AVL Reliability Engineering and Risk Management

Reliability is a key characteristic that significantly influences the economic success of a product. The AVL reliability process includes innovative reliability methods, risk management and product safety methods.

AVL Solution

The AVL Reliability Process accompanies a development project from concept phase to market release and beyond. The major topics are:

  • Systematic risk management for projects
  • Highly efficient FMEAs for the complete powertrain (Product FMEAs including Control Systems, Process FMEAs )
  • Determination of risk-based reliability targets for subsystems and components
  • Statistical design of experiments for development
  • Consulting in functional safety
  • Planning and optimisation of validation programs (AVL Load Matrix®)
  • Analysis of customer usage for load spectra derivation
  • Reliability growth monitoring
  • Near-real-time health monitoring of test fleets
  • Warranty cost modelling and return-on-invest assessment of development activities
  • Systematic root cause analysis and failure correction supported by statistical methods
  • Reliability training and consulting

Benefits at a Glance

With many years of expertise, the AVL reliability team combines experts from different fields such as risk management, statistics and data monitoring and management so that for every task the right team is available.

  • The most effective combination of scientific methods and best-practice approaches
  • State-of-the-art statistical and optimisation methods
  • Efficient integration in your processes
  • Highly integrated team-work between customer, supplier and AVL
  • International patents on reliability methodology (Load Matrix®)
  • Confidence by assessment, monitoring and prediction of reliability
  • Improvement of product reliability and reduction of warranty costs
  • An unbiased view on a sensitive topic
  • Absolute confidentiality


AVL has a proven record of successful reliability projects for leading OEMs and suppliers. A small selection of completed projects include:

  • Optimization of the reliability test program for a new truck family
  • Lifetime extension program for an agricultural tractor powertrain
  • Validation optimisation for an exhaust gas aftertreatment system
  • Warranty reduction program for a heavy-duty truck engine
  • Elaboration of a series of product FMEAs on system and assembly group level, including the control system for an off-road powertrain
  • Warranty risk estimation for long-term warranty parts
  • Design for reliability program for a large engine for genset application
  • Optimised reliability test planning for fuel cells
  • Derivation of market specific load spectra for an HV battery pack
  • Reliability consulting for innovative powertrain systems