A two-phase method for controlling Erlang-failure processes with high reliability

Monitoring a failure process and measuring its performance are important issues for complex nonrepairable and repairable systems. For a highly reliable process, traditional methods for reliability monitoring and performance measuring become inapplicable. This paper proposes a new two-phase controlling method for monitoring and measuring an Erlang-failure process (EFP). In the first-phase controlling method, a control chart is used to monitor the EFP condition. When special causes of variation have been removed from the EFP and all of the failure times plotted on the control chart lie within the control limits, the EFP is considered to be in control. However, the in-control EFP still likely carries out bad or out-of-lifetime-specification conditions. Thus, its lifetime-specification limit is taken into consideration as the second-phase controlling method for measuring the in-control EFP performance. We propose a lifetime-capability index. Its value has a one-to-one corresponding relationship with the lifetime-conforming rate, which indicates the lifetime performance of this EFP. Without collecting additional data efforts, in-control data gathered from the control chart in the first phase is employed to estimate the lifetime-capability index. To realize main lifetime-capability of the EFP impacting on downstream customers, the lower confidence bound of the estimate of the lifetime-capability index, capturing its minimum lifetime capability, is considered. The advantage of this two-phase method for controlling the failure processes can motivate the manufacturer to develop a reliability-monitoring technique, establish an adequate reliability improvement program and implement an appropriate analysis to ensure its lifetime performance meeting the customers requirement.