DRIVINGDFRTOBUILDPRODUCTRELIABILITYChinaWindPower201817-19Oct2018Beijing,ChinaLMReliabilityTeamagendaHighlightsLMBladesReliabilityDrivingDFRprocessinLMAllocation,DFMEA,PFMEA,Linkage&APQPProactiveRiskAssessmentsAssessmentMethodologyRiskMitigationProcessFlowConclusion234WhereareweKnowledgeofmorethan205,000bladesproducedsince1978ConstantlyintroducinglongerandcomplexbladesConsistentlydemonstratingeverincreasingreliabilityinfieldReliabilityofLMBladesare>99.6%for20YearsLargestIndependentBladeSupplierEvery5thBladeisLMmakeLMBladesReliability56Whatdrivesus7DrivingDFRprocessinLMIWCReportsReliabilityReportsPlantwiseMetricsReportsProactiveRiskassessmentsStandardizeddefectcategorizationStandardizedInspectionscope&AcceptanceCriteriaReliabilityBlockDiagramInterfaceMatrixReliabilityAllocation8D&RCAsupportMasterDFMEAControlPlanInitialRiskAssessmentsPhysicsofFailureDFR&FleetRotorbladewearout&defectcharacteristicsRotorbladewearout/defectsLossofsystemCollapsesUnrepairablefailuresMaintenanceactionsStructuralOperationalBondingAddon’sAestheticsRotorbladewearout/defectsmayleadtoeitherlossofsystemoranmaintenanceactionReliabilitybenchmarking-FeasibilityofObjectivesPragmaticapproachtoReliabilitybenchmarkingReliabilityApportionmentMethodComplexity(C)Criticality

(Cr)StateofArt(S)Cost(Co)DutyCycle(D)BladeSystemStructuralreliabilityGlueSystemRootInterfaceLightningSystemAddOns9RobustMDFMEAProcess10Crossfunctionalinvolvementofvariousfunctionsensurespotentialfailuremodes,itseffectandoccurrenceprobabilityarerightlyaccessedBladeSystem/ComponentSubSystem/SubComponentNPD1NPD2NPD‘N’BladeSpecificDFMEAsFieldIssuesPFMEALMExpertsNPDEnablersNewTechnologyprojectsQualityImprovementProgramsDFMEAEvolutionacrossPDLCDevelopmentStagesRecommendedActions:HighRPNsarelisted,executedandActionsrecommendeddocumented.RevisitingDFMEA:RecommendedActionsbasedontrialsandprototypewouldbeexecutedandbasedonresultsfurtherreductioninRPNwasdoneRPNReductionActivity:FocusedonaddressingHighRPNsInitialfailuremodesidentification-IModule1StructuralDesignandSpecificcomponentsBladeSpecificDFMEADFMEAInitialfailuremodesidentification-IIModule2StructuralDesignandSpecificcomponentsMasterDFMEATop40reviewIDFMEARPNreductionactivities(Reviewswiththeresponsibleengineer)IIIIIIVVVIVIIAddOnDFMEA11MasterDFMEATop40StageIIRPNrevision

DFMEAthroughmultiplesessionsandenormouseffortsensureseachpotentialfailuremodeisaddressedDFMEAtoPFMEA&APQP4WINDSystemicapproachtoprovidemitigation&controlstoDesignfailuremodespossessinglimiteddesigncontrolsFailuremodesfromDFMEAwithlimiteddesigncontrolstranslatestoPFMEAmakingsurethatitiscontrolledinprocesseffectivelythroughrobustcontrolplans12DesignFailuremodeRPN>AcceptedLimitsTransfertherisktoPFMEAIsthereeffectivedesigncontrolsAssessrisk&provideeffectiveprocesscontrol&controlplanRiskMitigated&controlledRiskmitigated&controlledDFMEAPFMEAControlPlanWorkInstructionsandInspectionListNoYesFeasibilitystudyoftransferringtheriskPFMEA13Whatnext14Excitingchanges!NewProductdevelopmentBladeTransfersTechnologydevelopmentprojectsNTD/NPIOEDetc.TransportProduct&CustomerQualityAllchangesthathasanaddedriskwillbeaddressedinthe“proactiveriskassessment”.Thisiseverythingfromnewprocesses,newmaterials,newtechnologies,bladetransfers…..WhyisProactiveRiskAssessmentImportantPrimaryobjectiveistoavoidriskandtohaveacontingencyplaninplacetohandleunavoidablerisksinacontrolledandeffectivemannerProactiveRiskAssessmentprovidesstructuredprocedurestoassess/estimatethewarrantycostprovisionsforvariousprojecttypesacrossorganization.ShiftLeftAttentiontoQualityintheinitialstagesofproject/productlifecycleProactiveRiskAssessment16Whatisenablingus-LiveFeedback205000bladesandcountingLiveDefectDashboards-EnablersTechniques:AssessmentMethodologyRiskAssessmentMethodsWeibullAnalysisUnderstandingthetrendoffailureratesandmakinglife/failurepredictionsbyfittingastatisticaldistributiontolifedatafromarepresentativesampleReliabilityPrediction

(RBD,SSIetc.)SSI:Productreliabilityisestimatedusinginterferencebetweenthestrengthoftheproductandthestressactingonit

RBD:BreakstheproductintocomponentstounderstandthefunctionalitydependenciesanddetermineReliabilityPredictiveAnalyticsPredictiveanalyticsdealswithextractinginformationfromdataandusingittopredicttrendsandbehaviorpatterns,capturingrelationshipsbetweeninfluencingandpredictedvariables.StatisticalTechniquesMakesuseofstatisticalmethods/distributionstocalculatereliability20PredictiveAnalyticsEveryriskassessmentsiscloselyalignedwithprojectstagegatemodelEndofeverygatestage,riskassessmentsareanalyzedreviewedandrevisedtoprovideeffectivefeedbackAdditionalRiskassessmentprocessforvariouschangetypes21TheProjectswithCostexposurepercentagesabovetargetgothroughamitigationprocessatregularintervalsthrougheveryGatestagesMitigationactionFinalRisk-Gate5Mitigated/Revised-Gate3InitialRiskGate0.922InitialRiskRiskDefinitionRiskAssessmentsRiskCommunicationPeerReviewAssessmentmethod/processEstimatedRisk%InfluencingFactorsMitigationactionsRiskreductionactivitiesImprovementsReassessmentsResidualRiskRiskassessmentandDFRstudiesareintegralpartofproductdevelopment–bothbladesandcomponents.Everypotentialriskisassessed,quantifiedandeithermitigatedoracceptedbeforeproductrelease.EnablesrobustfeedbackmechanismbetweenfieldandengineeringEnsuresthatLMbladesprovidesexcellentbalancebetweeninnovationandreliabilityProudtobepreferredbladesupplierforbladesthatlastslongConclusionThankyouforyourtimeContactdetails:Headquarters[AbhayLaxmanraoWaghmare]LMWindpowerA/S[Sr.Manager,Reliability]Jupitervej6[PDE&FleetReliability]6000KoldingDenmarkTel[+918066470333]Tel+4579840000Mob[+917022377041]Mob+4579840001E[abwa@]Einfo@WNote:Thecontentsofthispresentationareconfidentialandmaynotbecopied,distributed,publishedorreproducedinwholeorinpart,ordisclosedordistributedbyrecipientstoanyotherperson.ThankstomyCoAuthorsRaghuramKNevilleDucieAmithNagNAAppendixBladepopulationandFailureCategorizationInclusioninstudy&categorisationofissues1.Handlayupbladesfrom2003andbeforearehistoricallynotincludedinthepopulationreliabilityanalysisatLM.2.Reliabilityisonlybasedonbladefailures.Bladefailures(observed/reportedfromfield)arecategorizedinto3basicrootcausecategoryforanalysis::(I)LMIssues(II)Non-LMIssues(III)Inconclusive(I)LMIssues:

Thiscategoryincludesbladefailures

duetoproductionqualityrelatedissueslikeLeadingEdgecrack,Wrinkles,etc.(II)Non-LMIssues:Thiscategoryincludesbladefailuresdueto:(a)Environmentaldamage

ThisincludesbladefailuresduetoSiteConditionsabovespecifications,suchaswindspeed,snowfall,lightningstrike,collision,etc(b)CustomerIssues

ThisincludesbladefailuresduetoTurbineControlIssues,Overloadetc.forwhichthecustomerisresponsibleforthebladedamage(III)Inconclusive:

Thiscategoryincludesbladefailures

forwhichtherootcauseiseithernotavailableorrootcauseinvestigationison-going(C00-Pending/Noinspection,C09-inspectedbutinconclusive).SimplifiedGeneralModel??=Failurerateorslopeof“BathtubCurve”TB=PossibleBurn-inTimeTW=StartofWear-outTime(orendofusefullife)InfantMortalityUseful/DesignLifeWe