 h 2000 h 2500 h 3000 h 3500 h 4000 h

 FIE - Off-HW Marine:

Marine Pleasure Marine Commercial

Duty Class
1 2 3 4 4+ 5 5+

B10 Target 500 h 1000 h 1000 h 1500 h not defined

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8. Status of the RGM process

The RGM process is to be carried out (cf. section 2) and its status is to be assessed according the B10 life time
target. The status of the RGM process is not decisive for the proof of the reliability (cf. section 7).
 In Progress The B10 target has not yet been proven
Testing results are currently being included into the RGM
 Passed The B10 target has been proven
Test results are still being included into the RGM
(also applies for test results from AE projects)
 Completed The B10 target has been proven
The responsible testing center has decided to stop working on the RGM
(in general as soon as no more test results are expected from AE projects)
 Frozen The B10 target has not yet been proven
The responsible testing center has decided to stop working on the RGM
(in general as soon as no more test results are expected from AE projects)

Procedure in Case of Deviations

 The user of this PI must list any deviations from these specifications, give reasons for them and submit
them to DS/ETM for approval.
 The approval or rejection is documented by DS/ETM on the submitted documents. In complex cases,
a joint discussion will take place between the user and DS/ETM, and further experts, if applicable.
The results will be documented.

Attachments

Links
[1] Information about the RGM process
[2] RGM program (Download)
[3] Handbook on the RGM Program
[4] PI 02-15 (DS Handbook) Reliability testing at DS

Documents which refer to this Process Instruction

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