Using TRIZ for SystematicReliability Engineering

Erik Veninga – V2i (Vors to Innovate)

Contents• IntroductionV2i• TRIZ,theTheoryofInventiveProblemSolving

• BasicsoftheConcept• IFR(IdealFinalResult)• WhyTechnicalContradiction?• GeneralTRIZProblemsolvingModel

• ProjectingReliabilityonTRIZmodel• WhybringingtogetherTRIZandReliability?• UsingTRIZintheReliabilityDesignProcess• Example:ElectromigrationFailureMechanism• TheIFR(IdealFinalResult)• Furtherreading(anddoing)

• Summarising

V2i (Vors to Innovate)• Innovation,Reliability&Improvement

ManagementConsulting

AppliedResearch

DomainKnowledge

SystematicInnovation- TRIZ:MakingInnovationtangibleandpredictable- NPIOptimisation:AcceleratingTTM(TimetoMarket)

ProductReliability- DfR:Transitiontobuilt-inreliability- RCA:Solvinglonglasting/complicatedfailures- DesigningAcceleratedLifetimeTestsand

reliabilityprograms

ProcessImprovement- Processcapabilitystudies- Yieldimprovement- Productandprocessaudits

TRIZ, the Theory of Inventive Problem Solving

• Aproblem-solving,analysisandforecastingmethodologyderivedfrompatternsofinventioninpatents

• DevelopedbyGenrichAltshuller (1926-1998)whostartedwithTRIZin1946

Therearestillonly40Inventiveprinciplesavailabletosolvetechnicalproblems!

Alltechnologyevolutiontrendsarepredictable!

TRIZ, the Theory of Inventive Problem Solving

• Technicalsystemsevolveinadirectionthatincreasesideality• ProgresstotheIFR(IdealFinalResult)

Ideality“Value”=∑(Perceived)Benefits(∑Cost+∑Harm)

“Self…..……”

TRIZ, the Theory of Inventive Problem Solving

• “Whytechnicalcontradiction?”Almostalltechnicalproblems(atanylevelofasystem)canbereducedtocontradictions,contradictingcharacteristicsthatalsotendtoblockinnovations

“Themosteffective solutions/innovations(andreliabilityimprovements)canbeachievedwhentechnicalcontradictionsaresolved”

CommonengineeringpracticeImprovingparametersatthecostofother

parameters

OptimizationbyDOE(DesignofExperiments)Improvingmultipleparametersandinteractions

(stillatthecostofotherparameters)

TRIZNewlevelofimprovementandinnovationby

solvingcontradictions

TRIZ, the Theory of Inventive Problem Solving

• TRIZtooltosolvecontradictions:ContradictionAnalysis• 39(+)TRIZparameters• 40Inventiveprinciples

Contradictionmatrix:

TRIZ, the Theory of Inventive Problem Solving

• GeneralmodelfortheTRIZproblemsolvingprocess

SpecificProblem

TRIZGenericProblem

TRIZGenericSolutions

SpecificSolution

Traditional:TrialandErrorapproach

40InventivePrinciplesTrendsofEvolution76StandardSolutions, …….

Projecting Reliability on TRIZ modelCommonpractice

SpecificProblem

TRIZGenericProblem

TRIZGenericSolutions

SpecificSolution

Traditional:TrialandErrorapproach

40InventivePrinciplesTrendsofEvolution76StandardSolutions, …….

GenericProblem:Failuremechanism

SpecificProblem:Failuremode

GenericSolutions:e.g.DesignRules

SpecificSolution

Iterative”Design-Build-Test-Fix”Process

PhysicalModels

Why bringing together TRIZ and Reliability?

Becausethechallengeisstill:DesignforReliability(DfR)

However,aniterative,moretimeconsumingandcostly”Design-Build-Test-Fix”processiscommonpractice!

PhysicsofFailure(PoF)basedapproachesholdthekeytounderstandingandsystematicallyimprovingreliability,includingreducingtheTTM(TimetoMarket)!

"DesignforReliability(DfR)isaprocessforensuringthereliabilityofaproductorsystemduringthedesignstagebefore

physicalprototype."[DfR Solutions]

Using TRIZ in the Reliability Design Process

1) ConductaFMEA(orencountertest/fieldfailures)2) Identify(potential)failuremode3) Determineunderlyingfailuremechanism(expansiontoFMMEA)4) Inventoryinfluencingfactors(literature,availablemodels,……)5) ConvertfactorsintoTRIZparameters(problemdefinitioningeneric

andcontradictingparameters)6) ConductTRIZContradictionAnalysis(teameffort)

ConductFM(M)EA

StudyFailureMechanism(s)

Definecontradictions

Generatesolution(s)

Example: Electromigration Failure Mechanism

• Failuremode:e.g.Shortcircuit• Failuremechanism:Electromigration• Influencingfactors:currentdensity,potentialdifference,spacingbetweenanodeandcathode,interconnect/conductorsize,temperature,………..,………InventoryrelevantTRIZparameters*4.Lengthofstationaryobject10.Force13.Stabilityoftheobject'scomposition15.Durationofactionbyamovingobject17.Temperature19.Useofenergybymovingobject21.Power23.Lossofsubstance26.Quantityofsubstance/thematter27.Reliability30.Externalharmaffects theobject,……….

Inventiveprinciples**1.Segmentation12.Equipotentiality28.Mechanics substitution30.Flexible shellsandthinfilm

SelectionofcontradictingparemetersWorseningfeature:23.Losofsubstance

Improvingfeature:21.Power(or10.Force)

*Requiresexercise,useprofessionalliteraturewithexamplesandexplanations

Andtheninventiveness,technicalskillsandcreativityareneededtogetfromtheabstractinventiveprinciplestospecificsolutions!

The IFR (Ideal Final Result)• WhatabouttheevolutionofproductsandReliabilityEngineering?

• Selftesting• Selfdiagnosing• Selfrepairing/selfhealingmaterials• …..• ….

Selfdesigningforreliability?

Further reading (and doing)• Twoessentials

Greatproblemsolvingexamplesgivenbytheinventor.

ExcellentHandBooktoreallygetstartedandgenerateresults.

Summarising• PhysicsofFailure(PoF)basedapproachesholdthekeytounderstandingandsystematicallyimprovingreliability

• UsingtheTRIZmodelatearlydesignstagesforcestothinkandworkonfundamentalfailurebehaviourandcontrollingmechanismsinsteadoffightingfailuremodesattheendofthedesignprocess

• Reliabilityimprovementmeanschanging(sub)systems,justfindandsolvetheunderlyingcontradictions!

Thank you for your Attention

Contact

ErikVeninga|V2i- Vors toInnovateHoogeind IndustrialEstateZuiddijk 9,5705CSHelmond

TheNetherlandsE-mail:erik.veninga@v2i.nlTel:+31(0)651531740