Speaking Of Reliability: Friends Discussing Reliability Engineering Topics | Warranty | Plant Maintenance

How FMEA Worksheets can Help (and Hinder) Abstract Chris and Carl discuss FMEA worksheets (we know … boring) … but can be incredibly helpful and useful. So what are they and how do they help us? Key Points Join Chris and Carl as they discuss FMEA worksheets, which are an important part of a Failure Mode and Effects Analysis (FMEA) that help us identify the potential issues with a product or process before they become issues – meaning we can (hopefully) help us design them out of existence when it is cheap and easy to do. Topics include: What is a FMEA worksheet? … it is a table that documents the conduct of a FMEA, including things like functions, tolerances, failure modes, defects, their corresponding likelihoods along with things we can do to address them. What is ‘pre-population’? Before you conduct a FMEA, there will likely be a list of things that we might already know about how our process or product might fail. ‘Pre-population’ involves putting these failure scenarios into yor worksheet before you start your FMEA. BUT … humans are not good at seeing what is missing. In other words, if we see that a FMEA worksheet already has some ideas about how something might fail, our brains often struggle to brainstorm more ways. The solution? Keep any existing knowledge in the ‘back pocket’ of the facilitator, allowing the team to brainstorm everything from scratch, and then see if there is anything missing from those pre-existing ideas. What are the media you can use? Software or spreadsheets. There are FMEA software packages out there that construct FMEA worksheets for you. Or …  you construct your own using a worksheet (Chris prefers spreadsheets as you can tailor them to your product, process or system). Chris’s tip? Start with a COMPLETELY BLANK SPREADSHEET for your team – except for a single ‘remarks’ column. This might sound crazy, but it is less intimidating. You need to have a list of column headings prepared and also in your back pocket, but if you insert and label columns as you go it helps the team focus. It also means the ‘remarks’ column is always ‘right there’ and not to the right of 20 + empty column headings. Carl’s tip? Before starting the workshop, hand out a bunch of yellow post-it notes and give them around 45 minutes to come up with as many issues that are going to ‘keep them up at night.’ Put them up on a wall, take a photo of them, write them down or do whatever you need to keep them at the forefront of everyone’s minds during the workshop. Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques to field data analysis approaches. Download Audio RSS Show Notes The post SOR 1096 How FMEA Worksheets can Help (and Hinder) appeared first on Accendo Reliability.

Reliability Engineering and Artificial Intelligence Abstract Carl and Chris discuss the changing opportunities and challenges with AI and reliability engineering. What are the positive interactions, and where should we be concerned? Key Points Join Carl and Chris as they discuss their views on the roles that AI can play in reliability programs. Topics include: What are the limitations of AI in supporting reliability programs? One concern is if AI is being oversold, and replaces necessary human involvement. Another concern is the possibility of AI moving a company towards mediocrity. AI can be useful to help ensure you don’t miss something critical. AI cannot perform an FMEA. It can augment an FMEA. It can provide excellent input to FMEA. Discussion around having an AI bot as part of an FMEA team. However, it may lessen creativity. Humans cannot see what is missing. AI generated input can retard human innovation and creativity. For this reason, it may help to begin with human creativity before bringing AI generated input. The purpose of FMEA is not to fill out a form. It involves surfacing risk, and reducing risk to an acceptable level. FMEA helps to improve the design or manufacturing process. Example: ask AI if MTBF is a good reliability metric. The answer is not very useful. Tip: review the citations listed with AI responses. Tip: Use AI to fill in the gaps, not the other way around. Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques to field data analysis approaches. Download Audio RSS Show Notes   The post SOR 1095 Reliability Engineering and Artificial Intelligence appeared first on Accendo Reliability.

Show Me the Money Abstract Greg and Dianna discuss how quality and reliability engineers can become AI boomers NOT doomers.  Engineers are being challenged with AI.  What can and should we do to survive and even prosper in the age AI disruption. Key Points Join Greg and Dianna as they discuss AI opportunities. What can you do to become an AI boomer. Topics include: Stories of career disruption. What is the human in the loop or middle. Tips and tools to become an AI boomer. Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques to field data analysis approaches. Download Audio RSS Show Notes   The post SOR 1094 Show Me the Money appeared first on Accendo Reliability.

Quality and Reliability Disrupted Abstract Dianna and Greg discuss your employability in the AI age.  So, let’s run a hypothetical.  You’re a 22 year old mechanical engineer.  You do robotic quality and reliability with a knowledge half-life of 4 years.   That means by the time you’re 26 knowledge in your domain has doubled.  Let’s say, you’re now 30.  Knowledge in your domain has quadruped.  Problem:  you have not updated your knowledge skills and abilities.  Are you still employable. Key Points Join Dianna and Greg as they discuss what we all face nowadays.  Technology is running ahead of our abilities.  And, how do we stay current?  Topics include: What is the half like of knowledge? What are examples of knowledge disruptions? How does it impact and why it matters to you? Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques to field data analysis approaches. Download Audio RSS Show Notes   The post SOR 1093 Quality and Reliability Disrupted appeared first on Accendo Reliability.

Risk or Safety Triggers Abstract Greg and Fred discuss how and when to escalate problems and risks. Key Points Join Greg and Fred as they discuss resolution and escalation of risk and nonconforming products. Topics include: What is the role of a professional code of ethics? What is the trigger for escalation. What are different types of safety triggers. How can you mitigate risks if you an internal employee or professional engineer? Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques to field data analysis approaches. Download Audio RSS Show Notes   The post SOR 1092 Risk or Safety Triggers appeared first on Accendo Reliability.

Keep it Simple Abstract Kirk and Fred discuss the challenge of using simple models for one finite element to extrapolate damage scalar metrics to very complex systems. Key Points Join Kirk and Fred as they discuss system models and how most fatigue damage models have many input variables, such as vibration and temperature, that can be very difficult to simultaneously measure across a system during operation Topics include: The vibration response of a test unit can be very different depending on how it is coupled or mounted on a vibration table. This is why it should be held so that the unit under test is mechanically coupled with the same boundary (attachments) as in its end-use chassis Most new electronics systems are iterations of existing products with new capabilities and features. Instead of reviewing and modeling the entire system for reliability weaknesses, we should focus on the few subsystems or components that have the highest risk from our knowledge of predecessor products and the field warranty data. CAD and Multi-physics computer models can run useful simulations of vibration and fatigue damage in the design phase. When you get the first hardware prototypes, the real testing and discovery of mechanical or electrical weaknesses can be confirmed or dismissed. The more stress margin, the higher the probability of being a reliable product in the customer’s use. Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques to field data analysis approaches. Download Audio RSS Show Notes Please click on this link to access a relatively new analysis of traditional reliability prediction methods article from the US ARMY and CALCE titled  “Reliability Prediction – Continued Reliance on a Misleading Approach”. It is in the public domain, so please distribute freely. Attempting to predict reliability  is a misleading and costly approach to use for developing a reliable system. You can now purchase the most recent recording of Kirk Gray’s Hobbs Engineering 8 (two 4 hour sessions) hour Webinar “Rapid and Robust Reliability Development 2022 HALT & HASS Methodologies Online Seminar” from this link. For more information on the newest discovery testing methodology here is a link to the book “Next Generation HALT and HASS: Robust design of Electronics and Systems” written by Kirk Gray and John Paschkewitz. The post SOR 1091 Keep it Simple appeared first on Accendo Reliability.

Connectors Abstract Kirk and Fred discuss the reliability of electrical connectors Key Points Join Kirk and Fred as they discuss the many ways that electrical connectors can lead to system failures. Topics include: The connector manufacturer may design a connector that is slightly modified from a standard reference design, which worked for many applications, but they cannot know the details of how it may be affected by your products’ end-use environments, such as higher thermal or vibration conditions in your system. Many connector issues are due to fretting corrosion caused by removing a typically thin gold-plated surface, which can be instantly cured when the connector is re-seated, making it very difficult to isolate. This phenomenon was a typical reliability issue with PC's DIMM memory modules when testing in an 85 °C and 85% relative humidity environmental chamber. High-speed digital systems connectors can have a significant impact on the quality of the signal integrity and lead to high Bit Error Rates (BER) if they're poorly designed or manufactured. There are so many parameters that the system designer may not be aware of when specifying a cable or connectors. How much does the cable/connector manufacturer know, or can know, about the specifics of how the cable works in your system and the details of system EMI, temperature, and tolerance to parametric variations? Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques to field data analysis approaches. Download Audio RSS Show Notes Please click on this link to access a relatively new analysis of traditional reliability prediction methods article from the US ARMY and CALCE titled  “Reliability Prediction – Continued Reliance on a Misleading Approach”. It is in the public domain, so please distribute freely. Attempting to predict reliability is a misleading and costly approach to use for developing a reliable system. You can now purchase the most recent recording of Kirk Gray’s Hobbs Engineering 8 (two 4-hour sessions) Webinar, “Rapid and Robust Reliability Development 2022 HALT & HASS Methodologies Online Seminar, a link to the book “Next Generation HALT and HASS: Robust design of Electronics and Systems” written by Kirk Gray and John Paschkewitz. The post SOR 1090 Connectors appeared first on Accendo Reliability.

Ten Career Gems for New Reliability Engineers Abstract Carl and Fred discuss our top advice for those starting a role as a reliability engineer for the first time. Key Points Join Carl and Fred as they discuss Topics include: Academic question: What do you do when you research a subject and there are no meaningful results, and nothing to publish? By what criteria should you select future projects? Academic question: Feel like missing something in education program, how to get out and actually apply reliability? There are many potential paths in a reliability career What should you do when you finish reliability educational program? What are the opportunities? Advice to new graduates or new reliability engineers: 1. Listen to successful people in your field and your company; 2. Connect with customers who actually use your product; 3. Find your network and your partners, including in marketing and finance; 4. Do a really good job where you are for minimum two years; 5. Get involved in professional organizations; 6. Don’t be afraid to talk with management; 7. Augment tech skills with soft skills (reference chapter 11 and 12 of The Process of Reliability Engineering; ; 8. Speak up if something is not going the right way (but do your research first); 9. Ask questions, be curious, learn; 10. Continue learning with new courses and self study. Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques to field data analysis approaches. Download Audio RSS Show Notes   The post SOR 1089 10 Gems Career Start Advice appeared first on Accendo Reliability.

AI Future of FMEA Abstract Carl and Fred discuss the use of AI with FMEA, what works and what does not work. Key Points Join Carl and Fred as they discuss the broad subject of FMEA and AI. We look at early lessons learned, discuss opportunities, and focus on the most important concerns. Topics include: How FMEA can interact with Model-Based Engineering? FMEA pre-population, which fields can be pre-populated and which should not? What is role of human team in FMEA? What are primary ways to reduce FMEA in-meeting time? How do team-based FMEAs, done very well, compare to AI automated FMEAs? How can AI augment well-done FMEAs? What specific support can AI provide to FMEA? AI can review past problems and provide excellent input to new FMEAs Look for areas of concern by proper FMEA team One concern about pre-population: people don’t see what isn’t there Consider AI bot as FMEA team member, with specifically defined role AI cannot replace human creativity and ingenuity Part of the value of FMEA is the deep discussion between subject matter experts AI will not solve potential blind spots AI can help with augmentation for FMEA, but not taking over the FMEA process. Download Audio RSS Show Notes   The post SOR 1088 AI Future of FMEA appeared first on Accendo Reliability.

What do Reliability Engineers Do? Abstract Dianna and Fred discuss what do Reliability Engineers do? Key Points Join Dianna and Fred as they discuss what do Reliability Engineers do? An RE’s role extends far beyond just crunching numbers and running tests. Topics include: How they act as crucial links between diverse teams Their ability to help teams shape decisions that profoundly affect product performance, customer satisfaction, and business outcomes. Bridging departmental silos, managing inherent conflicts, and advocating for the voice of the customer They also talk about why interpersonal skills and the ability to influence are just as vital as technical expertise for a successful reliability engineering career, even if they aren’t taught in school. Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques to field data analysis approaches. Download Audio RSS Show Notes In this episode of Speaking of Reliability, Fred Schenkelberg and Dianna Deeney dive into a question: “What does a reliability engineer do?” They quickly establish that while data analysis, regression, and failure analysis are indeed tools they use, these activities do not fully define the job. Fred and Dianna clarify that reliability engineers are fundamentally problem solvers and problem finders, often serving as bridges between different ideas and groups within an organization. They hold an important independent viewpoint and use their tools and data to influence decision-makers, impacting critical aspects like customer satisfaction, product pricing, field longevity, and safety. They emphasize that reliability engineers possess a unique, overarching view of the product due to their extensive collaboration across various departments, including marketing, sales, design, manufacturing, and vendors. This cross-functional engagement allows them to act as advocates for the customer, ensuring the product works reliably in its real-world environment. A key challenge they highlight is the need to prioritize important, preventive work over merely reacting to urgent failures, setting up organizational “guard rails” to systematically prevent problems. They also frequently find themselves managing inter-departmental conflicts arising from differing constraints and perspectives, a role often requiring them to step in and facilitate solutions. Ultimately, Fred and Dianna stress that while a strong technical foundation is essential, the ability to work with and influence people is a crucial, yet often untaught, skill for effective reliability engineering. This interpersonal aspect, combined with their expertise, makes reliability engineering a truly interesting and empowering position within any company. The post SOR 1087 What do Reliability Engineers Do? appeared first on Accendo Reliability.