button_kxc-dna-generators

map your
product DNA

Design Limit Nature of Failure Actual Life

Eliminate recalls
in 5 steps

with kxc dna generatorS™

mechatronics
hydrotronics
Electronics
hydraulics
Mechanical

pumps
valves
motors
actuators
electronics
batteries
solenoids
sensors
bearings
seals

Results set you free

Kepstrum leads the field in deterministic reliability and risk reduction methodologies.
Kepstrum is the inventor and patent holder of
Intelligent Reliability Technology™ (IRT).

Intelligent Reliability Technologies map the PRODUCT DNA

Design Limit Nature of Failure Actual Life

IN OUR METHODOLOGY

Specification
Analysis or
Testing (Lab or Field)

Arrow-Down

GENERATES

PRODUCT DNA

dna-map

A Traceable and Repeatable Index

Arrow-Down OUTPUTS

Life Expectancy & Residual Life

SETTING A NEW NORM IN RELIABILITY …

 

Global Product DNA Labs

about_canada

Canada: product dna lab research and development

about_austria

austria: kxc dna generator manufacturing facilities

about_austria_2

austria: product dna application center

GERMANY STARTING JANUARY 2017: PRODUCT DNA APPLICATION CENTER

product dna

THE kxc OUTPUT – a unique identifier

find field failures before production

Product DNA is a deterministic, repeatable and traceable reliability measure. It correlates the Stress-Drivers with how and when the Product will fail.

Design Limit: Stress limit correlated with a Stress-Driver
(x-axis)

Nature of Failure: Failure mechanism correlating the limit and life
(map)

Actual Life: Time to failure correlated with a Stress-Driver
(y-axis)

Product DNA replaces the conventional test-to-pass with test-to-map
replicating field failures to find product weaknesses and provide design
solutions. Product DNA controls risk by reducing field failures significantly.


 

product_dna-graphic

An impact on modern reliability

DNA LIBRARY

Controlling risk in global development

solve complex problems

Product DNA connects development and production information
to field failures. It provides the global development, application and
production sites with a common reliability indicator to control risk.

KXC generates the Product DNA for the development baseline, new
suppliers, engineering changes and production parts. They are mapped
together to produce the DNA Library.

Field failures will be compared with the DNA Library to determine the root cause rapidly. The DNA Library provides a deterministic solution
to solve complex problems systematically, eliminating trial and error.


 

Connecting management to the big picture

CONVENTIONAL METHODS

with PARALLEL TEST BENCHES?

NO STRESS INTERACTIONS
CANNOT REPLICATE FIELD FAILURES

test-to-pass, mainly driven by experience, is not efficient
in qualifying the reliability of new and complex components
without historical information

TRIAL & ERROR
REWORK
RECALLS

DEMANDING A CHANGE …


INTELLIGENT RELIABILITY TECHNOLOGY™

IS THE SOLUTION

solution-graphic

with kxc dna generators™

ALL STRESS INTERACTIONS
can Replicate FIELD conditions and FAILURES

test-to-map replacing uncorrelated test-to-pass producing the
Design Limit, Nature of Failure and Actual Life
to map the „Product DNA

Measurable
REPEATABLE
TRACEABLE

Setting A New Reliability Norm …

KXC technology

imagine the real-time product DNA
for every sample

with kxc dna generatorS™


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Simultaneous profiling and control of
all Stress-Drivers (interface parameters):

  • Fluid contamination
  • Fluid properties, temperature and pressure
  • Ambient temperature
  • Thermal shock
  • Mechanical shock
  • Mounting vibration
  • Driver signals

KXC underlying technologies:

  • Simultaneous profiling of all Stress-Drivers to replicate field conditions
  • Profile simulator to virtually visualize the field conditions prior to testing
  • Simultaneous controlling of all Stress-Drivers to ensure repeatability
  • Automated failure criteria monitoring and trending to find the limits
  • Advanced sensing, algorithms and analytics to Map Product DNA
  • Remote access and monitoring with advanced diagnostics
  • Real-Time Product DNA Map display

ALL STRESS INTERACTIONS FOR FIELD REPLICATIONS

INFINITE profiling POSSIBILITIES

GIVING YOU THE CONTROL

THE EVOLUTION OF MACHINE CONTROL

DSP allows users to build and upload unique testing sequences easily.
It eliminates the need for a detailed knowledge of programming and
controls with an easy and ready to use text-based interface.

comparing dsp with
conventional programming

imagine testing an electronic oil pump …

  • Oil contamination set at ISO 18
  • Run pump at 90% PWM for 60s
  • DAQ averaged over 10s
  • Total of 10 data points

CONTAMINATION tests

why?

IT IS THE LEADING CAUSE
OF HYDRAULIC COMPONENT FAILURES!

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Contamination under controlled conditions can reveal
a multitude of complex failure mechanisms:

1. Validates clearances
2. Verifies tolerance stack-up
3. Reveals mating part interactions
4. Evaluates surface finish quality
5. Measures in-assembly wear properties
6. Accounts for fluid degradation

an essential part of hydraulic testing

KXC DIVERSITY IN application

Replicating Field conditions and failures

KXC DNA Generators are patented test systems with embedded
Intelligent Reliability algorithms to profile contamination, temperature,
vibration and fluid properties simultaneously to vary and control
the stress interactions. They monitor and trend the product Key
Performance Factors (KPFs) and internal stresses to determine
the gap to failure and Design Limit.

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kxc100at
engine and powertrain components

kxc100at-u
mechatronics & hydrotronics components

kxc250hp
aviation hydraulics and components

kxc300lp
nuclear and engine cooling systems

kxc350hp
power hydraulics and industrial components

ALL-IN-ONE Reliability Solution

KXC Global CONNECTIVITY

PRODUCT DNA – A language with no barriers

KXC provides a common reliability indicator, connecting development and production sites around the world.

  • Measurable
  • Repeatable
  • Traceable

KXC produces the same quality measure globally, making reliable
products effortless.

All sites connected with the same
Product DNA

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KEEP YOUR GLOBAL DEVELOPMENT IN CONTROL

Try Our
kxc dna Generators™

Run projects with our KXC
at kepstrum’s product dna laboratory
to verify your exact configurations and needs

•    Allocate 3 samples
•    Identify your product’s driver signals
•    Specify your product’s Key Performance Factors (kpfs)

We deliver your Product DNA

5 steps

ONE POWERFUL INDEX …

MAP PRODUCT DNA TO PREVENT RECALLS

step 1: Map your Design DNA
step 2: Map your Production Parts
step 3: Map your Design Changes
step 4: Map your Field Failures
step 5: Map your DNA Library

kxc
A COMMON TEST PLATFORM FOR ALL STEPS

KXC maps the Product DNA through critical stages of development and production in 5 patented steps. It generates an intelligent DNA Library that connects the engineering teams to field failures.

Benefits:

  • Eliminates the need for multiple test benches
  • Connects OEMs and suppliers through a unique reliability measure
  • Generates a traceable reference point for future designs
  • Keeps development and production sites connected and in control
  • Reduces field failures by finding product weaknesses in development
  • Solves complex problems through simultaneous stress interactions
  • Shortens the development time
  • Reduces the development cost
  • Controls risk to prevent recalls

Maximizing your profitability

step 1

MAP YOUR DESIGN DNA

CREATE A DESIGN BASELINE

Map and modify your Product DNA to reach the design baseline with
the desired service life. Use the DNA Baseline to check production
quality, validate changes and connect to field failures. Analytical
baselines are generated from first principles to identify the theoretical limits, failures and life.

Benefits:

  • Replicate real world complexity
  • Derive key stresses
  • Reveal product weaknesses
  • Replace meaningless test-to-pass with measurable test-to-map
  • Replace long term durability tests with a Product DNA Map

step1_dna

step 2

MAP YOUR PRODUCTION PARTS

STRESS PRODUCTION BATCHES

Compare the Product DNA Baseline with production batches to regularly verify your output quality.

Benefits:

  • Monitor production variations over the entire stress spectrum
  • Compare production part failures with the DNA Baseline
  • Correlate with the analytical maps

step2_productionmap

step 3

MAP YOUR DESIGN CHANGES

STRESS ALTERNATIVE DESIGNS

Compare the Product DNA Baseline with alternative designs to verify cost reduction changes and support continuous improvement initiatives.

Benefits:

  • Validate the design changes and alternative suppliers
  • Compare failures for new prototypes with the DNA Baseline
  • Correlate with the analytical maps

step 4

MAP YOUR FIELD FAILURES

CONNECT DEVELOPMENT TO FIELD

Map the field failures with your Product DNA Baseline to correlate with development, identify root-causes and refine your database. Demand Product DNA for purchased components from current and alternative suppliers as controls to meet your reliability goals.

Benefits:

  • Close the loop between development knowledge and field information
  • Compare in-service failure mechanisms with the DNA Baseline
  • Solve complex field problems rapidly and systematically

step4_fieldmap

step 5

MAP YOUR DNA LIBRARY

CREATE AN ACCURATE VIEW

Product DNA is an intelligent library, containing all you need to know about your product, its revisions, design limits, failure mechanisms and service life expectancy. The DNA library creates an accurate view of product behaviour, supporting design innovation to maintain market leadership.

Benefits:

  • A repeatable benchmark from research to production
  • A traceable reliability measure between OEMs and suppliers
  • A new norm and approach to generate SORs (statement of operational
    requirements) and LASTENHEFTE
  • Creating an effortless decision making process
  • Keeping management well informed and in control

GLOBAL REALITY

“We cannot solve our problems with the same thinking we used when we created them.”
Albert Einstein

1. OEMs map Product DNA
2. OEMs demand Product DNA
3. Part Suppliers map Product DNA
4. Test labs adopt KXC DNA Generators
5. Research facilities map Product DNA to accelerate learning

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OEMs set a new reliability norm
in their LASTENHEFTE and SORs
(statement of operational requirements)

To eliminate recalls …

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Intelligent Reliability™ provides the forward thinkers
and industry leaders with the solutions to qualify their
ideas safely and reliably.

Any Questions?

DNAgenerators@kepstrum.com

CALL US!
+1 905 482 8688

Best Defence Conference

November 8th & 9th, 2016

kepstrum-booth

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Consult our Intelligent Reliability analysts for your detailed application and DNA Generator configuration

+1 905 482 8688 | Kepstrum.com | DNAgenerators@kepstrum.com