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Achieving Maximum Reliability Growth in Newly Designed Systems

Newly designed systems often have unexpectedly high failure rates which can be reduced by successive redesign until the system achieves an acceptable failure rate. Reliability can grow at the maximum possible rate if the causes of all the failures that occur are identified and removed without introducing new failure modes. Typically, the expected failures are random, infrequent, and need not be corrected. But there are many causes of early and unexpected failures that do require correction. New systems may have incorrect specifications, design oversights, or unanticipated environmental or operational challenges. These occur during the “infant mortality” phase and correcting such unexpected problems as soon as they are observed can produce large early reliability growth.