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 …

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

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

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

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

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.

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

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

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

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

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

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

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

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

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

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

“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