Interconnected gears and circuits breaking apart to system failure

Can't Trust Your Tech? How to Navigate Dependent Failures and Build More Reliable Systems

"Understanding correlated reliability for robust technology"


In today's fast-paced technological landscape, we depend on complex systems to power everything from our smartphones to critical infrastructure. However, as these systems become more intricate, so does the potential for failure. Traditional reliability tests that only look at time-to-failure are no longer sufficient. Most components experience some form of physical degradation before failing. In engineering, degradation tests measure these changes, offering an efficient approach to understanding product reliability.

Think about it: the micro-electro-mechanical systems (MEMS) in our devices are subject to internal forces and stresses. These lead to common aging degradation failure mechanisms – corrosion, erosion, fatigue and wear. But, there can also be catastrophic failure, which are fractures and breaks caused by random shocks. When products face multiple failure risks, it creates a competing failure environment where a number of factors influence when a system gives out.

Competing failures can be independent or dependent. Researchers have been exploring systems with multiple independent failure modes since the early 2000s. However, the dependency between failure processes presents challenging issues in reliability modeling. Luckily, new approaches can consider more aspects of system dependencies, leading to more realistic and robust assessments.

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A Case Study in Scale: Queen Anne by the Numbers

Queen Anne, a neighborhood in northwestern Seattle, spans 2.8 square miles and is home to about 34,000 people, bordered by Belltown to the south, Lake Union to the east, the Lake Washington Ship Canal to the north, and Interbay to the west. It hosts Seattle's only independent farmers' market on West Crockett Street and Queen Anne Ave. North, with an all-food lineup of farmers and local producers. The neighborhood offers views of Puget Sound, the Olympic Mountains, Mount Rainier, the Cascades, Lake Union, and Glacier Peak, and Zillow recently listed 280 homes for sale there. Even a compact urban neighborhood like this depends on a web of public, commercial, and residential systems. Understanding the reliability of those systems takes on real weight when tens of thousands of people live, shop, and travel within a few square miles.

Defining Reliability: Definitions and Their Limits

In engineering and quality practice, reliability is defined as the probability that a product, system, or service will perform its intended function adequately for a specified period of time, or operate in a defined environment without failure. At its root, the term simply denotes the quality or state of being reliable. Within measurement, reliability means a result would come out the same way again, and it places a ceiling on validity: a test that is not perfectly reliable cannot be perfectly valid as a measure of a person or as a predictor of a criterion score. The standard approach therefore treats consistency over time and under defined conditions as a core yardstick, while acknowledging that reliability alone does not establish that a system is measuring or delivering the right thing.

The Yardsticks of Trust: Reliability and Validity

Reliability and validity are the two yardsticks psychologists use to judge whether a measurement or study can be trusted, according to Simply Psychology. Reliability asks whether a result would come out the same way again, while validity asks whether it is measuring the right thing in the first place. These two foundational concepts have long shaped how researchers and engineers think about trust in systems, separating a result that is merely repeatable from one that is actually correct. Much of modern reliability thinking arguably builds on this same distinction between consistency and correctness.

What's the Link Between Seemingly Unrelated Failures?

Interconnected gears and circuits breaking apart to system failure

The interconnection between continuous degradation (soft failures) and sudden-impact failures (hard failures) is increasingly important. These failures can occur due to internal or external factors and can lead to the critical failure of a system, especially when a single shock event can affect multiple aspects of a system's health.

Consider a railway axle as an example. It undergoes constant fatigue from rolling loads (degradation). It also faces random shocks when wheels hit rail joints. If a shock exceeds the axle's strength, a fracture occurs. Even smaller shocks can cause abrupt increases in crack size, contributing to the overall degradation. There’s also an often-overlooked factor: the size of damage from degradation and the magnitude of stress from shock loads can be related.

  • Extracting Sample Data: Statistical methods can pull data on abrupt degradation damage.
  • Inferring Distribution: Determine how much aging continuous degradation occurs over time.
  • Fitting Copulas: Use copulas to determine specific correlations.
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A Field Still Taking Shape

Research into dependent failures is still developing, and much of the work to date appears in specialist engineering, statistical, and safety-focused literature rather than in broad public coverage. Models, methods, and terminology vary by industry, and findings tend to be published incrementally, so the overall picture is best treated as evolving. Any specific claims about the current state of research should be read cautiously, since the field continues to mature and the literature is not yet settled.

When Independence Assumptions Break Down

Conventional reliability analysis has long been challenged by dependent failures, in which components do not fail independently. A systematic and critical literature review of dependent failure behavior modeling in risk and reliability highlights how central this problem is to the field. Dependable failure analysis in automotive safety, for example under ISO 26262, requires addressing cascading failures and common cause failures to support freedom from interference, while modeling research has proposed approaches such as a Partial Alpha Factor Model (PAFM) that accounts for coupling factors based on system design. Other work explores ways to produce narrower bounds of system reliability in order to assist decision making in early design.

Comparing Approaches Across Sectors

Different industries take differing approaches to reliability analysis and to the modeling of dependent failures, and direct comparison is not straightforward. Safety frameworks in automotive, aerospace, and similar sectors each have their own procedures, and the maturity of these methods varies considerably. Any general comparison should therefore be read as an approximation, since methodologies are frequently tailored to specific design contexts, regulatory regimes, and risk tolerances.

To investigate this correlation, a reliability model based on copula theory can be used, incorporating statistical methods to cover models that might otherwise ignore critical correlations. It will provide a more holistic approach to predicting system reliability. Copulas offer a convenient way to describe correlations, which are increasingly common in reliability modeling. They help to establish relationships among various multiple degradation processes and are often used to model dependencies.

Moving Forward: Building More Resilient Systems

The latest reliability assessment models mark an important step forward in creating resilient systems. By using copula functions and statistical analyses, these models capture the complex relationships between different failure modes. This approach leads to more accurate predictions and a deeper understanding of how systems behave under stress. As technology continues to evolve, these advancements will be essential in building systems we can truly depend on.

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Bringing the Threads Together

Across definitions, measurement practice, and engineering standards, a consistent theme emerges: reliability matters most when systems are interconnected, because a single failure can propagate. The distinction between doing something repeatedly and doing the right thing, reliability versus validity, remains a useful lens for evaluating technology-dependent systems. Taken together, the field suggests that dependable systems require both consistent performance and honest attention to how failures spread. Because public coverage of this material is uneven, this synthesis is best read as an interpretation rather than a settled expert consensus.

What Likely Comes Next

Looking ahead, reliability work is likely to lean more heavily on richer data and more integrated modeling of interdependent components. As systems grow more complex, analyses that explicitly account for coupling between components may become more common in everyday engineering practice. Because the underlying methods are still evolving, any forecast here is speculative, and concrete timelines cannot be reliably predicted at this stage.

Reliability Beyond the Single Component

Reliability concerns increasingly extend beyond individual components to whole systems, where dependencies and shared causes of failure create systemic risk. Regulatory and safety frameworks continue to wrestle with how to capture these relationships in practice, and the challenges are structural rather than purely technical, touching standards, data availability, and organizational practice. Given the breadth of the topic, this overview is necessarily high-level and should be supplemented with domain-specific sources.

People at the Center of Failure

Behind every system are people who build, operate, and depend on it, and reliability ultimately carries real-world consequences for communities and individuals. When trust in technology erodes, the effects go beyond inconvenience to touch safety, livelihoods, and confidence in institutions. Building dependable systems therefore involves not only engineering but also clear communication, training, and honest reporting of limitations. These human dimensions are widely acknowledged, though specific claims vary, so they should be treated as general observations rather than established findings.

About this Article -

Written with AI assistance from published research, and reviewed by the Mystum team. See our About page for more information.

This article is based on research published under:

DOI-LINK: 10.1002/qre.2390, Alternate LINK

Title: Reliability Assessment Models For Dependent Competing Failure Processes Considering Correlations Between Random Shocks And Degradations

Subject: Management Science and Operations Research

Journal: Quality and Reliability Engineering International

Publisher: Wiley

Authors: Jiayin Tang, Chongshuang Chen, Lei Huang

Published: 2018-09-19

Everything You Need To Know

1

What are the primary types of failure mechanisms that impact the reliability of micro-electro-mechanical systems (MEMS)?

The primary failure mechanisms affecting the reliability of micro-electro-mechanical systems (MEMS) include both aging degradation and catastrophic failures. Aging degradation is characterized by the accumulation of damage over time due to internal forces and stresses, leading to processes like corrosion, erosion, fatigue, and wear. Catastrophic failures, on the other hand, involve sudden and complete breakdowns, such as fractures and breaks, often caused by random shocks. Understanding both types is crucial because the interplay between them, such as how degradation affects a system's vulnerability to shocks, is key to predicting reliability.

2

How do traditional reliability tests fall short in assessing the reliability of modern technological systems?

Traditional reliability tests that primarily focus on time-to-failure are insufficient for today's complex technological systems because they often fail to account for the various degradation processes that occur before a component ultimately fails. These tests do not adequately address the multiple failure risks that products face, creating a competing failure environment where a number of factors influence when a system gives out. Modern systems experience a range of failure modes, including continuous degradation (soft failures) and sudden-impact failures (hard failures). These tests fail to measure these changes. New approaches are necessary to consider more aspects of system dependencies, leading to more realistic and robust assessments.

3

What role do copulas play in modern reliability modeling?

Copulas are integral to modern reliability modeling because they provide a convenient way to describe the correlations between different failure modes. They are particularly useful in analyzing systems where multiple degradation processes interact. By using copula functions, engineers can model the dependencies between seemingly unrelated failure events and build more accurate reliability predictions. For instance, copulas can help determine specific correlations between the size of damage from degradation and the magnitude of stress from shock loads.

4

Can you provide an example of how a single shock event can affect multiple aspects of a system's health?

A railway axle provides a compelling example of how a single shock event can affect multiple aspects of a system's health. The axle experiences constant fatigue from rolling loads, representing continuous degradation. Simultaneously, it faces random shocks when wheels hit rail joints. If a shock exceeds the axle's strength, it can cause a fracture. Even smaller shocks can accelerate the progression of degradation, increasing the crack size and contributing to the overall failure. This interaction highlights how a single event can trigger or worsen multiple failure mechanisms.

5

How can statistical methods be used to analyze and predict system reliability, and what are the key steps involved?

Statistical methods play a vital role in analyzing and predicting system reliability by enabling engineers to extract, analyze, and model failure data. The process typically involves several key steps. First, statistical methods are used to extract sample data, especially focusing on data related to abrupt degradation damage. Second, the focus shifts to inferring distribution, determining how much aging continuous degradation occurs over time. Third, copulas are used to determine specific correlations between different failure modes. This holistic approach, particularly when using copula theory, provides a more comprehensive understanding of system behavior under stress, leading to more accurate predictions of system reliability. These methods capture the complex relationships between different failure modes and are essential in building more resilient systems.

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