Reliability loss–oriented product assembling quality risk modeling approach based on reliability–quality–reliability chain

Assembling variations caused by assembling system reliability degradation are the root causes of poor-assembled product reliability, and the reliability loss is the barometer of assembling quality risks. However, few studies have integrated reliability loss with assembling quality risk analysis. Therefore, a modeling approach of assembling quality risk regarding product reliability loss is expounded in this work. First, the assembling quality risk is divided into systematic, exterior, and interior risks, and a formation mechanism of assembling quality risk is presented. Second, the fusion framework of big operational data in assembling is described, an assembling reliability–quality–reliability chain is established, and the parameters of the chain constitute assembling system reliability (R), assembling process quality (Q), and assembled product reliability (R). Third, on the basis of the reliability–quality–reliability chain, the risk priority number is adopted to quantify the assembling quality risk, which is extended by quantifying the undetectable rate of the assembling system, the occurrence possibility of process variations, and the product reliability loss. Finally, an assembling quality risk of a circuit maintenance cover of a car is conducted to validate the effectiveness and advancement of the presented approach. The result shows that the proposed method can systematically quantify the assembling quality risk.