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In this paper, a simplified and systematic approach to integrate reliability and durability aspects in design process is presented. A six step process is explained with the help of examples. Two alternatives for gathering means and standard deviations for key parameters are discussed. First a DOE approach based on orthogonal arrays is presented. Second approach is based on Taylor Series expansion. An example of beam design is solved with both of these approaches. The Second example also considers the degradation with time in service.

Avoiding failure modes is the ultimate goal of reliability engineering [1, 2]. Design for Six Sigma [3] coupled with Transfer Function [4] analysis is a process that can help to achieve this goal at every stage of product design process. In this paper, the authors integrate Design for Six Sigma and Transfer Function into an Engineering Plan for Failure Mode Avoidance. The authors also define the Distance from Failure Mode with an example of beam.