Reliability Engineering for AI Systems: Challenges, Methods, and Directions

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AI reliability concerns whether an AI system performs its intended function dependably over a stated period and under stated operating conditions, with stated evidence. As these systems become more autonomous, that function includes more than a correct output. Retrieval, memory, tool use, permissions, human oversight, and interactions among systems must operate consistently and safely, and, for generative systems, so must the reasoning process that produces the output. Average benchmark accuracy measures capability; it does not quantify this broader reliability claim. This paper adapts established reliability engineering methods, from failure definitions and operational envelopes to FMEA, accelerated testing, field monitoring, and reliability growth, to AI systems. A four-level diagnostic framework classifies failures as component, operational-loop, agentic-conduct, or network and governance failures. Test, evaluation, verification, and validation (TEVV), sequential monitoring, and FRACAS create and refresh evidence. SMART provides statistical guidance for measurement, analysis, assessment, and test planning; the NIST AI Risk Management Framework provides organizational guidance for governance, evaluation, monitoring, and mitigation. Three cases illustrate the program: adversarial testing of a convolutional neural network, perception-error propagation, and autonomous-vehicle disengagements. Established reliability engineering provides a usable foundation; new measurements and safety guardrails are still needed as these systems are self-evolving.