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First and Beyond First Time Field Failure Analysis for Effective Reliability & Service Planning

A field failure of a component or a subsystem in a repairable system for the first time is markedly different from a once repair/replaced component/subsystem failure. First time failed parts are expected to assemble under controlled environments such as in an assembly line with right tools, ergonomics and accessibility assuming the right skill sets were available. On the other hand, field replaced parts are assembled after a field diagnosis, removed and replaced by field service personnel in varying field settings. Field environment is markedly different from the assembly line. It may not provide the comfort of the assembly line for the service personnel and the accessibility is often a challenge. Since the lowest part reliability determines the overall system reliability, field replaced parts can bring down the overall system reliability. Modern systems have complex configurations with more components in limited spaces while losing the service accessibility within the system. Large systems may be installed in places like top of high rise buildings or in the outer space with difficult and expensive accessibility. Understanding of the phenomenon that once replaced parts are having lower reliabilities than the pristine part population can lead to a better design reliability and operational maintenance planning.