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

Pushing the Limits Abstract Greg and Fred discuss pushing the limits for personal and professional development.  Greg discusses wearing a pink tutu to Oregon Country Faire and Burning Man.  Fred discusses pushing the limits for product testing and product development. Key Points Join Greg and Fred as they discuss pushing personal, design, and testing limits. Topics include: What is a successful reliability test? What are the limits that we impose and design in product testing. How do we measure product test and development success? How do we ensure that our product testing matters? 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 986 Pushing the Limits appeared first on Accendo Reliability.

Pursuing Ribbons Abstract Greg and Fred discuss the importance of the pursuit of ribbons.  What are ribbons?  They are the  badges, degrees, brands, and certificates that we all strive for.   They confer knowledge, skills, and abilities to others.  They are the things of life that we do for personal improvement and enrichment.  Greg believes the pursuit of ribbons or recognition is what we all do from the day we are born to the day we pass on.  Fred believes knowledge by itself is sufficient.  What do you think? Key Points Join Greg and Fred as they discuss why pursuing ribbons like green, yellow, and black belts are so important to quality and reliability engineers.  Topics include: What are the types of ribbons we pursue? Why do ribbons matter? Why do you go after the ribbons you do? 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 985 Pursuing Ribbons appeared first on Accendo Reliability.

Instead of Reliability Prediction Abstract Chris and Fred discuss reliability prediction and how it can relate to the ‘design’ phase when there is no data. How do you ‘predict reliability?’ Key Points Join Chris and Fred as they discuss what reliability prediction is. There are quite a few answers to this question … and some of them can be helpful! Topics include: What is ‘reliability prediction’ #1? Depends on who you ask. Reliability prediction is often seen as looking up a book or standard of ‘failure rates’ for specific ‘types’ of components. These ‘prediction tables’ include generic descriptions of things like ball valves, small two stroke engines and so on. The many problems with this is that these tables are not compiled with a lot of rigour, neglects the fact that the ‘same’ component from different suppliers can much more or less reliable than any other … and once you have a ‘number’ for that component reliability is never thought of again. What is ‘reliability prediction’ #2? What it should be is a more analytical, considered approach to looking at your design and analyzing what it’s reliability is. And this doesn’t need ‘data.’ There is nothing wrong with engineering judgment, and then understanding the (lack of) confidence in the results. This is OK. But it allows you to work out which ‘vital few’ components drive reliability performance. And those are the ones you study. What is ‘reliability prediction’ #3? Not the MTBF. That is the only number you get from those tables. But the MTBF is not reliability. … and why aren’t we trying to IMPROVE reliability before MEASURING it? Good question! There are many companies out there that make really reliable stuff without ever measuring how reliable it is. That’s right. So if you haven’t finished designing your product (presumably because there are more design changes to be made to improve the design), then why would you even try to come up with a number beforehand? 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 984 Instead of Reliability Prediction appeared first on Accendo Reliability.

Good Reliability Testing Abstract Chris and Fred discuss the difference between good and poor reliability testing. Key Points Join Chris and Fred as they discuss what makes a meaningful and valuable reliability test. And more importantly, how to use test results to make valuable decisions. And to make a decision – you need to read the reports! Topics include: Leadership needs to be bought in. There are plenty of really good tests where for whatever reason, the leadership team won’t read (or believe) the reports. NASA did this when they disregarded reports that suggested that detaching foam insulation couldn’t damage the wings of the space shuttle (which is precisely what happened in the 2003 Columbia disaster). And then there are leadership groups that give reliability engineers two data points and then want to demonstrate that the item will have a 99 % chance of lasting 20 years. And it matters ‘when’ you do testing. Most militaries focus on receiving ‘production ready’ tanks, planes, and weapon platforms after years and millions of dollars of development to be subjected to ‘acceptance testing.’ This ‘acceptance testing’ can often be exhaustive, involve lots of data points … but because it is done after the production process is complete, if the item fails the test, there is no feasible way of walking away from buying that item. There is no time or money left to do anything to improve the design, so the test results get ‘doctored’ or data points are explained away with minor corrective actions so that the fundamentally unchanged item is now deemed reliable enough. Pointless. There needs to be a strategy … tied to a decision. If at test doesn’t influence a decision, then don’t do it. If you are going to accept an item regardless of how it performs on the test … don’t do it. If you are going to conduct HALT testing, but the boss will never read the report … don’t do it. Work out what decisions you need to inform, work out if there is a test that can help, and only then implement that test. And when it comes to reliability … nothing beats actually understanding ‘how’ your thing fails. If you are a reliability engineer who only gains confidence based on data points in a spreadsheet, then you are not a ‘good’ reliability 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 983 Good Reliability Testing appeared first on Accendo Reliability.

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.