Reliability modelling and verification of manufacturing processes based on process knowledge management

Abstract

Reliability modelling and verification is indispensable in modern manufacturing, especially for product development risk reduction. Based on the discussion of the deficiencies of traditional reliability modelling methods for process reliability, a novel modelling method is presented herein that draws upon a knowledge network of process scenarios based on the analytic network process (ANP). An integration framework of manufacturing process reliability and product quality is presented together with a product development and reliability verification process. According to the roles of key characteristics (KCs) in manufacturing processes, KCs are organised into four clusters, that is, product KCs, material KCs, operation KCs and equipment KCs, which represent the process knowledge network of manufacturing processes. A mathematical model and algorithm is developed for calculating the reliability requirements of KCs with respect to different manufacturing process scenarios. A case study on valve–sleeve component manufacturing is provided as an application example of the new reliability modelling and verification procedure. This methodology is applied in the valve–sleeve component manufacturing processes to manage and deploy production resources.

Keywords:

• manufacturing processes
• knowledge management
• process reliability
• reliability modelling
• reliability verification

Acknowledgement

The authors wish to acknowledge the financial support of the State Scholarship Fund of China, as well as the Engineering and Physical Sciences Research Council’s Innovative Design & Manufacturing Research Centre at the University of Bath, United Kingdom.