PEMP

PDN 505

Session 15
Design for Serviceability

Lecture delivered by
Prof. M. N. Sudhindra Kumar
Professor MSRSAS-Bangalore
Sudhindra MSRSAS

 M.S Ramaiah School of Advanced Studies - Bangalore 1

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Session Objectives
At the end of this session the delegate would have understood
• Concurrent engineering with design
• Benefits of Design for Serviceability
Sudhindra MSRSAS

 M.S Ramaiah School of Advanced Studies - Bangalore 2

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PDN 505

Session Topics
At the end of this session the delegate would have understood
• Concurrent Engineering
• Design For Serviceability
Sudhindra MSRSAS

 M.S Ramaiah School of Advanced Studies - Bangalore 3

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PDN 505
Sudhindra MSRSAS

OBJECTIVES: Cost, Time, Feasibility, Performance, Quality, Acceptance Criteria, Production and distribution, Life.

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PDN 505
Sudhindra MSRSAS

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PDN 505

DESIGN FOR SERVICEABLITY

•Considering during the design cycle the ease

with which it can be serviced in the field.
•The ease with which it can be returned to use
after some failure has occurred.
•The ease with which it can be attended
to avoid future failures.

Reduce service requirements by

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increasing the reliability of the product.

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Design for Serviceability

•Serviceability factors in product design
influences the performance and availability of
products in use.

•The design solution must make service

unnecessary or reduce it substantially.

•Only when such features cannot be realized or

are too expensive, should service measures be
introduced.
Sudhindra MSRSAS

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PDN 505

Design for Serviceability

•Possible service measures are:
Service to maintain the intended condition
Inspection to monitor and assess the actual
condition
Repair to recover the intended condition

Anticipate everything that could go wrong with a product and

design such potential faults out of the products.
Sudhindra MSRSAS

 M.S Ramaiah School of Advanced Studies - Bangalore 8

 PEMP
PDN 505

Design for Serviceability

•Prevent damage and increase reliability
•Avoid possibility of errors (Poka - Yoke) during disassembly,
reassembly and start up
•Simplify service procedure
•Make the results of service checkable
•Simplify inspection procedures
•Aim at simplicity and fewer parts
•Use standard readily available interchangeable
replacement parts
•Allow easy access to all test, adjustment and service points with
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adequate visibility
•Provide for easy disassembly

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PDN 505

Design for Serviceability

•Apply modular principles-design units utilizing quick-change

replacement modules
•Use few and similar service and inspection tools
•When fasteners are used use one type as far as possible with
adequate space for tool manipulations.
•Design maintenance parts of a size to be handled by
one person
•Provide adequate worker protection against hazards
•Provide for easy exchange of parts
•Damage localization should be possible
•Place frequently pulled service units on roller, slides or hinges
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•Assure that cases and covers open without interference.

•Design cases that lift off of units instead of units out of cases

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Design for Serviceability

•Replace soldered connectors with plug-in connectors

•Polarize connectors

•Eliminate adjustments

•Color code/ number wire ends

•Provide sensory clues to product malfunctions

•Prepare user friendly installation, assembly, operation and maintenance manuals

Sudhindra MSRSAS

 M.S Ramaiah School of Advanced Studies - Bangalore 11

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Design for Serviceability

•Anticipate everything that could go wrong with
a product and design such potential faults out of
the products.

•Do design FMEA and process FMEA before

finalizing design.
This will ensure that you seldom see a field problem that someone has not already
seen
In-house.
Sudhindra MSRSAS

 M.S Ramaiah School of Advanced Studies - Bangalore 12

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PDN 505

Failure Modes
A failure mode is defined as the manner in which a component,
subsystem, system, process, etc. could potentially fail to meet the
design intent.
Examples of potential failure modes include:
• Corrosion
• Hydrogen embrittlement
• Electrical Short or Open
• Torque Fatigue
• Deformation
• Cracking
Sudhindra MSRSAS

 M.S Ramaiah School of Advanced Studies - Bangalore 13

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Causes of failure
A failure cause is defined as a design weakness that may result in a
failure. The potential causes for each failure mode should be identified
and documented. The causes should be listed in technical terms and
not in terms of symptoms. Examples of potential causes include:
• Improper torque applied
• Improper operating conditions
• Contamination
• Erroneous algorithms
• Improper alignment
• Excessive loading
• Excessive voltage
Sudhindra MSRSAS

 M.S Ramaiah School of Advanced Studies - Bangalore 14

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Effects of faliure
A failure effect is defined as the result of a failure mode on the
function of the product/process as perceived by the customer. They
should be described in terms of what the customer (internal as well as
external customer)might see or experience should the identified failure
mode occur.. Examples of failure effects include:
• Injury to the user
• Inoperability of the product or process
• Improper appearance of the product or process
• Odors
• Degraded performance
• Noise
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Design for Serviceability

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Design for Serviceability

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Design for Serviceability

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Design for Serviceability

•
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Design for Serviceability

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Design for Serviceability

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Design for Serviceability

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Design for Serviceability

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Design for Serviceability

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Design for Serviceability

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PDN 505

Design for Serviceability

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PDN 505

Design for Serviceability

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PDN 505

Design for Serviceability

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PDN 505

Design for Serviceability

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PDN 505

Design for Serviceability

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Design for Serviceability
When you think how
Designing for well basic appliances
Serviceability work, it’s hard to
Reliability believe any one ever
gets on an airplane.

Times Of India – 18 Nov 2002

Sudhindra MSRSAS

 M.S Ramaiah School of Advanced Studies - Bangalore 31

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PDN 505

Summary
• Design for serviceability is considering during the design cycle the ease
at which a product can be serviced in the field
• This requires a concurrent engineering approach involving
manufacturing, service and sales representatives right from product
design specification stage
• The aim should be to increase reliability of the product to make service
unnecessary
• If this is not possible or too expensive, service measures are to be
provided to quickly inspect and maintain the intended condition at
customers place or repair to bring the product back to intended condition
• Modular design should be provided where quick replacement is possible
at customers end , and repair within the module can be done at the back
Sudhindra MSRSAS

end by factory trained personnel

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