Podcast
Questions and Answers
What is the primary aim of Quality Assurance?
What is the primary aim of Quality Assurance?
- To maintain records for auditing purposes
- To detect and reject defective work
- To prevent defects from appearing (correct)
- To ensure specifications are met
Which of the following is NOT a specific quality aspect in manufacturing?
Which of the following is NOT a specific quality aspect in manufacturing?
- Choice of machinery and tools
- Selection and training of production personnel
- Implementation of marketing strategies (correct)
- Planning quality controls
What is one purpose of using trial lots in manufacturing?
What is one purpose of using trial lots in manufacturing?
- To prove that the product will meet field performance (correct)
- To gather customer feedback on prototypes
- To conduct full-scale production immediately
- To minimize production costs
Which aspect is crucial for Choice of tools used in manufacturing?
Which aspect is crucial for Choice of tools used in manufacturing?
What is a key method to eliminate defects according to Quality Assurance principles?
What is a key method to eliminate defects according to Quality Assurance principles?
Why is it important to maintain detailed records in Quality Assurance?
Why is it important to maintain detailed records in Quality Assurance?
What distinguishes the pilot plant from the production shop?
What distinguishes the pilot plant from the production shop?
What is a major risk of using an incorrect sampling plan?
What is a major risk of using an incorrect sampling plan?
What does reliability engineering primarily focus on preventing?
What does reliability engineering primarily focus on preventing?
For which types of failures is reliability engineering most suitable?
For which types of failures is reliability engineering most suitable?
Which of the following aspects does reliability engineering NOT typically address?
Which of the following aspects does reliability engineering NOT typically address?
What is one of the goals of reliability engineering?
What is one of the goals of reliability engineering?
Which process is essential in reliability engineering for identifying root causes of failures?
Which process is essential in reliability engineering for identifying root causes of failures?
In reliability engineering, what type of items can the discipline be applied to?
In reliability engineering, what type of items can the discipline be applied to?
Which component of reliability engineering aims to improve operational efficiency?
Which component of reliability engineering aims to improve operational efficiency?
What happens when adequate sampling methods are not utilized?
What happens when adequate sampling methods are not utilized?
What is the primary focus of the Failure Review Group (FRG)?
What is the primary focus of the Failure Review Group (FRG)?
Which of the following best describes reliability engineering's contribution to costs?
Which of the following best describes reliability engineering's contribution to costs?
How often should the Failure Review Group (FRG) meet to review failure reports?
How often should the Failure Review Group (FRG) meet to review failure reports?
Which of the following should NOT be the role of the FRG?
Which of the following should NOT be the role of the FRG?
What are some elements that failure report forms should include?
What are some elements that failure report forms should include?
Under what circumstances should an FRG be established?
Under what circumstances should an FRG be established?
What does the term 'Indifference Quality Level' (SQL) represent?
What does the term 'Indifference Quality Level' (SQL) represent?
How is the Average Outgoing Quality Limit (AOQL) affected when incoming quality is significantly poor?
How is the Average Outgoing Quality Limit (AOQL) affected when incoming quality is significantly poor?
What is essential for ensuring proper inspection between a purchaser and a supplier?
What is essential for ensuring proper inspection between a purchaser and a supplier?
What should an inspector do if sampling acceptance is not specified in the inspection guidelines?
What should an inspector do if sampling acceptance is not specified in the inspection guidelines?
Which factor influences the sample size specified for inspection?
Which factor influences the sample size specified for inspection?
What is the likely outcome if both incoming quality is perfect and outgoing quality is also perfect?
What is the likely outcome if both incoming quality is perfect and outgoing quality is also perfect?
What is the primary concern with the consumer's risk regarding the RQL?
What is the primary concern with the consumer's risk regarding the RQL?
In the context of sampling plans, what is the significance of the inspector's role?
In the context of sampling plans, what is the significance of the inspector's role?
What is the relationship represented by the formula AOQ = pPa?
What is the relationship represented by the formula AOQ = pPa?
What is reliability defined as?
What is reliability defined as?
What characterizes a 'misuse failure'?
What characterizes a 'misuse failure'?
During which period is the failure rate considered approximately constant?
During which period is the failure rate considered approximately constant?
What is indicated by a systematic failure?
What is indicated by a systematic failure?
What occurs during the wear out failure period?
What occurs during the wear out failure period?
How can failures be classified based on their cause?
How can failures be classified based on their cause?
What happens after the early failures have been removed?
What happens after the early failures have been removed?
Which of the following describes 'inherent weakness failure'?
Which of the following describes 'inherent weakness failure'?
Which of the following represents a characteristic of 'random or chance failures'?
Which of the following represents a characteristic of 'random or chance failures'?
What does reliability engineering primarily study?
What does reliability engineering primarily study?
Which of the following is a component of maintaining quality in traction assets?
Which of the following is a component of maintaining quality in traction assets?
What is essential for the effective implementation of Quality Management within an organization?
What is essential for the effective implementation of Quality Management within an organization?
Which method contributes to the improvement of service quality and equipment availability?
Which method contributes to the improvement of service quality and equipment availability?
What role does sound engineering practice play in the definition of quality?
What role does sound engineering practice play in the definition of quality?
Which guideline is emphasized for the purchase of spare parts?
Which guideline is emphasized for the purchase of spare parts?
What is a significant factor in defining quality as stated in the guidelines for traction assets?
What is a significant factor in defining quality as stated in the guidelines for traction assets?
What aspect is considered crucial for enhancing the quality of products and services?
What aspect is considered crucial for enhancing the quality of products and services?
What is the primary responsibility of the Failure Review Group (FRG)?
What is the primary responsibility of the Failure Review Group (FRG)?
What should be included in a failure report form according to standard practices?
What should be included in a failure report form according to standard practices?
How should the FRG approach the meeting frequency regarding failure reports?
How should the FRG approach the meeting frequency regarding failure reports?
What is a key guideline for the FRG when dealing with newly commissioned equipment?
What is a key guideline for the FRG when dealing with newly commissioned equipment?
What is a significant limitation of the FRG's function as outlined?
What is a significant limitation of the FRG's function as outlined?
What is the primary focus of Quality Assurance?
What is the primary focus of Quality Assurance?
Which of the following is part of the Quality aspects in manufacturing?
Which of the following is part of the Quality aspects in manufacturing?
What is the purpose of a trial lot in manufacturing?
What is the purpose of a trial lot in manufacturing?
Why is it essential to maintain records in Quality Assurance?
Why is it essential to maintain records in Quality Assurance?
Which of the following describes the distinction of the production shop compared to the pilot plant?
Which of the following describes the distinction of the production shop compared to the pilot plant?
What does Quality Assurance aim to eliminate in processes?
What does Quality Assurance aim to eliminate in processes?
Which of the following is true regarding the choice of tools in manufacturing?
Which of the following is true regarding the choice of tools in manufacturing?
What principle governs the use of acceptance sampling?
What principle governs the use of acceptance sampling?
Which statement correctly reflects the Quality Assurance objectives in terms of rework?
Which statement correctly reflects the Quality Assurance objectives in terms of rework?
What is the most accurate definition of reliability in engineering?
What is the most accurate definition of reliability in engineering?
Which statement accurately describes a 'misuse failure'?
Which statement accurately describes a 'misuse failure'?
What is characterized by a relatively high incidence of failures due to components exceeding their service life?
What is characterized by a relatively high incidence of failures due to components exceeding their service life?
What distinguishes systematic failures from random failures?
What distinguishes systematic failures from random failures?
How is the reliability at time t calculated?
How is the reliability at time t calculated?
What is the purpose of defining the Indifference Quality Level (SQL) in sampling plans?
What is the purpose of defining the Indifference Quality Level (SQL) in sampling plans?
What type of failure is caused by weaknesses inherent within the item?
What type of failure is caused by weaknesses inherent within the item?
What can be inferred about the Average Outgoing Quality Limit (AOQL) when incoming quality is very bad?
What can be inferred about the Average Outgoing Quality Limit (AOQL) when incoming quality is very bad?
During which phase is the failure rate described as approximately constant?
During which phase is the failure rate described as approximately constant?
Why should sampling plans be specified clearly by the purchaser?
Why should sampling plans be specified clearly by the purchaser?
What best explains the term 'random or chance failures'?
What best explains the term 'random or chance failures'?
How does the incoming quality influence the outgoing quality according to the AOQ formula?
How does the incoming quality influence the outgoing quality according to the AOQ formula?
Which failure classification does NOT relate to the cause of failure?
Which failure classification does NOT relate to the cause of failure?
What action should be taken if the inspection specification does not include Acceptance by Sampling?
What action should be taken if the inspection specification does not include Acceptance by Sampling?
What happens to items during the early failure period?
What happens to items during the early failure period?
What is the implication of using smaller sample sizes in inspections of items produced by fully automatic machines?
What is the implication of using smaller sample sizes in inspections of items produced by fully automatic machines?
In terms of sampling plans, which property might necessitate checking a larger sample size?
In terms of sampling plans, which property might necessitate checking a larger sample size?
What does the formula AOQ = pPa signify in the context of quality inspection?
What does the formula AOQ = pPa signify in the context of quality inspection?
What is the consumer's risk associated with a specified RQL?
What is the consumer's risk associated with a specified RQL?
Flashcards
Quality Assurance
Quality Assurance
Measures to ensure specifications, design details, and sound engineering practice are met.
QA Objective
QA Objective
Prevent defects, not just detect and reject them.
Trial Lot
Trial Lot
Used to fine tune production process and verify product functionality before full-scale production.
Trial Lot Purpose
Trial Lot Purpose
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Quality Aspects in Manufacturing
Quality Aspects in Manufacturing
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Acceptance Sampling
Acceptance Sampling
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Trial Lot vs. Pilot Plant
Trial Lot vs. Pilot Plant
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Consumer's Risk
Consumer's Risk
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RQL
RQL
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SQL
SQL
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AOQ
AOQ
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AOQL
AOQL
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Sampling Plan
Sampling Plan
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100% Inspection
100% Inspection
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AQL
AQL
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Incoming Quality (p)
Incoming Quality (p)
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Reliability Engineering
Reliability Engineering
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Root Causes of Failures
Root Causes of Failures
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Repetitive Failures
Repetitive Failures
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Acceptance Sampling
Acceptance Sampling
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Destructive Tests
Destructive Tests
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Sampling Plan
Sampling Plan
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Randomized Sample Selection
Randomized Sample Selection
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Bad Lots Acceptance
Bad Lots Acceptance
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Reliability
Reliability
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Reliability at time t (R(t))
Reliability at time t (R(t))
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Failure
Failure
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Misuse Failure
Misuse Failure
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Inherent Weakness Failure
Inherent Weakness Failure
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Constant Failure Period
Constant Failure Period
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Random Failure
Random Failure
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Systematic Failure
Systematic Failure
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Wear-out Failure Period
Wear-out Failure Period
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FRACAS
FRACAS
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Failure Review Group (FRG)
Failure Review Group (FRG)
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FRG membership
FRG membership
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FRG purpose
FRG purpose
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FRG corrective actions
FRG corrective actions
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FRG meeting frequency
FRG meeting frequency
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FRG new equipment
FRG new equipment
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FRG old equipment problems
FRG old equipment problems
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FRG duration
FRG duration
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FRG starting information
FRG starting information
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Failure report contents
Failure report contents
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Failure report forms
Failure report forms
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Corrective action implementation
Corrective action implementation
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Quality Assurance
Quality Assurance
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Quality of a product
Quality of a product
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Quality Spares
Quality Spares
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Purchase of Spares
Purchase of Spares
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Reliability Engineering
Reliability Engineering
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Employee Participation
Employee Participation
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Quality Assurance (QA)
Quality Assurance (QA)
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QA Objective
QA Objective
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Trial Lot
Trial Lot
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Trial Lot Purpose
Trial Lot Purpose
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Quality Aspects in Manufacturing
Quality Aspects in Manufacturing
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Acceptance Sampling
Acceptance Sampling
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Consumer's Risk
Consumer's Risk
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RQL
RQL
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SQL
SQL
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AOQ
AOQ
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AOQL
AOQL
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Sampling Plan
Sampling Plan
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100% Inspection
100% Inspection
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AQL
AQL
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Incoming Quality (p)
Incoming Quality (p)
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Sampling Plans
Sampling Plans
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Reliability
Reliability
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Reliability at time t (R(t))
Reliability at time t (R(t))
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Failure
Failure
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Misuse Failure
Misuse Failure
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Inherent Weakness Failure
Inherent Weakness Failure
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Constant Failure Period
Constant Failure Period
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Random Failure
Random Failure
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Systematic Failure
Systematic Failure
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Wear-out Failure Period
Wear-out Failure Period
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FRACAS
FRACAS
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FRG
FRG
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FRG Membership
FRG Membership
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FRG Purpose
FRG Purpose
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FRG Corrective Actions
FRG Corrective Actions
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FRG Meeting Frequency
FRG Meeting Frequency
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FRG New Equipment
FRG New Equipment
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FRG Old Equipment Problems
FRG Old Equipment Problems
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FRG Duration
FRG Duration
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FRG Starting Information
FRG Starting Information
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Failure Report Contents
Failure Report Contents
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Failure Report Forms
Failure Report Forms
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Corrective Action Implementation
Corrective Action Implementation
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Study Notes
Quality Assurance & Reliability Engineering
- 10900 General: Every official should improve quality, productivity, and efficiency in their department. Quality Assurance involves improving, developing, and maintaining quality to meet service requirements economically.
Definition of Quality
- 10901 Definition: Quality spares are vital for reliable train operation. Quality is defined by:
- Purchaser's specifications accepted by the supplier.
- Supplier's declared design details accepted by the purchaser.
- Sound engineering practice.
Purchase of Spares
- 10902 Purchase: Quality spares guidelines are outlined in Board letters (73/RS(G)/30/RLL, 30.3.87 & 17.2.89).
- Spares sourced from original / approved suppliers.
- Railways maintain a list of RDSO approved manufacturers.
- Only the Chief Electrical Engineer can approve variations.
Application of Reliability Engineering
- 10903 Application: Using reliability engineering improves equipment availability and service quality.
- Reliability engineering concepts for this are detailed in Annexure 9.2.
Employees Participation
- 10904 Participation: Employee participation in quality circles and quality improvement is essential for quality management.
- Quality involves all levels in the company, including workers and managers.
- Aim to build an organizational culture where improving quality is embedded in everyday work.
Scope of Quality Assurance
- Annexure 9.1: Quality Assurance ensures three conditions:
- Purchaser specifications and supplier acceptance.
- Supplier design details and purchaser acceptance.
- Sound engineering practices.
- Aim is to prevent defects, not just detect and reject defective work.
- Maintain records for investigating problems and failures during the item's lifetime.
- Manufacturing quality aspects include:
- Appropriate machines, processes, and tools.
- Accurate and controlled processes.
- Planning of manufacturing information.
- Planning of process quality controls.
- Selecting and training production staff.
- Planning quality of purchasing and shipping.
Acceptance Sampling
- Annexure 9.1, 1. Introduction: Acceptance sampling is a process for accepting or rejecting a shipment of items based on samples (not on a 100% inspection of every item)
- Annexure 9.1, 1.2/1.3: Sampling plans define how many items to sample, from how many lots, and how many defects are permissible in each sample.
- Annexure 9.1, 2 Quality Indices: Acceptable Quality Level (AQL) shows the maximum acceptable percent defective for sampling inspection. Rejectable Quality Level (RQL) specifies unacceptable quality levels. Indifference Quality Level (SQL) represents a probability of acceptance of 0.50.
- Annexure 9.1, 2.4: Average Outgoing Quality Limit (AOQL) is the maximum percent of defective items remaining after inspection.
Sampling Plans
- Annexure 9.1, 3. Sampling Plans: Sampling Plans are specified by the purchaser in agreement with the supplier. Inspectors must strictly follow the plan.
- Different sampling plans may be necessary for different quality aspects.
- Lot size considerations may influence the sample size.
Random Sampling
- Annexure 9.1, 4. Random Sampling: Random, unbiased sampling from a lot is necessary for accurate conclusions about the whole lot.
- Sample size consideration is relevant for reliable assessment; larger lots require larger samples.
Limitations of Acceptance Sampling
- Annexure 9.1, 6: Acceptance sampling involves risk and uncertainty.
- Sampling may not accurately determine quality. Sampling plans must be accurately designed.
Reliability Engineering
- Annexure 9.2, 1. Introduction: Reliability engineering aims to prevent failures in all hardware (from simple tools to complex systems) to improve equipment availability, reduce costs, and enhance efficiency.
- Annexure 9.2, 2 Basic Principles: Reliability is the probability that an item will perform as required, for a stated period of time.
- Annexure 9.2, 2.2. Failures: Failure is the termination of an item's ability to perform its required function.
- Annexure 9.2, 2.3. Failure Classifications: Failures are classified based on cause, suddenness (sudden or gradual), and degree (partial or complete).
- Annexure 9.2, 2.4. Failure Patterns: Failures can be categorized by their rate of occurrence; early life, constant, and wear-out periods.
- Annexure 9.2, 2.5. Failure Mechanisms: Common failure mechanisms: adhesion, arcing, backlash, bleeding, carbonisation, and more
Mean Time Between Failures (MTBF)/ Mean Time To Failure (MTTF)
- Annexure 9.2, 2.6/2.7: MTBF measures the average time between failures; MTTF is used when failures cannot be repaired.
Failure Mode and Effects Criticality Analysis (FMECA)
- Annexure 9.2, 3: FMECA assesses the impact of potential hardware failures to aid in early-stage reliability design and identify vulnerable components..
- Use this method for a formal application to electronic systems, heavy electrical systems, or mechanical systems.
Failure Reporting and Corrective Action System (FRACAS)
- Annexure 9.2, 4: This is a system for reporting and investigating failures for systematic improvement in equipment reliability.
- Failure review group (FRG) comprises of key staff to evaluate and propose solutions to equipment failures.
Design and Manufacturing Stage
- Annexure 9.2-5.1 & 5.2: Importance of detailed design review and adherence to drawings and processes during the design and manufacture stage. Critical inspection and testing are essential at every stage to prevent potential failure points.
Operational and Maintenance Stage
- Annexure 9.2, 5.4: Operation and maintenance staff have valuable input in identifying failures and initiating corrective actions. Importance of promptly addressing and analyzing failures to improve equipment reliability.
Reliability and Cost
- Annexure 9.2, 6: Reliability improvements may not always require significant cost increases.
- Proper cost estimations for reliability improvements may be challenging.
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Description
Test your understanding of Quality Assurance and Reliability Engineering principles as they apply to the railway sector. This quiz covers topics including the definition of quality, purchasing guidelines for spares, and the application of reliability engineering to enhance train operations. Explore the importance of quality in ensuring reliable services.