MTBF - How we Measure Reliability in Harsh Environments

What is MTBF?
Maintaining critical systems can be costly, especially those essential for everyday life. Downtime is expected to be at a minimum, meaning it is critical to design a system with high quality and reliable equipment. Westermo delivers devices that operate at the heart of complex ecosystems of instruments, devices, and SCADA networks, all built to withstand the harshest environments and last for years.

 

But how do you measure reliability? Predicting how long equipment will last isn’t always straightforward, which is why standardised calculations are used. These calculations provide a clear, measurable, and comparable way to evaluate the likelihood of failure.

 

Mean Time Between Failure (MTBF) is a maintenance calculation to predict the time between failures of components in a repairable system, measured in hours, especially designed for critical and complex systems. It can help determine the reliability of asset and assist in reducing the overall cost of maintenance. Westermo tests its devices and provides MTBF results according to internationally recognised standards. Two key standards are used.

A man working in the factory with product heat testing.

MIL-HDBK-217 (Military Handbook 217)

  • One of the most widely used reliability standards, despite its age
  • Originally developed by the US Military for defence application
  • Adopted across many industries, including telecommunication
  • Strength: broad coverage of components such as capacitors, microcircuits, relays, and resistors
  • Limitation: only accounts for hardware components, not software or manufacturability

Telecordia SR-332

  • Developed later by Telcordia (formerly Bell Labs)
  • Created to address shortcomings of MIL-HDBK-217, which was often overly conservative
  • Specifically designed for telecommunications equipment
  • Includes newer technologies, such as integrated circuits
  • Tends to provide more optimistic (“generous”) failure rate predictions

For most Westermo products we use MIL-HDBK-217 and Telcordia SR 332. There is no preferred version, which is why we test to both.

What do the results mean?

To ensure credibility, Westermo, along wit other leading vendors, has its devices externally tested and verified by independent third parties. This means the MTBF results we share are both accurate and trustworthy, giving customers confidence that our products are fully prepared for deployment in the field.

 

Take the Lynx 3000 (link) series as an example. This product is available in several models, with either Power over Ethernet (PoE) or non-PoE models.

Three important take-aways for these results:

1MTBF is always given in hours. To put it in perspective, 1,138,000 hours equals roughly 129 years. Of course, this doesn’t mean the device will literally last for more than a century - it simply means that, statistically, failures are extremely unlikely over the product’s expected lifetime.

 

2. The second thing to note is that the MTBF varies per product. Different models include different components, so results will naturally vary. It’s important to look at the MTBF value for the specific device you plan to purchase rather than relying on the highest figure. Still, even the lowest result here represents well over half a century, which reflects exceptional reliability.

 

3. The last thing to note is the variation between standards. As discussed earlier, MIL-HDBK-217 is stricter and more conservative, while Telcordia SR-332 tends to produce more generous results. When comparing vendors, always check which standard has been used - some manufacturers may report higher MTBF values simply because they rely on less conservative testing.

 

At Westermo, we often highlight results from MIL-HDBK-217 because of its stricter methodology. This ensures our products are measured against the toughest standards, reflecting their suitability for harsh, demanding, and mission-critical environments. Telcordia SR-332 is also used, particularly for benchmarking against other vendors in the telecommunications industry.

 

Conclusion

In summary, MTBF is a valuable calculation that predicts the average time between failures in a repairable system. While it serves as an important benchmark when selecting or comparing devices, it should never be the only factor considered.

 

Other measurements, such as MTTR are equally important, as it’s evaluating the supplier behind the product. Reliability is not just about numbers on paper - it’s about how the product is manufactured, whether its components are ethically sourced, and whether there is full traceability and rigorous testing throughout the supply chain.

 

At Westermo, we take all these factors into account, ensuring that our products are not only backed by strong MTBF results - but are also designed to meet the highest possible standards for long-term, reliable performance.

Carl de Bruin

International sales

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