Band 3 Teil1 en

Quality Management in
3
the Automotive Industry
Reliability Assurance Part 1
of Car Manufacturers
and Suppliers
Reliability Management
Volume 3 Part 1
VDA Band
VDA Band
4th revised edition, July 2019

Qualitäts Management Center
im Verband der Automobilindustrie
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Reliability Assurance
of Car Manufacturers
and Suppliers
4th revised edition, July 2019
Verband der Automobilindustrie e.V. (VDA)


ISSN 0943-9412
Printed: August 2019
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VDA-QMC Internetportal am 27.09.2019 um 07:04 3

Preface to the 4th edition
Three VDA volumes cover the topic area of reliability. In 2016, the 4th
completely revised edition of Volume 3.2 "Reliability methods and tools"
was published. Subsequently, the first edition of Volume 3.3 "Case studies
in the reliability control circle" appeared. The last edition of Volume 3.1
"Reliability Management" originates from 2000. The publication of the new
volumes necessitated the amendment of the content of Volume 3.1.
Software reliability is not taken into account in any of the volumes.
As a superordinate work, Volume 3.1 "Reliability Management" addresses

company management, responsible persons and their employees in all
product and project phases, from the creation of a product to its
decommissioning.
Berlin, 2019

4 VDA-QMC Internetportal am 27.09.2019 um 07:04

Table of contents
1 Introduction 7
2 Possible Organizational Structures for the Integration

of the Reliability Control Circle 9
3 Phase Distribution of the Product Life Cycle 14

Explanation of the Graphic Representation of the Phases 14
Concept Phase 16
3.2.1 Objective in the Concept Phase 16
3.2.2 Typical Questions in the Concept Phase 17
3.2.3 Core Tasks in the Concept Phase 18
3.2.4 Tabular Process Description with Process Roles 19
Development Phase 22
3.3.1 Objective in the Development Phase 22
3.3.2 Typical Questions in the Development Phase 23
3.3.3 Core Tasks in the Development Phase 24
Production Phase 28
3.4.1 Objective in the Production Phase 28
3.4.2 Typical Questions in the Production Phase 29
3.4.3 Core Tasks in the Production Phase 30
Use Phase 34
3.5.1 Objective in the Use Phase 34
3.5.2 Typical Questions in the Use Phase 35
3.5.3 Core Tasks in the Use Phase 37
3.5.4 Tabular process description with process roles 38
4 Application of Methods in the Phases of the Product

Life Cycle 41
5 Information about Use in other Phases 43
Appendixes A1 - A3 44


List of abbreviations
CODT Customer Oriented Driving Test

CP Control Plan
FIT Failures In Time
FQE Field Quality Engineer
HR Human Resources
KPI Key Performance Indicator
NTF No Trouble Found
P-FMEA Process Failure Mode and Effects Analysis
REL Reliability
SOP Start Of Production
SQE Supplier Quality Engineer


1 Introduction
The automotive industry in Germany is characterized by intensive,
innovative competition. This situation is intensified by increasing demands
on the part of customers, the market and the constantly growing complexity
of the products. Meeting these demands and offering reliable and high-
quality products represent central objectives of German automotive
manufacturers. However, deficiencies in design, process deviations in the
vehicle production plants or the supply chain, incorrectly installed parts,
disregarded customer behavior, or even a combination of these causes can
result in falling short of the defined quality and reliability objectives.
Deviations from targets not only have financial effects on the manufacturer
in the form of warranty and goodwill costs, but also result in negative
customer experiences, such as workshop stays and repair costs. Moreover,
the increasing development of new business models demands calculable
reliability values, as they have a direct influence on economic success.
Operator models constitute a prime example of this.
From these vantage points, it is now more necessary than ever to achieve
the seamless component-related communication of reliability related
information with all those involved in the manufacturing process of a
vehicle. With each logistical step within the supply chain, there is an
increasing quantity of product information, such as production and design
characteristics and/or delivery information. With the registration by the
customer and the resulting characteristic load values and operating
characteristics, the information density continues to grow. The data
volumes very rapidly reach magnitudes that only allow conventional
reliability analysis to a limited extent. The term "big data" describes such a
flood of information that, due to its size and inhomogeneity, represents a
challenge for conventional hardware and software [Big Data 2016]. With
the increasing market shares of series-produced electric cars and the
vision of autonomous driving, the information provided is increasing
exponentially. Even today, vehicles from the mid-range segment produce
up to 25 GB of data per hour from sensors. This user data harbors a wealth
of potential for reliability analysis to be realized for the German automotive
industry. Following this approach, automotive manufacturers and suppliers
aim to incorporate the information acquired from the use phase already in
the concept, development, and production of new products. Failures that

occur during use are a valuable source of information for the elimination of
design flaws and the improvement of future products with respect to the
pursued quality and reliability objectives. An expedient measure for the
attainment of these objectives is to install a continuous reliability process in
the form of a reliability control circle in the entire value-added chain. This
encompasses all four phases of the product life cycle. Characteristic is the
constant tracing of data and information from downstream phases back to
preceding phases. The reliability control circle is a central element of the
revised VDA volume series 3.
Fig. 1-1: Schematic diagram of the reliability control circle
Reliability control circle
Conception Development Production Use
Findings from subsequent stages
The effectiveness of a continuous reliability process over the entire product

life cycle requires that the participating companies have a suitable
organizational structure. Chapter 2 describes these organizational factors
and introduces potential forms of implementation. Chapter 3 addresses the
phases of the reliability process. It describes the objectives, tasks, and
activities involved and allots responsibilities for each phase. Chapters 4
and 5 briefly describe the phase-based applicability of the methods and the
use of the acquired information in further phases of the process
development cycle.


2 Possible Organizational Structures for the
Integration of the Reliability Control Circle
Reliability assurance in the product development process can only be

successful if corporate management gives high priority to product reliability.
Product reliability is an integral part of corporate policy. It is required and
promoted by management. Thanks to continuous target monitoring, product
reliability is a special management focus.
In order to achieve effective reliability management, it is necessary to

define a suitable organizational structure including responsibilities and
powers for reliability activities. This is realized in most cases through the
consistent implementation of a continuous and cross-divisional reliability
process that is coordinated by a process owner, who also harmonizes the
process with process management and covers all the phases of the
reliability control circle.
For the development of a reliable product, four essential conditions must be

met:
1. The manufacturer requires a plan for the achievement of reliability

targets. The manufacturer must know which values (indicators such
as MTTF, mileage, etc.) its new product should have with respect
to reliability. This applies to the entire product and its components.
For this purpose, suitable targets must be defined.
2. Component design oriented to customer use and component

testing are imperative. The actual loads that components are
exposed to over their service life must be validated and changes to
stress/ strength must be monitored with respect to their effect on
reliability.
3. Reliability is the result of a strictly managed development process:

the reliability process. This process derives verifiably precise
reliability targets and defines suitable testing procedures to test
failures and stresses qualitatively and quantitatively. Furthermore,


it ensures that the reliability targets defined for the product are
reached.
4. A special management focus is required that ensures a deliberate

and systematic management of all involved, provides suitable
resources for implementation, and obligates those involved to the
consistent achievement of targets.
Based on [Brunner 1992], various organizational structures can be

discussed with respect to the question of how a possible allocation of the
reliability function within a company can be realized (see Fig. 2-1).
Fig. 2-1: Possibilities for allocating reliability management within a corporate

structure
1. Management
Quality Development Production Sales Purchasing …
2. Management
3. Management


In order to realize the principles and meet the strategic goals of the
organization, it is strictly necessary to provide reliability management with
the following powers [VDI 4003, 2007]:
! Receives full right of information about all technical processes

relevant to the respective order.
! Receives significant influence on all approvals made over the
course of a project.
! Is a voting member of relevant review and approval panels.
! Receives powers over all other (executive) reliability positions (this
means either direct subordination or at least the authority to issue
work directives).
! Must be informed about all reliability-relevant issues.
The reliability process in the automotive and supplier industry covers all
phases of the product life cycle. The task of reliability management is to
adapt the reliability process to the individual milestones of the product
development process and to ensure its application. Within the reliability
control circle, the use phase is an integral part of the reliability process, as
information from this phase has a significant impact on the core tasks of the
upstream phases.
In order to represent the process in a more practice-oriented way, it is

recommendable to assign the responsibilities to specific process roles
(functions) instead of company departments or individual persons. These
role profiles should be harmonized with job descriptions by human
resources.
As an example the following roles could be described:

! Management: project decision-makers, management
! Quality Engineer
! FQE: Field Quality Engineer
! SQE: Supplier Quality Engineer
! Reliability Manager


! Developer: Design & Development and also Pre-Developer
depending on the project scale
! Test Engineer
! Product Manager, sales view
! Project Manager
! External realization partner (e.g. supplier)
The following figure describes the reliability control circle based on the
process including a role matrix. This can be referred to for the
recommended allocation of the tasks, competencies, and responsibilities
for the implementation of the process. This form of reliability assurance
program also comprehensively satisfies the framework of total quality
management [Birolini 1997]. The illustration of the complete reliability
control circle can be found in the Appendix.
Fig. 2-2: Reliability process – Role matrix (excerpt)
Description of the reliability control circle

Process name: Reliability control circle Version: V01
Process owner: Reliability management dept.
Name: Department: Location: Revision:
Production planner
Input
Product manager
Project manager
Quality engineer
Output
(document,
Test engineer
Rel. manager
Process sequence (document, software,

Management
Process step
software,
process interface)
Developer
process interface)
phase
SQE
FQE
New system
1 R I I I I I I I I I
- Practical knowledge of
predecessor models - REL target for system
- REL subsystems
Concept
- REL actual value equal REL target - REL target for

Define system
2 C I C C C I I I C R to REL target subsystem
- REL actual value
greater than REL target - REL target for
- REL actual value less component / assembly
than REL target
The process description is subdivided into four segments: role matrix, input,
activity and output. The role matrix maps all involved departments, with the
respective responsibility and cooperation in the reliability process clearly
assigned to each role.


Fig. 2-3: Description of reliability control circle (excerpt)
Description of the reliability control circle

Process name: Reliability control circle Version: V01
Process owner: Reliability management dept.
Output
Literature references, Input
Interface type
Process step
(document,
references to (document,
Process sequence software,
VDA volumes software,
process
phase
(example) process interface)

interface)
Border point;
1 New system
VDA volume: Customer-

General processing, processing unit
Practical knowledge
specific QM system
of predecessor
requirements
models - REL target for
- Chap. 3 Establishing and
- REL actual value system
controlling customer-specific
equal to REL target
requirements
Concept
- REL target for

VDA Volume 3.2: REL target
2 - REL actual value subsystem
- Chap. 3.1.1: Reliability Define system
greater than REL
aspects in the conception
target - REL target for
phase- Chap. 3.1.2:
component /
Objectives of reliability work
- REL actual value assembly
in the conception phase
less than REL
- Chap. 4.2: Reliability
target
targets
The "Input" column in Fig. 2-3 contains all information and documents
required for the successful execution of the individual process steps. The
"Process sequence" column clarifies the sequence of individual process
steps in the form of a flow diagram. The "Output" column contains the
result of the respective process step and forms the input for the subsequent
activities. The "Literature references" column is used to provide exemplary
contextual links (interfaces) to other VDA volumes.


3 Phase Distribution of the Product Life Cycle
This chapter defines and describes core tasks according to the four
relevant phases of the product life cycle (concept, development,
production, and use phases).
Explanation of the Graphic Representation of the Phases

The respective objectives of the phases are used to derive central tasks in
an iterative process (planning, implementation, validation, and transfer)
until the prescribed reliability target is achieved. The result is documented
and transferred to the following phase. If the targets cannot be reached, a
reliability target adjustment must be made in the upstream phases or in the
phase itself.
Fig. 3-1: Cyclical representation of the core tasks in the phases
Core tasks Current phase

Core tasks
Planning Implementation
Subsequent phase
Previous phase
Input
Validation and transfer
Documentation and transfer
Core tasks
Validation & Information from downstream phases
transfer
Following the presentation of each phase, a table will demonstrate the

individual process steps in detail and assign them to the responsibilities.
Furthermore, it will also list inputs and outputs and potential data sources.
The layout used for this purpose is shown in Table 1.

Table 1: Layout for process descriptions with process roles in the phases
Phase
Process step
Work content
Realization partner
Project manager
Development
Management
Production
Customer
Quality
Sales
Documentation:
Documentation content to be formulated with

definitions of the responsibilities within the
roles
Subdivided into
R: Responsible
S: Supportive
Input Output
● Possible inputs from upstream phases or ● Results of the phase

product predecessors
Additional sources of information
● Sources of information for input ● Sources of information for output


Concept Phase
3.2.1 Objective in the Concept Phase
In the concept phase, the reliability target of the system must be defined
assuming the identified load spectra and planned strength of the system.
The reliability target of the system is defined in an iterative process by
summing up all the reliability targets for the subsystems and components
down to the reliability targets for the assemblies. This yields the structure of
the reliability targets of the assemblies in the system. A virtual subsystem
may exist within the system that combines the assemblies that should not
be considered individually, e.g. due to very low failure probabilities or lack
of statutory or safety-related requirements.
To establish the structure and to assess the reliability targets of the system,
the knowledge gained from the usage, production, and development of
predecessor models is used, as well as findings from the Concept FMEA.
Possible objectives include:
! Reliability target requirements, functional requirements, and

environmental conditions of customers operation (if known)
! Alternative reliability targets defined according to the current state

of the art
! Target specifications derived from the system level applied to the

component/part level
! Approval for the target specifications
! Adherence to deadlines


3.2.2 Typical Questions in the Concept Phase
In the concept phase, the following typical questions arise within the
reliability control circle:
! Which reliability target should be defined for the system in

consideration of customer expectations, competitor and market
analyses, life cycle costs, and Statutory provisions and, for
example, safety issues?
! Which components/assemblies have to be considered individually

over the entire reliability control circle and how can the residual
influences on the reliability target of the overall system be recorded
statistically?
! How can compliance with the reliability target of the overall system
be ensured?
! In case of a successor product, is an adjustment of the reliability

target required due to its components and possible interactions?
! How can the reliability targets be achieved in the event of changes

to strength (aging processes, spare parts) and/or stresses (change
in usage behavior, statutory changes, changed regions/market)?
! What insights can be gained from field data from similar products
for defining reliability targets (e.g. production fluctuations, tolerance
definitions, identification of deviations, damage symptoms, failure
behavior, user profiles)?
! How can the information from previously made assumptions and

the changes originating from subsequent phases be documented
for the definition of reliability targets (data model)?
! How should the information from the concept phase (e.g. key
indicators) be compressed and transferred to the following phase?


3.2.3 Core Tasks in the Concept Phase
Fig. 3-2 shows the core tasks in the concept phase divided into the process
steps planning, implementation, validation, and transfer. Once the basic
requirements are defined at the system level in the planning process step
and the strategic reliability targets based on them are derived, these are
iteratively derived in the implementation process step at the level of
subsystems, components, and assemblies. Subsequently, the reliability
targets must be verified and approved in consideration of all relevant
aspects, including information from downstream phases. This is followed by
documentation and transfer to the development phase.
Fig. 3-2: Core tasks in the concept phase
Definition of basic requirements Iterative formulation of strategic

at the system level
Concept REL targets for subsystem,
components, and assemblies
Formulation of strategic REL
targets at the system level
DEVELOPMENT
START
Input
Iterative verification of REL

targets at the system level
Information from downstream phases
REL approval for development
phase


3.2.4 Tabular Process Description with Process Roles
Table 2: Concept phase/planning
Concept phase
Planning
Work content
Realization partner
Project manager
Development
Management
Production
Customer
Quality
Sales
Definition of basic requirements at the system
level:
Identify countries, usage markets, and
R S S
conditions
Define customer bases R S S
Identify customer requirements R S S
Identify statutory provisions R S S
Identify safety-relevant requirements R S S
Formulation of strategic reliability targets at
the system level:
Define target for market positioning R S
Identification and assessment of risks and
R S
opportunities of the system
Carry out comparison with reliability data (test
R S
& field) of comparable products
Define feasible market position R S S
Define strategic reliability target R S S
Review strategic reliability target and correct if
S S S R
necessary
Input Output
● Framework conditions ● Strategic reliability targets
● Customer requirements ● Assumptions about loads, load spectra,
● Internal requirements and failure probabilities
● Statutory requirements
● Comparison with similar products
● Market-specific requirements
● Countries, usage markets and conditions ● Complaint-related data
● Target groups ● Workshop reports
● Customer requirements ● Concept FMEA
● Statutory provisions ● Customer/market studies
● Safety-relevant requirements
● Reliability data (test & field) of similar
products


Table 3: Concept phase/implementation
Concept phase
Implementation
Work content
Realization partner
Project manager
Development
Management
Production
Customer
Quality
Sales
Iterative formulation of strategic reliability targets
for subsystem, components, and assemblies:
Identify subsystems, components,
R S S
and assemblies
Risk classification of assemblies R S
Draft reliability system model R S
Identify loads and stresses R S S

Identify mutual influence and required
R S
redundancies
Determine and compare stress and strength R S S
Define reliability targets for classified assemblies
R S S
with implementation partners
Review reliability assembly targets and correct if
R S
necessary
Define concept for traceability R S S S
Input Output
● Strategic reliability targets ● Strategic reliability targets for subsystem,
● Assumptions about loads, load spectra, components, and assemblies
and failure probabilities
● Countries, usage markets and conditions ● System structure
● Target groups (assemblies/components)
● Customer requirements ● Complaint-related data
● Statutory provisions ● Workshop reports
● Safety-relevant requirements ● Concept FMEA
● Reliability data (test & field) of similar ● Customer/market studies
products ● Interface diagram


Table 4: Concept phase/validation & transfer
Concept phase
Validation & transfer
Work content
Realization partner
Project manager
Development
Management
Production
Customer
Quality
Sales
Iterative verification of reliability targets at the
system level:
Aggregate reliability targets for assemblies R S S
Review reliability system targets and correct
R S S
if necessary
Documentation and transfer:
Documentation of all assumptions and the

R S S
results from the concept phase
Creation of the chapter Reliability in the

R S S
product specification document
Input Output
● Strategic reliability targets for subsystem, ● Reliability approval for the development
components, and assemblies phase including documentation and
approval of specification
● Countries, usage markets and conditions ● Complaint-related data
● Target groups ● Workshop reports
● Customer requirements ● Concept FMEA
● Statutory provisions ● Customer/market studies
● Safety-relevant requirements ● Interface diagram
● Reliability data (test & field) of similar
products
● System structure (assemblies/components)


Development Phase
3.3.1 Objective in the Development Phase
Standardized load collectives are generally developed in the development

phase. These are tested with respect to the load capacity of the system,
subsystem, components or assemblies using limit sample prototypes, e.g.
by means of acceleration tests, in order to verify the defined reliability
targets. Particularly great benefit can be derived from this if all relevant
findings with respect to the actual strength and stress figures from the
production/use phase are actually used. It allows a direct comparison of the
real field load with the derived reliability target. This makes control, and
where applicable, a collective split into variants feasible for the system.
Overall, evidence of the reliability target from the concept phase is provided
and product qualification for serial production is executed. In addition, the
reliability-relevant characteristic tolerances are derived and transferred as
the basis for compliance with the defined load spectra for the production
phase.
Possible points include:
! Derivation of tests to verify the reliability targets
! Verification of reliability targets through tests
! Definition of reliability-relevant characteristics (reliability indicators)

for production and anchoring in the Control Plan
(P-FMEA and CP)
! Definition and documentation of reliability indicators for the use

phase


3.3.2 Typical Questions in the Development Phase
In the development phase, the reliability structure and targets are stated
more precisely and verified based on the product requirement document.
The following typical questions arise in the process within the reliability
control circle:
! How can the reliability targets from the concept phase be
implemented and verified?
! How can the loads occurring in the later use phase be identified,
quantified, and combined into collectives?
! How is it feasible for all components of the system to be recorded
and assessed with respect to the influence on the reliability target?
! Which failure mechanisms are to be expected and how are they
causally connected to the already determined stresses/collectives?
! How are the residual risks which are not considered individually
systematically recorded and assessed?
! Which test types should be conducted at which aggregation level to
uncover all failure mechanisms?
! What testing efforts are required for the quantitative verification of
the time progression of the reliability targets (method, testing time,
acceleration, number of test subjects), while taking changing load
spectra (robustness) and strength limits (e.g. seal wear) into
consideration?
! How are the test results combined before the SOP to make a
statement about overall reliability, documented and compared with
the reliability target?
! How can test bench tests be projected to the field (acceleration
factors derived) and how can isolated field failures be used to draw
conclusions regarding test bench tests?
! What should be the procedure for the non-achievement of the
reliability target?
! What specifications should be defined for the later production
phase and field monitoring?


! How and where are reliability-relevant characteristics defined and
documented?
3.3.3 Core Tasks in the Development Phase
The reliability targets transferred from the concept phase serve as the basis
for the detailed planning of the verification and calculation of test
conditions. Information is also considered from downstream phases, and if
applicable also from predecessor products. During implementation, iterative
verification through testing/feasibility study is carried out. If the reliability
targets are verified by validation, they can be transferred to the
downstream phases. In the process, the reliability-relevant characteristics
(e.g. in the Control Plan) are transferred to the production phase and the
reliability targets to be achieved are transferred to the use phase for
monitoring purposes. If the set reliability targets are not achieved during the
development phase, an iterative adjustment can be made within the phase
or the concept phase.
Fig. 3-3: Core tasks in the development phase
Iterative detailed planning of Iterative implementation of

calculation and testing Development testing and feasibility study
Production
Concept
Input
Iterative validation and

subsequent planning
Review REL approval for
production phase


Table 5: Development phase/planning
Development
Planning
Work content
Realization partner
Project manager
Development
Management
Production
Customer
Quality
Sales
Iterative detailed planning of calculation and testing:
Qualitative reliability analysis of potential failures at
R S S
the assembly level
Identification of influence factors of potential failures

R S S
at the assembly level
Derive load collectives from target groups and

R S
quantification
Systematic identification of all possible failure

R S
combinations
Linking of assemblies, potential failures, and loads to

R S
tests
Define test plans with targets for the assemblies and

R S S
system
Review test plans and correct if necessary R S

Input Output
● Qualitative reliability targets from the ● Test plans with targets for the assemblies
concept phase and system
● Usage conditions
● Measurement data with respect to loads ● Relevant usage/environmental data from
● Environmental data internal/external reference sources
● Reliability data (test & field) of similar ● Simulations
products


Table 6: Development phase/implementation
Development
Implementation
Work content
Realization partner
Project manager
Development
Management
Production
Customer
Quality
Sales
Iterative implementation of testing and
feasibility study:
Calculate system reliability R S
Define and procure boundary sample and

S R S
document prototype status
Identify and define reliability indicators S S S R
Define traceability system R S S S S
Execute and document testing on test

R S
benches and in driving operation
Define in-process tests R S S S
Determine process and product-critical

R S S
characteristics
Revise feasibility of production S S S R
Track growth of reliability of assembly and

S S R
system
Revise achieved reliability targets of system

S S R S
and assemblies
Input Output
● Test plans with targets for the assemblies ● Actual reliability value, growth of reliability
and system ● Reliability-critical characteristics
● In-process test
● Traceability system
● Test data ● Test documentation
● Data from the use phase of similar products ● Simulation
● Warranty/Goodwill data systems


Table 7: Development phase/validation & transfer
Development
Work content
Realization partner
Project manager
Development
Management
Production
Customer
Quality
Sales
Iterative validation and subsequent planning
Design validation after industrialization R S
Review reliability indicators and correct if

R S
necessary and integrate in the Control Plan
Define strategy for production quality

S R
monitoring and failure elimination process
Define strategy for field monitoring and failure

S R
elimination process in the supply chain
Documentation of all assumptions and results
R S S
from the development phase
Issue and approval of supporting

R S S
documentation for authorities/customers
Define key reliability indicators for field

R S
observation
Input Output
● Actual reliability value ● Proof of maturity level
● Reliability-critical characteristics ● Key indicators for field observation
● In-process tests ● Integrated reliability-relevant
● Traceability system characteristics and tests in the Control
Plan
● Test data ● Test documentation
● Data from the use phase of comparable ● Simulation
products ● Contractual warranty and goodwill
● Results of benchmarks provisions


Production Phase
3.4.1 Objective in the Production Phase
In this phase, compliance with the defined load capacity of the system must
be ensured both through (statistical) characteristic monitoring and through
in-process reliability tests with the load spectra defined from development.
The monitoring and the demonstration of process capability of reliability-
relevant characteristics are carried out in order to prevent negative impacts
on product reliability and to identify process deviations as early as possible.
Moreover, it is necessary to trace and evaluate the risk and influence of
executed process modifications on reliability, especially in the ramp-up
phase.
In the production phase, the defined and verified reliability targets must be
monitored in intervals as short as possible, regularly. Deviations should be
identified early on in order to be integrated as information into the reliability
control circle again. This allows the readjustment of the reliability target.
The data from the use phase must be analyzed in order to determine the
extent to which deviations are to be attributed to the internal production
process or to the upstream supplier process. Non-capable processes must
be improved or where necessary adjustments need to be made to the
specifications in the development process.
Possible points include:

! Transfer of reliability-relevant characteristics to the Process FMEA
and Control Plan.
! Proof of the process capability of reliability-relevant characteristics
! Verification of reliability indicators by in-process tests during
production


3.4.2 Typical Questions in the Production Phase
In the production phase, the following typical questions arise within the
reliability control circle:
! What is the relationship between produced quality, reliability-
relevant characteristics, and field quality? What effects do
deviations in the characteristics have on the field quality? How can
the reliability target of the use phase transferred to the production
phase?
! Have the special characteristics defined in the Process FMEA been
completely recorded and do they completely cover the reliability-
relevant characteristics?
! Are the processes, that influence the reliability-relevant
characteristics controlled (stable) and capable (sufficiently low
variation and centered)?
! How can higher-level test scenarios to test the reliability targets of
assemblies be set up?


3.4.3 Core Tasks in the Production Phase
The reliability-relevant indicators and targets transferred from the

development phase are now monitored in the production phase. This is
implemented, for example, in the form of in-process tests or process
capability analyses in the supply chain. Furthermore, it is target-oriented to
identify and limit the relevant process parameters, e.g. by means of DoE, in
order to make the process more controllable and to increase robustness. If
the reliability-target specifications are verified, have to be documented and
reliability approval for the use phase can be issued.
Fig. 3-4: Core tasks in the production phase
Monitor REL-relevant indicators Implementation and monitoring

and targets in the production Production of in-process tests and tests for
process products in the supply chain
Development
Use
Input

Review REL approval for
production phase


Table 8: Production phase/planning
Production
Planning
Work content
Realization partner
Project manager
Development
Management
Production
Customer
Quality
Sales
Monitor reliability-relevant indicators and
targets in the production process:
Implement strategy for production quality
S R S
monitoring
Implement Control Plan S S R
Review Control Plan and correct if necessary S R S

Input Output
● Control Plan ● Organizational integration of the Control
● Test instructions Plan in production
● Resource planning


Table 9: Production phase/implementation
Production
Implementation
Work content
Realization partner
Project manager
Development
Management
Production
Customer
Quality
Sales
Implementation and monitoring of in-process
tests and tests for products in the supply chain:
Carry out in-process tests and screening of
reliability-critical indicators within the processes S R S
and products in the supply chain
Monitor stability and capability of reliability

S R S S S
indicators, analyze deviations
Carry out corrective actions in case of deviations S R S S S
Monitor effectiveness of corrective actions for

S R S S S
process and product
Review reliability-critical indicators and targets

R S S S
and correct if necessary
Apply traceability system S S R

Input Output
● Organizational integration of the Control Plan in ● Actual condition of reliability-relevant
the production characteristics
● Resource planning
● Test results ● Test documentation


Table 10: Production phase/validation & implementation
Production
Validation & implementation
Work content
Realization partner
Project manager
Development
Management
Production
Customer
Quality
Sales
Documentation of reliability target
achievement and provision of proof for S R S S
process and product
Review reliability targets and correct if

S R S S
necessary
Input Output
● Actual condition of reliability-relevant ● Verification of reliability targets of the
characteristics production status
● Test results ● Test documentation


Use Phase
3.5.1 Objective in the Use Phase
In the use phase, monitoring is carried out to assure compliance with the
defined reliability targets. If deviations are detected, the reasons for them
must be identified. Failures can be subdivided into early, random, and
wear-out failures.
With early failures, the failure rate (number of failures divided by the
number of intact units in the field per time interval) increases sharply briefly
after first operation and decreases again over time. These include, for
example, problems due to the transition from development to production
(industrialization).
With random failures, the failure rate remains constant over time. This is
often due to the coincidence of multiple influence factors, such as incorrect
failure diagnosis, NTF cases (No Trouble Found), improper use, or
incorrect disassembly.
Wear-out failures show a rising failure rate over time. The primary reasons
for these are that damage parameters and acceleration factors in the test
phase were not identified completely or because of a non-production-ready,
robust design, e.g. due to not executed boundary sample tests. Wear-out
failures occur if the combination of stress and strength was not sufficiently
considered in the overall design process. Reasons for strength problems
can be either production-related or design-related. Considerations of
strength are generally made in the scope of the Design-FMEA. In
particular, changes in stress must be detected and taken into account early
on by means of systematic field observations.
Apart from identifying deviations from the reliability target due to the failure
mechanisms described above, a proactive field observation has to be
implemented. This may also mean to observe specifically parts in the field
that have not been complained yet or to retrieve them. The residual lifetime
of the retrieved parts must be determined and compared to the failed parts
and the test conditions. This allows any deviations from specified behavior
to be identified. From actual use, knowledge about the failure behavior of

the system can be reflected back with higher quantities and secured
processes from manufacturing to the affected phases design, development,
and production. Therefore, for example, it is possible to identify instable
production processes. Identifying stress/strength represents an important
information yield for the accelerated tests used in development. This
enables the improvement of ongoing series production. For new
developments, the findings gained during the use phase can be
reintegrated via the design into the concept phase. Moreover, they can
serve as the basis for additional business models, such as maintenance
contracts and operator models, for example.
Possible KPIs are:
! Effective implementation of monitoring

! Transfer of reliability indicators to the upstream phases
! Effectiveness of the interfaces to other processes, such as the
problem-solving process, change management, and lessons
learned
3.5.2 Typical Questions in the Use Phase
In the use phase, the following typical questions arise within the reliability
control circle:
! How can the field be actively monitored?

! How does the system and its components behave in the field from
the customer, manufacturer, and supplier perspective?
! How can the failure behavior in the field be described statistically?
! What are the dependencies in the supply chain? How and where
are the reliability characteristics and change history documented?
! Is part traceability assured so that reliability characteristics can be
clearly allocated?


! How can possible causes for deviations (unidentified stress or
excessively low strength due to faulty design or production
fluctuations) be identified by means of defective part analyses?
! How can deviations from the defined reliability targets be identified
as quickly as possible, e.g. by observing individual user groups?
! How can standardized error codes be generated and maintained in
all phases (data model)?
! How can complaints be analyzed and predicted by means of a
structured and standardized procedure? How can different failure
mechanisms be distinguished?
! Which information related to reliability-relevant characteristics from
the use phase is required in the other phases of the reliability
control circle? How and in which way can the information be traced
back? Which complaints can be traced back to the production,
development or concept phase?
! What is the importance of the deviation of reliability targets from the
manufacturer, supplier, and customer perspective?
! What actions should be defined and how can the effectiveness be
examined and proved (e.g. 8D methodology)?


3.5.3 Core Tasks in the Use Phase
In the use phase, first the structures and methods for monitoring the
reliability-relevant targets are planned and defined. During implementation,
the transferred target specifications are compared to the actual field data. If
deviations are identified, a correction process has to be initiated in the
upstream phases. The findings acquired from use phase serve in the
upstream phases to further specify assumptions.
Fig. 3-5: Core tasks in the use phase
Monitor REL-relevant targets in Monitoring of products in the field

the field Use
Production
End
Input
Information from upstream

phases Documentation
Initiation of corrective process


3.5.4 Tabular process description with process roles
Table 11: Use phase/planning
Use
Planning
Work content
Realization partner
Project manager
Development
Management
Production
Customer
Quality
Sales
Monitor reliability-relevant targets in the field:
Implement strategy for field monitoring R S S
Implement and review failure elimination

R S S
process and correct if necessary
Implement reporting S S R S
Input Output
● Reliability targets from the development ● Organizational integration of field
phase monitoring in the use phase
● Information about warranty/goodwill data
● Sales data ● Warranty database
● Production data ● Customer information
● Registration data ● Logistics database
● Repair data ● Sales data
● Error codes
● Environmental variables
● Vehicle classifications
● Complaints


Table 12: Use phase/implementation
Use
Implementation
Work content
Realization partner
Project manager
Development
Management
Production
Customer
Quality
Sales
Monitoring of products in the field:
Supply the required field and production data
S R S S
to the supply chain
Identify field data from failures and analyze,
delimit, predict, prioritize, and categorize it S R S S S S
with respect to the process and product
Actual comparison of stress and strength in
S R
case of failure
Initiate remedial actions via the failure
S S R S S S
correction process
Monitor actions S R S S S
Active component monitoring during
R S S
operation
Component analysis of products withdrawn
S R S
from usage
Operating/fault memory data analysis R S S
Review reliability targets and correct if
S S S R S
necessary
Transfer actual data to target data model S R S
Monitor stability and capability of reliability
S R S
indicators, analyze and report deviations
Input Output
● Integrated field monitoring ● Field data analysis, failure prediction
● Failure correction process
● Active component monitoring during
operation
● Monitoring of reliability data


● Error codes
● Complaints
Table 13: Use phase/validation & transfer
Use
Work content
Realization partner
Project manager
Development
Management
Production
Customer
Quality
Sales
Documentation:
Documentation of identified deviations S R S S
Feedback of information about actual

condition and changes in individual S S R S S
assumptions back to previous phases
Input Output
● Integrated field monitoring ● Field data analysis
● Initiation of the failure correction process
● Active component monitoring during
operation
● Monitoring of reliability specifications
● Error codes
● Complaints


4 Application of Methods in the Phases of the Product Life
Cycle
This volume does not treat the application of possible methods. The
description and phase-specific applicability is the content of Volume 3.2
"Reliability methods and tools".
Table 14: Application of methods in the phases [VDA Vol. 3.2, 2016]
VDA Volume 3.2

Phase of the
Development
reliability control circle
Production
Topic Section
Concept
Page
Use
Method
4.1 Load and service life (load spectrum)
• • • 53
Reliability targets 4.2 Reliability targets

• • 61
and
requirements
4.3 Transformation of reliability targets
• • 76
4.4 Reliability requirements in the specification
• • 78
sheet
5.1 Overview
◦ • 85
5.2 Determination of stress
◦ • 85
Component 5.3 Determination of capacity to withstand stress
◦ • 90
reliability 5.4 Probability of failure in case of single-stage
◦ • 97
load
5.5 Lifetime in case of variable stress
◦ • 105
6.1 System analysis
• ◦ 109
6.2 Boolean model
• • ◦ ◦ 116
6.3 Calculation of system reliability
• • 124
6.4 Fault tree analysis
• • ◦ ◦ 128
System reliability
6.5 Importance parameter
• 137
6.6 System availability
◦ • ◦ 142
6.7 FMEA
◦ • • ◦ 152
6.8 Cause-effect-diagram
• • • • 157
6.9 Analysis of course of events
• ◦ 164
6.10 Design review
• ◦ 165
7.1 Verification and validation
• • ◦ 168
7.2 Accelerated test procedures –
• ◦ • 169
Accelerated Life Testing (ALT)
Test planning and

7.3 HALT method
• ◦ 172
tracking
7.4 Step-stress method
• 174
7.5 Accelerated tests
• ◦ • 177
7.6 Success Run & WeiBayes
• • 184
(minimum sample size)
7.7 Reliability growth analysis and management
• ◦ 195


Phase of the
Development
reliability control circle
Production
Topic Section
Concept
Page
Use
Method
8.1 Non-parametric processes ◦ • • • 201
Parametric lifetime analyses - distribution
8.2
functions ◦ • • • 221
Parametric lifetime analyses - solution

8.3
methods ◦ • • • 247
Lifetime analysis with intact components

8.4 without knowledge of their actual lifetime - • • • 254
Lifetime analysis simplified sudden death procedure
8.5 Monte Carlo simulation ◦ • • • 258
Lifetime analysis with intact components and
8.6
knowledge of their actual lifetime • • • 265
8.7 Mixture distributions • • • 276

8.8 Protection of lifetime analyses • • • 285
8.9 Repeat complaints ◦ • • 309
Reliability tests
Reliability 9.1
during production ◦ • 313
monitoring in
production
9.2 Process monitoring ◦ • 317
9.3 Requalification • 319
10.1 Data sources • • • • 320
10.2 Data aggregation • 326
Reliability
10.3 Error analysis and error management ◦ • • 339
monitoring in use 10.4 Evaluation of field data ◦ • 340

10.5 Connection between test and field data ◦ • • 350
Guideline for field data analysis and
10.6
Field observation • 360


5 Information about Use in other Phases
In each phase, the relation to the reliability target for the observed
reliability-relevant characteristics must be established, documented, and
communicated.
1. In the concept phase: Estimation of the reliability target by

observation of predecessor products, incorporation of sales
planning for the expansion/change of use and particular features of
the market, and the use of projections
2. In the development phase: Review of previous testing in relation to

the mapping of current stresses (user groups), plausibility check by
road and test bench tests (e.g. S/N-Curve) of planned technical
improvements or expansions, and the extension of stress by new
user groups
3. In the production phase: Review of fluctuations in production

quality of predecessors and estimation of whether the production
quality can be elevated to a higher level
4. In the use phase: Review of the actual condition in the field of the
predecessor, if applicable production of the actual situation to
longer operating time and comparison between defined reliability
targets and the actual situation of the predecessor
An understanding of these relationships already allows the product

specification document to be made more precisely in the concept phase,
which results in an improvement of the further reliability target
development, verification, and tracking. The exchange of information
required for this entails a systematic integration of the reliability control
circle into the processes, structures, and roles of the organization.


Appendixes
Appendix A1: List of figures

Fig. 1-1: Schematic diagram of the reliability control circle .......................... 8
Fig. 2-1: Possibilities for allocating reliability management within a
corporate structure........................................................................ 10
Fig. 2-2: Reliability process – Role matrix (excerpt) ................................... 12
Fig. 2-3: Description of reliability control circle (excerpt) ............................ 13
Fig. 3-1: Cyclical representation of the core tasks in the phases ............... 14
Fig. 3-2: Core tasks in the concept phase .................................................. 18
Fig. 3-3: Core tasks in the development phase .......................................... 24
Fig. 3-4: Core tasks in the production phase.............................................. 30
Fig. 3-5: Core tasks in the use phase ......................................................... 37


Appendix A2: List of tables
Table 1: Layout for process descriptions with process roles in the phases15
Table 2: Concept phase/planning ............................................................... 19
Table 3: Concept phase/implementation .................................................... 20
Table 4: Concept phase/validation & transfer............................................. 21
Table 5: Development phase/planning ....................................................... 25
Table 6: Development phase/implementation ............................................ 26
Table 7: Development phase/validation & transfer..................................... 27
Table 8: Production phase/planning ........................................................... 31
Table 9: Production phase/implementation ................................................ 32
Table 10: Production phase/validation & implementation .......................... 33
Table 11: Use phase/planning .................................................................... 38
Table 12: Use phase/implementation ......................................................... 39
Table 13: Use phase/validation & transfer.................................................. 40
Table 14: Application of methods in the phases [VDA Vol. 3.2, 2016] ....... 41


Appendix A3: Role Matrix for Centralized Reliability
Management
Process owner: Reliability Management Dept.

Name: Department:
ProduStion planner Location: Revision:
ProduSt manager
ProjeSt manager
Quality engineer
Input Output
Test engineer
Rel. manager
Management
Process step
(document, (document,
Process sequence
Developer
software, software, process

process interface) interface)
Phase
SQE
FQE
New system
1 R I I I I I I I I I
– Practical
knowledge of
predecessor
models – REL target for
– REL subsystems system
Concept
– REL actual value – REL target for

2 S I S S S I I I S R equal to REL target Define system subsystem
value REL target – REL target for
– REL actual value component /
higher than REL assembly
target
– REL actual value
less than REL target
– REL target for
system
Concept
– REL target for Sys. REL Yes to 27

3 R I S S S I S I S subsystem target
– REL target for verified?
component /
assembly No
Concept
– REL target for

4 R S system Identify – Subsystems
– System structure subsystems
Define
Concept
– Proportionate REL
proportionate
5 S S I R – Subsystems REL targets targets for the
subsystem subsystems
Concept
– Proportionate REL
Calculate REL
6 S R targets for the – REL system
system
subsystems
Concept
No REL target
7 I I I I I I I I I R – Subsystems system
achieved?
Yes
Yes
Concept
REL target
8 I I I I I I I I R – Subsystems subsystems
to 27
verified?
No
R: Responsible, S: Supportive, I: Informative


ProduStion planner
ProduSt manager
ProjeSt manager
Quality engineer
Input Output
Test engineer
Rel. manager
Management
Process step
Process sequence
Developer
Phase
SQE
FQE
REL target
Concept
Identify components/ – Components/

9 S R S – Subsystems assemblies per assemblies per
subsystem subsystem
Determine
Concept
– Components/ – Reliability
reliability
10 S R S assemblies per structure,
structure per
subsystem subsystem subsystems
Start Concept
Concept
– Reliability
FMEA for – Concept FMEA
11 R S I structure, subsystems for subsystems
subsystems
Prioritize – Prioritized
Concept
components/ components/
– Concept FMEA
12 R S assemblies for assemblies for REL
for subsystems
REL targets target for
subsystems subsystems
– Prioritized
components/ – Components/
assemblies for REL assemblies to be
Concept
target for Select considered isolated

13 R S S subsystems components/ – Components/
– Findings of assemblies to be assemblies to be
Design-FMEA considered considered not
isolated
(special isolated
characteristics)
– REL target for
– Components/ Definition of REL target components/
assemblies to be for each assemblies
Concept
considered isolated component/assembly – REL targets for

14 S S S S I I S S R – Components/
Definition of REL components/
assemblies to be
targets proportionate assemblies
considered not
to overall subsystem proportionate to
isolated
target subsystem
– REL target for

components/
assemblies
– REL targets for
components/
assemblies
Concept
proportionate to Calculate REL

15 S R subsystem subsystems – REL subsystems
– Comparison with
predecessor
models (field data,
test data, warranty
data)
REL target
Concept
for
16 I I I I I I I I R – REL subsystems subsystems
No
verified?
Yes


ProduStion planner
ProduSt manager
ProjeSt manager
Quality engineer
Input Output
Test engineer
Rel. manager
Management
Process step
Process sequence
Developer
Phase
SQE
FQE
REL target
Concept
to 27 components/
17 I I I I I I I I R – REL target system
assemblies
Yes verified?
No
– Framework Compare and

conditions: derive framework
environment, conditions for
Concept
components/ – Derived
volume,
18 S S R S S S S S assemblies framework
manufacturer, usage
conditions
– REL target for
components/
assemblies
Determine
Concept
– Derived – Component/
component/assembly
19 S R S S S I framework requirements assembly
conditions qualitatively and requirements
quantitatively
– Loading of
Determine loads components/
Concept
– Component/
(qualitative) assemblies
20 S S R S I I assembly
Determine strength – Strength of
requirements (qualitative) components/
assemblies
Determine
Concept
– Loading of
21 S S R S I components/ stresses (from – Stresses
loads) and
assemblies
classify
– Stresses
Concept
Determine – Component/
– Strength of
22 S S R admissible assembly failure
components/
failure probability probability
assemblies
Yes
Concept
– Component/ REL
23 I I I I I I I I R assembly failure target
probability met? to 27
No
– Component/
assembly failure
Concept
– Convergence
probability Test
24 R convergence statement about
– Test data from
REL target
predecessor
models


ProduStion planner
ProduSt manager
ProjeSt manager
Quality engineer Input Output
Test engineer
Rel. manager
Management
Process step
Process sequence
Developer software, software, process
Phase
SQE
FQE
Conver-
Concept
– Convergence No gence
25 S S R S S statement about foresee-
to 13
REL target able?
Yes
– Loading of
components/
Concept
– Component/ Reduce loading

or assemblies
26 I I I R I S I I S assembly
increase stress – Stress resistance
requirements
resistance of components/
assemblies
– REL targets for

system
– REL targets for
– REL target for
subsystems
system
– Overall REL target
Concept
– REL target for

Create product - non-isolated
27 I S S S S S S S S R subsystem
specification components/
– REL target for
document for assemblies
components /
REL targets – Individual REL
assemblies
targets - isolated
components/
assemblies
Development
– Special
Start/revise to 13 characteristics
28 S R S I S – Concept FMEA
design FMEA – Traceability
concept
– Individual REL
target - isolated
components/
assemblies
Development
– Preventive
maintenance
29 S R S S S S Yes Strength
intervals
– Additional known?
components/
assemblies
– Non-segregated
load spectra No
– FEM calculations, – Qualified

Development
simulations, S/N- Determine strength tolerances of the

Curve i.e. through parameters for
30 S R S S I calculation,
– Material influencing the
characteristics from representative strength
tests, predecessors
test – Strength
Development
Strength Yes
31 I R I I I I – Strength sufficient?
No


ProduStion planner
ProduSt manager
ProjeSt manager
Test engineer
Rel. manager
Management
Process step
Process sequence
Phase
SQE
FQE
Development
Change – Changed
32 I I R I I I components/ components/
assemblies to 29 assemblies
– Individual REL
target - isolated
components/
Development
Occurring
assemblies
loads
– Preventive (individual Yes
33 I R I I I
maintenance load
intervals spectra)
– Additional known?
component/
assembly
No
– Field data analysis – Technical loads

Development
– Market – Environmental
observation loads
34 S S R S S S S
– Field tests, black- Determine loads – statutorily
box measurements provisions
– Simulation results - use load
– Technical loads
Development
– Environmental
loads Determine – Individual and
35 S S R S S S I individual and
– statutorily mixed load spectra
provisions mixed load
spectra
- use load
Development
– Individual and
36 S R S I I Combine load – n-load spectra
mixed load spectra spectra for stress
Development
No
Calculation
37 R S I – Stresses
possible?
Yes
Development
– Calculated
reliability acc. to
38 R I I – Stresses Calculate useful Weibull, S/N-Curve,
life Arrhenius, FIT,
Coffin-Manson etc.


ProduStion planner
ProduSt manager
ProjeSt manager
Test engineer
Rel. manager
Management
Process step
Process sequence
Phase
SQE
FQE
Development
– Calculated
Yes
reliability acc. to REL
39 I I I S I I I I I R Weibull, S/N-Curve, target
Arrhenius, FIT, achieved?
Coffin-Manson etc. No
Development
– Calculated Check changes – Possibilities for

40 S S R S S S S of loads or
reliability change
strength
to 13
No
Development
Loads/
– Possibilities for strength
41 S R S S S I S
change changeable
?
Yes
No
Development
– Possibilities for Loads

42 S R S S S I S
change changeable?
Yes
Development
– Segregated load
– Possibilities for spectra
43 R Split spectra
change (n=n-1) – Non-segregated
load spectra
Yes
Development
Special
– Segregated load component
44 S I S R S S S S S or assembly
spectra
expedient?
No


ProduStion planner
ProduSt manager
ProjeSt manager
Test engineer
Rel. manager
Management
Process step
Process sequence
Phase
SQE
FQE
Development
Derive – Preventive
– Segregated load preventive
45 I S S S S I I R maintenance
collectives maintenance intervals
intervals
Development
– Additional
– Segregated load Develop new
46 R component/
collectives component for
assembly
segregated
collective
– Calculatedl
Development
reliability Identify main

– Warranty data failure
mechanisms – Failure
47 S R S S from predecessor
through load mechanisms
models
– Test bench results spectra
– FMEA
– Residual
Residual influences on
influence
strength
analysis -
Development
Identify strength – Residual

influences on loads
– Failure
48 R S – Main influences on
mechanisms
strength
– Main influences on
Main influence
loads
analysis -
Identify loads
Development
– Main influences on Identify relations – Relations between

between loads,
strength loads, component/
49 S R S S components/ass
– Main influences on emblies, and assembly, and
loads failure failure type
mechanisms
Identify and
define test,
Development
– Relations between confidence

loads, intervals and – Tests and their
50 S S S R number of test
component/assembl acceleration factors
y, and failure type subjects for the
representative
illustration of use
Development
– Relations between
– Tests and their Fill in loading
51 S S S R loads, failure types,
acceleration factors test matrix and tests


ProduStion planner
ProduSt manager
ProjeSt manager
Test engineer
Rel. manager
Management
Process step
Process sequence
Phase
SQE
FQE
Development
– Relations between Execution of – Test results and

52 R I loads, failure types, tests occurring loads
and tests
Development
– Reliability from
Calculate
– Test results and reliability from tests for
53 S S R
occurring loads test results component/
assembly
No
Development
REL target
– Possibilities for component
54 S S I R level
change
verified?
Yes
– Reliability from
tests for
Development
component/
assembly Calculate
55 I I R subsystem – System reliability
– Overall REL target
- non-isolated reliability
components/
assemblies
Development
REL target Yes

– System reliability
subsystem
56 S I R – REL target for
achieved?
subsystems No
to 13
Yes
Component/
Development
– System reliability assembly to

– Component/ be observed in
57 R
assembly for failure No isolation?
identified


ProduStion planner
ProduSt manager
ProjeSt manager
Test engineer
Rel. manager
Management
Process step
Process sequence
Phase
SQE
FQE
No
Development
– Residual
influences on Should
58 S R I strength accelerated
– Residual tests be
carried out?
influences on loads
Yes
Development
Subsystem
ystem tests – Subsystem
59 S R I underr increased reliability under
stress increased stress
Development
Yes
– Subsystem REL
60 S S I R reliability under subsystem
increased stress met?
No
Development
Identify – Component/
component/
61 R assembly for assembly for failure
failure identified
Determine
Development
subsystem
– Component/ reliability with – Subsystem
62 S R S assembly for failure prototypical test reliability field
identified vehicles testing (prototypes)
No
Development
REL of
– Subsystem subsystem
63 S S I R reliability field met?
testing (prototypes) (prototype)
Yes


ProduStion planner
ProduSt manager
ProjeSt manager
Test engineer
Rel. manager
Management
Process step
Process sequence
Phase
SQE
FQE
Development
Calculate REL
64 I R system – System reliability
No
Development
– System reliability REL

65 S I R – REL targets for system
system mets
target?
Yes
No
Development
Should
66 S R S accelerated
tests be
carried out?
Yes
Development
Execute system – Subsystem

67 S R I tests under reliability under
increased stress accelerated tests
No
Development
– Subsystem REL system

68 I S S I R reliability under met?
accelerated tests
Yes
Development
REL system with – Subsystem

69 S S R S prototypical test reliability field
vehicles testing (prototypes)
No
Development
– Subsystem REL system

70 I I S S S I I I I R reliability field satisfactory?
testing (prototypes)
Yes


ProduStion planner
ProduSt manager
ProjeSt manager
Test engineer
Rel. manager
Management
Process step
Process sequence
Phase
SQE
FQE
REL system -
Production
prototype – System reliability -

– Pilot series test
71 S S R I S vehicle, pre- pre-production / pilot
planning production/ pilot production
production
No
Production
– System reliability - REL system

72 I S S I I R pre-production / pilot satisfactory?
production
Yes
– Product
specification
Production
– Results of Design document approval

Start/update
FMEA for machine
73 S R S Process FMEA
– Special procurement
characteristics – Traceability
concept
– Testing concept
– Product
specification
Production
document approval
Plan, define, and
for machine execute in- – System reliability
74 S S R
procurement process REL (production)
– Traceability tests
concept
– Testing concept
Production
(production) Monitor critical – System reliability
75 S S R characteristics
– Characteristic (SPC) (production)
capability
No
Deviations/
Production
– System reliability - anomalies

76 S R pre-production / pilot in REL
production system
Yes


ProduStion planner
ProduSt manager
ProjeSt manager
Test engineer
Rel. manager
Management
Process step
Process sequence
Phase
SQE
FQE
Production
No Production
– Technical problem
77 R S problem?
description
Yes
– Field analysis Structured

problem-solving
Production
– Results Process
process: – REL production
FMEA
78 R S I Eliminate REL problem eliminated
– Process flow
production – 8D Process
diagram
problem
– REL test results
Production
No
– System reliability Production
79 I S S R S
(production) ramp-up?
Yes
Production
Issue REL
80 S S R approval – REL approval
Production
Customer- – System reliability

81 S R S I – REL approval oriented driving (CODT)
test
(CODT)
Production
– REL actual value Yes

higher than REL REL
82 I S I I I I I I I R system
target
– REL actual value met?
value
No


ProduStion planner
ProduSt manager
ProjeSt manager
Test engineer
Rel. manager
Management
Process step
Process sequence
Phase
SQE
FQE
– REL approval
Production
greater than REL

Tech. problem – technical problem
83 R S target
analysis description
value
Use
84 Vehicle – Complaints
use by customer
– Systematic field
Conduct failures
Use
85 R – Complaints systematic field – Structured

monitoring problem-solving
process
– Delimited field
Structured failures (data-
problem-solving oriented)
– Systematic field
Use
86 R I process: Delimit – 8D process

failures to 75
and describe – Preventive actions
to 61 field failures
– Feedback to
to 23
upstream phases
– Delimited field
Forecast extent – Forecast extent of
Use
87 S S S R failures (data- of field failures field failures

oriented)

higher than REL
– Forecast extent of Execute REL target value
Use
88 I S S I R monitoring
field failures – REL actual value
value
to 86 REL
– REL actual values
actual at
compared to target target
values Actual < Target
End
1 I R


Literature
[Big Data 2016] Big Data. Grundlagen, Systeme und
Nutzungspotenziale. Wiesbaden: Springer Vieweg
(Edition HMD), 2016
[Birolini 1997] Birolini, A.: Zuverlässigkeit von Geräten und

Systemen. Berlin, Heidelberg: Springer-Verlag,
1997
[Brunner 1992] Brunner, F. J.: Wirtschaftlichkeit industrieller

Zuverlässigkeitssicherung. Braunschweig,
Wiesbaden: Springer Vieweg, 1992
[VDA Vol. 3.2, 2016] Verband der Automobilindustrie e.V.: Reliability

Assurance of Car Manufacturers and Suppliers, 4th
completely revised edition, May 2016
[VDI 4003, 2007] VDI 4003: Reliability Management. Berlin: Beuth

Verlag, 2007


Index
Component quality 30 Organizational structures 10, 11

Concept 17, 21, 36 Process capability 29
Concept phase 17, 24, 25, 44 Process roles 12, 15, 20, 26, 32,
Control plan 23, 25, 28, 32 39
Customer use 10 Production 16, 17, 21, 23, 27, 30,
Development 8, 16, 17, 21, 24, 35, 36, 42
29, 35, 36, 42 Production phase 29, 31
Development phase 23, 44 REL indicators 23, 27, 28, 29, 33,
Failure elimination process 16, 41 36, 40
Field data 18, 38, 40 Role matrix 13
Field data analysis 40, 41 Start-up phase 29
Field observation 28, 35 Stress 10, 21, 23, 35, 36, 37, 40,
Field quality 30 44
FMEA 17, 20, 21, 22, 23, 29, 30, Stress resistance 18, 21
35 Testing 10, 25, 26, 27, 44
Load collectives 29 Use 17, 30, 35, 42
Loads 20, 21, 24, 26 Use phase 38
Monitoring 35


Quality Management in the Automotive Industry
You can find the current status of the published VDA volumes on Quality
Management in the Automotive Industry (QAI) in the Internet at
http://www.vda-qmc.de.
You can also place direct orders at this homepage.
Reference:
Qualitäts Management Center (QMC)
Behrenstraße 35, 10117 Berlin
Telephone +49 (0) 30 8978 42-235, Fax +49 (0) 30 8978 42-605
E-mail: info@vda-qmc.de, Internet: www.vda-qmc.de


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What are the different phases discussed in the document?

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2 Possible Organizational Structures for the Integration

3 Phase Distribution of the Product Life Cycle 14

4 Application of Methods in the Phases of the Product

5 Information about Use in other Phases 43

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CODT Customer Oriented Driving Test

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Fig. 1-1: Schematic diagram of the reliability control circle

Reliability control circle

Conception Development Production Use

Findings from subsequent stages

The effectiveness of a continuous reliability process over the entire product

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Reliability assurance in the product development process can only be

In order to achieve effective reliability management, it is necessary to

For the development of a reliable product, four essential conditions must be

1. The manufacturer requires a plan for the achievement of reliability

2. Component design oriented to customer use and component

3. Reliability is the result of a strictly managed development process:

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4. A special management focus is required that ensures a deliberate

Based on [Brunner 1992], various organizational structures can be

Fig. 2-1: Possibilities for allocating reliability management within a corporate

Quality Development Production Sales Purchasing …

Quality Development Production Sales Purchasing …

Quality Development Production Sales Purchasing …

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! Receives full right of information about all technical processes

In order to represent the process in a more practice-oriented way, it is

As an example the following roles could be described: