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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.

As automotive competition is becoming more and more global, automotive products (vehicles or systems or components) are often developed in one market and made and/or used in other markets. The operating conditions are often different from one market to another market. If the market unique operating conditions are not considered in its development and manufacture process, the product may not fully perform its intended function over useful life period, and may experience fewer failure modes in one market but more or different failure modes in other markets. This paper presents a Reliability Engineering approach, based on “Failure Mode Avoidance”, to the product development for global automotive markets. The approach includes three phases: Discover operating conditions (noise factors) and their potential failure modes Develop countermeasures to deal with the noise factors, and Verify the effectiveness of the countermeasures using Reliability Demonstration Matrix.

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.