map your
product DNA
Design Limit Nature of Failure Actual Life
map your
product DNA
Design Limit Nature of Failure Actual Life
Eliminate recalls
with Intelligent Reliability
mechatronics
hydrotronics
Electronics
hydraulics
Mechanical
Computers
Control Systems
computers
software code
control systems code
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 Methodology (IRM).
Intelligent Reliability Methodology to map the PRODUCT DNA
Design Limit Nature of Failure Actual Life
IN OUR METHODOLOGY
Specification
Analysis or
Testing (Lab or Field)
GENERATES
PRODUCT DNA
A Traceable and Repeatable Index
OUTPUTS
Life Expectancy & Residual Life
SETTING A NEW NORM IN RELIABILITY …
Global Product DNA Labs
Canada: product dna lab research and development
austria: kxc dna generator manufacturing facilities
austria: product dna application center
product dna
a unique identifier
find field failures before production
Product DNA generates Stress-Life Failure Models. It is a deterministic, repeatable and traceable reliability measure, correlating 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.
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 Industry 4.0
DNA STRUCTURED PLATFORM
A Digital Twin Technology
Kepstrum’s DSP “DNA Structured Platform”, is a computer-aided analytical implementation of IRM “Intelligent Reliability Methodology.”
It is a multi-user, multi-project, enterprise software, enabling engineers to map the PRODUCT DNA of their components, in the early stages of development and prototyping.
DSP provides the main engine for Digital Twin, from Digital Specification to Digital DNA for products.
Kepstrum’s Digital Grid
Digital Twin Solution for Rising Complexity & Industry 4.0 Digitalization
Generating Cross-Talk and Transparency
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 METHODOLOGY
IS THE SOLUTION
with INTELLIGENT RELIABILITY
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™

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!
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.
engine and powertrain components
mechatronics & hydrotronics components
aviation hydraulics and components
nuclear and engine cooling systems
power hydraulics and industrial components
ALL-IN-ONE Reliability Solution
YOUR GLOBAL CONNECTIVITY
PRODUCT DNA – A language with no barriers
DSP provides a common reliability indicator, connecting development and production sites around the world.
- Measurable
- Repeatable
- Traceable
DSP produces the same quality measure globally, making reliable
products effortless.
Cross-Talk, Transparency, Knowledge Share and Retention
KEEP YOUR GLOBAL INNOVATION IN CONTROL
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
A COMMON TEST PLATFORM FOR ALL STEPS
Map the Product DNA through critical stages of development and production in 5 structured steps, generating 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
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
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
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
OEMs set a new reliability norm
in their LASTENHEFTE and SORs
(statement of operational requirements)
To eliminate recalls …
Intelligent Reliability™ provides the forward thinkers
and industry leaders with the solutions to qualify their
ideas safely and reliably.
KSM Solutions GMBH
Berndorf, Austria
Michael Kreger, MSc.
Director
ksmsolutions.at
mk@ksmsolution.at
TU WIEN
Vienna, Austria
IVWS – Institute for Transport Science
Dr. Bernhard Hofko,
Professor, Civil Engineering, TU Wien
www.ivws.tuwien.ac.at
bernhard.hofko@tuwien.at
Any Questions?
CONTACT US!
siavash.kianpour@kepstrum.com
Best Defence Conference
November 8th & 9th, 2016
siavash.kianpour@kepstrum.com