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

High Precision Planning and Maintenance Abstract Philip and Fred discuss new shiny objects and why digital twins and IIOT will not solve your core problems. High Precision Planning (HPP) supports High Precision Maintenance (HPM) which is a program running in elite industries today. The emphasis on HPP is an absolute requirement to achieve HPM. The benefits of achieving HPM have been demonstrated to be an improvement up to 250% in first-pass quality. Key Points Join Philip and Fred as they discuss HPP and HPM Topics include: A special focus on Precision Deployment of LEAN principles to remove waste from the maintenance delivery cycle. Purposeful reduction in variability in the way a maintenance technician performs a specific job Goal is “Every Technician does the same job the same way”. The obvious deliverable is to remove maintenance induced failures and to ensure the maintenance strategy deployed actually suppresses the failure modes expected. 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 Given the example of typical shaft alignment what can we learn relative to HPP and HPM? Write down your alignment plan Make darn sure all the shims, bolt torques and sockets, or hex keys needed are part of the plan. With HPP engaged, we do not accept an empty box if shims – it must be restocked with all sizes and ready for each use. We need to determine what bolt torques are specific to the base bolts and coupling bolts. Where locking devices can be used, they should be – Nordloc is preferred based on Junkers machine testing We obviously need a torque wrench to ensure the torque applied satisfies the bolt specifications for tightness. All couplings are NOT the same! Some couplings require tighter tolerances to  allow the bearings on each side of the coupling to survive. Work Force Amplification With planning Typical lore is 3.5X work can be accomplished with the same crew. Philip’s experiment in Asia revealed this may be as high as 11X with HPP engaged! With HPP we counter the myth that every technician knows how to install every part. A typical factory has ~ 30,000 parts in the storeroom It is unrealistic to expect every technician every time to install 30,000 different things extremely well. Its a long Game Operations Managers are incentivized to  perform today – this shift. Precision concepts like shaft alignment extend asset life to > 5 years Its therefore a long game Benfits include Low wear No indusced quality problems Get it right the first time and it will serve you well. Dig out of reactive world. Kitting Up work ensures it gets does with HPP Precision So important to remove waste from the daily work force Infers planning beyond what we are used to. Average industrial technician performs ~2 jobs per day. If we have 100 technician’s we can expect 200 jobs per day. If we adhere to the golden rile of 80% proactive and 20% reactive work as the transition to first quatile performance We need to plan 160 jobs a day So we must accept incremental planning each time we do a specific job The post SOR 982 High Precision Planning and Maintenance appeared first on Accendo Reliability.

Asset Management vs Performance Abstract Philip and Fred discuss the important differences between Asset Management “Systems” and “Asset Performance”. Philip has been teaching at the university level for over 10 years as an industry expert and has concluded that adherence to Asset Management System and certification does not equate into great asset performance. There is a very big disconnect between the asset performance of those organizations who are actually certified in asset management systems like ISO 55000. If you have a good Asset management “System” in the industry today it does not guarantee that you will have great “Asset Performance”. Why ISO “management systems” like ISO 9000 and ISO 55000 and ISO 14000 are not well suited to produce top “Asset Performance”. ISO is after all – a self-confession – “say what you do – then back it up with documentation to prove you do what you say!” Why is poor asset performance possible form certified organizations? Why is top performance in an industry occuring where organizations are not certified to ISO 55000? Why do digital twins fail to deliver? Remember – “the pursuit of Performance is the only thing that makes you Excellent!”. Key Points Join Philip and Fred as they discuss Topics include: Asset Management Systems do not guarantee top Asset Performance Top Asset Performance often occurs without a standard based Asset Management System The pursuit of Excellence delivers the best in Class performance. 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 981 Asset Management vs Performance appeared first on Accendo Reliability.

Effect and Likelihood Abstract Carl and Fred discuss a listener question on FMEA, about reducing the severity level through mitigation strategy. Specifically, can FMEA reduce the likelihood of the effect of failure? Key Points Join Carl and Fred as they discuss how FMEA deals with mitigation of the Effect of failure. Topics include: How design change can mitigate seriousness of the effect of failure Strategies to reduce severity of a problem during operation FMEA design prevention methods Difference between likelihood of the Cause in an FMEA, and and likelihood of effect, not determined in FMEA FMEA does not quantify the likelihood the a bad event (effect) FMEA does assess the likelihood of the cause of failure What techniques will determine the likelihood of the bad event? FMEA can point to need for testing Relationship of FMEA with Hazard Analysis Proper use of FMEA Regulations that require FMEA can promote “checkbox” Interacting with regulatory bodies Use of Fault Tree Analysis to analyze unwanted event 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 980 Effect and Likelihood appeared first on Accendo Reliability.

Conveying FMEA Results Abstract Carl and Fred discuss an interesting listener question. The listener’s management asked him to create an “eye-popping” chart that summarizes the results on an FMEA. Key Points Join Carl and Fred as they discuss how best to share the results of an FMEA with management or engineering. The emphasis is on visually conveying the information, clearly showing the highest risk issues. Topics include: Option 1: summarize FMEA based on value, such as cost savings Option 2: summarize the high-risk issues on a risk matrix. See Show Notes. Option 3: one page for each high-risk failure mode, with status of resolution Risk management typically characterizes risk on two axis plot: severity, likelihood Consider animation to show status of resolution of how high-risk issues In order to identify savings from FMEA, you either have to wait for field results or perform reliablity prediction Remember to focus on your audience Quantify your potential savings, if you can Consider plotting results on SO Matrix and include cost savings (be sure to document your assumptions) Management always wants to know the return on investment 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 Here is an example of plotting the results of fictitious Brake Cable Design FMEA on an SO Matrix. SxOMatrix The post SOR 979 Conveying FMEA Results appeared first on Accendo Reliability.

Supply Management and Context Abstract Greg and Fred discuss why today’s business model is often based on managing an organization’s brand and outsourcing design, reliability, and quality. Key Points Join Greg and Fred as they discuss supply context and risk. Topics include: Changes in today’s business and operating models. Changes in how suppliers are evaluated and chosen. Why risk is important in supply management decisions. How companies make money through reliability. 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 978 Supply Management and Context appeared first on Accendo Reliability.

Telling the Boss NO Abstract Greg and Fred discuss work communications and job politics.  Greg takes the management point of view.  Fred advocates the individual contributor point of view. Key Points Have you ever told your boss ‘NO’?  Join Greg and Fred as they discuss boss requirements and individual work expectations. Topics include: How to share bad or difficult information with your boss. What do great bosses want. What should conscientious employees do with a difficult boss. 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 977 Telling the Boss No appeared first on Accendo Reliability.

Reliability in a Short Term Org Abstract Chris and Fred discuss the problems we experience when we are in an organization with very ‘short-term’ thinking. What can we do? Key Points Join Chris and Fred as they discuss how challenging it can be to work in an organization that perhaps one day had a long-term goal or vision, but now has a vicious focus on ‘short-term’ goals and quarterly results. What can we do? Topics include: Leadership turnover is not helpful. CEO turnover has never been higher. Current militaries (for some reason) value senior officers spending no more than two years in a position before they move on (all for the purpose of  ‘gathering experience’ and ‘insight’). But the reality is the most successful companies and military operations are associated with a particular person. Whether it be Steve Jobs, George Patton, Bill Gates, Boudica, Oprah Winfrey and lots of others … most organizations that were once ‘industry-leading’ had stable, insightful leaders who were invested in long-term success and never wanted to be ‘swapped out.’ If there are no leaders … you need a champion. That is someone who can remain a rock throughout changing leadership to create an ever-building focus on reliability engineering, what it does, and why we want to do it. Not perfect … but better. Don’t put lipstick on a ‘short-term organization’ pig. This will not yield ‘long-term’ happiness for you personally. The reality is that if leaders are expected to be in roles for short periods of time, they can never get the chance to be associated with success. So failure is not a problem. 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 976 Reliability in a Short Term Org appeared first on Accendo Reliability.

Eye-Popping Stunning Results Abstract Chris and Fred discuss the challenge of being asked by someone to show (or visualize) stunning, eye-popping results for some reliability activity. How do we do this? Is this possible? Key Points Join Chris and Fred as they discuss how we go about demonstrating stunning, eye-popping results for the amount of resources and organization has invested in a reliability activity. It could be a FMEA. It could be a HALT program. It could be reliability data analysis. So how do you begin? Topics include: What do the ‘people’ want? If your boss is viciously focused on time to market (and not much else), then make sure your stunning, eye-popping results are not all about warranty costs. Your boss (incorrectly) doesn’t care about this. But reliability activities (for example) always make your production process faster and less problematic. So focus on this if this is what the boss wants to see. So always know what the people want. But we also need patience. For example, a FMEA is something whose benefit will be realized throughout the production process (even if those benefits are apparent to the participants at the start). So you can’t be halfway through your first amazing FMEA and then have wonderful results to demonstrate. At best, the people participating in the FMEA will be able to speculate or brainstorm the problems that would like be solved, along with indicative costs or delays associated with them. But a successful FMEA program will start to show that projects start to become less delay-prone and cheaper overall. The problem is that this is often not just due to a FMEA, or the other activity you are asked to show results from. And less is more. Or quantity is not quality. That’s right … if there is one ‘big ticket’ item, such as a $ 10 million saving, then have that be perhaps the ‘only’ thing in your presentation or visual. More words or messages dilutes your keywords or messages. 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 975 Eye-Popping Stunning Results appeared first on Accendo Reliability.

New Position Advice Abstract Kirk and Fred discuss the advice we would give a engineer just starting a career in Reliability Engineering Key Points Join Kirk and Fred as they discuss the way to best way to learn and apply the many tools and methodology of reliability engineering. Topics include: First seek to understand the history of failures in the current and previous lnowledge of how the reliability problems happened, the root cause and how the corrective action was implemented. This can be challenging as most companies do not want to discuss product or production failures. Second, seek to understand the company culture and who the decision makers are, and what the managements priorities are.Reliability may not be the highest priority. The field of reliability engineering and the benefits of the development of a reliable product take a long time to manifest in the field. At the same time engineers and management may change monthly so it is difficult to prove the efficacy of  a particular method in the short term. There is a “honeymoon” period in starting a new job position and that is the best time to ask questions to engineering and management, and dig into the field data and what was the corrective action and costs involved. 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. Trying to predict reliability for development is a misleading a costly approach. 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 974 New Position Advice appeared first on Accendo Reliability.

Reliability Allocation Methods Abstract Kirk and Fred discuss reliability allocations for individual components and subsystems. Key Points Join Kirk and Fred as they discuss a question from one of our listeners and why solid state electronics and mechanical systems have significant differences in the intrinsic life entitlements and have to be analyzed with different models that may be available. Topics include: Knowing what the intrinsic life of a component in a new application is difficult if not to predict, but in power electronics there are some wear out mechanisms as seen in IGBT (Insulated Gate Bipolar Transistors) and batteries do wear out before the systems are technologically obsolete. There are many variables in the life estimate of a component subsystems such as manufacturing, multiple suppliers, and variation in end-use environments that would take significant effort and time to test for. HALT and Accelerated life testing (ALT) have different goals, where HALT can empirically expose a products fatigue weaknesses, and ALT is to quantify the time to failures, but ALT typically takes longer with more samples. Prognostic and Health Management (PHM) have become a more significant method in electronics life measurement and is based on finding leading parametric measurements that indicate component degradation and eventual wear out. 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. Trying to predict reliability for development is a misleading and costly approach. 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 973 Reliability Allocation Methods appeared first on Accendo Reliability.