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

Using DFR Tools Abstract Kirk and Fred discuss using Design for Reliability (DFR) for reliability development of a new product. Key Points Join Kirk and Fred as they discuss the use of DFx, being design for tests, design for manufacturing and design for reliability and the basics of good designs. Topics include: There are many CAD tools that have existed, such as SPICE for circuit analysis, that have been improved significantly over the decades. There are also powerful multi-physics software packages that can simulate environmental stresses on designs that can be applied before actual hardware is built. “All models are wrong, some are useful” a quote from George Box is true about the CAD models in that the values used are averages of well manufactured components and do not account for the manufacturing variations or variations of the same component from different vendors. It is important to document the weaknesses found in development of a new product to prevent future design weaknesses in the next iteration of the product or a new product to become more efficient in reliability development. Companies that do frequent reo0rganizations can make this very difficult to transfer the lessons learned to a new reliability team. 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 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. 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” 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 913 Using DFR Tools appeared first on Accendo Reliability.

Using Outside Labs Abstract Kirk and Fred discuss the use and tradeoffs of using external environmental testing and failure analysis labs versus having in-house equipment Key Points Join Kirk and Fred as they discuss the advantages and drawbacks of a independent test and or failure analysis lab, versus stetting up an internal lab. Topics include: Companies that are going to be using environmental stress for reliability development for current and future products have an exponential value of having and internal test lab over trying to use a remote or external test lab. External test labs for failure analysis may have more advantages in that the lab can do SEM imaging and component cross-sectioning with experienced FA engineers familiar  with component failure physics. Being able to have access to the multiple design engineers when you have an internal lab and are able to show engineers and reproduce product weaknesses under stress makes it much easier to improve the weak links in the product. Standard long duration tests, such as a week long test at 85C and 85% RH are the  pass-fail tests that are there are more good reasons to send to external labs. HALT testing to limits requires continuous monitoring and observation during the testing, and that it is critical to have engineers, and maybe several depending on the complexity of the device, to be able to isolate a weakness when found. Some products in HALT  that are robust and are as strong as the fundamental limit of technology can show and sometimes surprise engineers how much actual margin is possible, setting a new safe stress benchmark for accelerated stress testing. Some specialized testing, such as dust or salt spray, would most likely be best done at an external lab. 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 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. 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” 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 912 Using Outside Labs appeared first on Accendo Reliability.

Dealing with Data Abstract Philip and Fred discuss the first basic steps when confronted with a pile of data. What do you do with a stack of data – can you make any sense of this – please? Can you believe the analysis results? Designing systems to capture the data you need, not the data you have. How do you work with less than perfect failure information? What happens when we mix end of life data with functional failure data – when do we “informatively censor” and how do we treat this type of data? Interwoven life renewal data and asset failure – how do we “see” missing data? Deploying the Reliability Performance Index (RpK) – how to adapt Statistical Process Control topics (SPC) Reliability. What is Integrated Process Control (IPC), Key Input Variables (KIV) and Key Output Variables (KOV)? What is an Asset failure? How to manage data from our CMMS or ERP system – how to deal with data sets with only replacement events? Key Points Join Philip and Fred as they discuss these great topics which include: Consider the source and collection method Is the data fit for purpose? Does it match the intent of your analysis software? What sections of data are missing? Separating clerical push the button tasks from the analysis steps where you need a brain. Consider what we are trying to learn and need to know Plot the data – dot plots, histograms, etc. 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 911 Dealing with Data appeared first on Accendo Reliability.

Consumable Product Reliability Abstract Chris and Fred discuss how to approach reliability objectives and testing for consumable elements of a product or system. Key Points Join Chris and Fred as they discuss how to deal with consumable product reliability … that is the bits of your system that aren’t ‘components’ or ‘subsystems’ and are like fuel to your constantly degrading system. What is the reliability of these things? Topics include: Consumables either work or they don’t (usually). Think of things like gaskets, batteries, lubricants, glues and bonding agents. These are often forgotten when it comes to system reliability analysis. But if your system fails when a consumable stops doing what it is supposed to do before you think it should … then you have to place consumables into your system reliability model. Some consumables have a shelf life – which we can treat like reliability. Some people call this ‘shelf-life’ reliability, or ‘ageing.’ Whatever you call it, what happens to your consumable while it is sitting on a shelf (or a shipping container in a tropical environment) before you put it into your system also needs to be thought of. What can we do without time to failure data? Consumables can be a lot easier to deal with when it comes to more complex components. For example, we usually have a pretty good idea of how we need to store glue in order for it to be ‘sticky’ when you use it. And suppliers are often able to give you shelf-life guidelines that help you keep track of that bottle of glue while it sits on your shelf (in perhaps a controlled environment). The easy thing to do is to assume that your consumables are ‘perfect.’ If failure of a consumable costs you money, then it is a reliability concern. … and understand what failure is. Does your smart lock ‘fail’ if the batteries run flat? … or does it fail if the batteries run flat with you getting no warning? So you absolutely need to take consumables into consideration for your system. 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 910 Consumable Product Reliability appeared first on Accendo Reliability.

Assumptions and Analysis Abstract Philip and Fred discuss a fundamental element of all statistical analysis. Key Points Join Philip and Fred as they discuss Topics include: Every analysis or model has assumptions – understand them first Check the assumptions Assumptions are not true because we wish they were 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 909 Assumptions and Analysis appeared first on Accendo Reliability.

Why is Reliability a Process? Abstract Carl and Fred discuss the process of reliability, which also happens to be the name of their new book. They answer the question “why is reliability a process”? and discuss what happens if reliability is only approached as a series of methods. Key Points Join Carl and Fred as they discuss the process steps to attaining high reliability and the principles behind the steps. Topics include: Is there a set formula for achieving reliability? What will influence decisions to add the most value? What will guide the team to make the best products? Everything in life is a process; cooking is a process Stepping back and determining the specific steps to achieve reliability Measure how well you achieve your reliability goals Each step in the 6-step process to achieve high reliability requires knowing the principles behind the step. People who take the time to learn the process of reliability will do well Always ask why you are doing a method or step Passing a test vs understanding why you are testing There is a place for standards, but they have limitations; you need to know the principle behind the standard There is no “bulletproof” standard The process of learning is making and learning from mistakes If you are a mentor or instructor, don’t just tell your student what to do, ask them what to do and why. Always begin with the vision for where you are headed Fred and Carl discussed the possibility of hosting a webinar on “the process of reliability” with an interactive forum, encouraging lost of questions. Price of entry is bring one question. 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 908 Why is Reliability a Process? appeared first on Accendo Reliability.

How Root is the Cause? Abstract Carl and Fred discuss the broad subject of identifying root causes and how deep to go.  It’s not as simple as getting to the “root.” Key Points Join Carl and Fred as they share experiences in root cause analysis and how it is applied in various reliability engineering methods. Topics include: There is no single method for identifying root cause; it depends on the analysis being used. Root cause for Design FMEA goes down to the design deficiency level; whereas root cause for Supportability FMEA goes to the maintenance-actionable level Ask: at what level is it appropriate to take action? Fix problems now, and systemically, both Some root cause analyses continue to the human level, ask: what is the human system and how does human error contribute to the root cause? The level of the analysis should be agreed on before beginning What about multiple causes, is there more than one root? Is the human deficiency part of the root cause for Design FMEA? Ask: where are you going to take action? what part of our process enabled this to occur? Eight Disciplines (8D), step 4 is determine, identify, and verify root causes Severity and occurrence are both part of risk analysis Don’t merely blame the supplier or operator The root cause needs to be something you can remedy One of aspects of root cause is to ask if resources are available to fix the cause 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 907 How Root is the Cause? appeared first on Accendo Reliability.

Environmental Testing Abstract Kirk and Fred discuss the question of using a standard series of environmental test for reliability development. Key Points Join Kirk and Fred as they discuss standard environmental test suites such as MIL-STD 810 which describe many environmental tests that can be applied depending on the end-use conditions. Topics include: Many of these standards include the stresses and duration, they do not define what can be considered a failure. Many of the standard tests do not use stresses very much more intense than the expected end-use field stresses and therefore do not provide acceleration to find many latent design weaknesses. Many of the standard environmental tests can be converted to HALT type testing by increasing stress levels until a operational failure or destruction happens and determining how to make it stronger to the fundamental limit of technology. 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 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. 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” 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 906 Environmental Testing appeared first on Accendo Reliability.

A HALT Plan Question Abstract Kirk and Fred discuss a test plan sent to Kirk and how this plan misses the point of accelerated testing. Key Points Join Kirk and Fred as they discuss the fact that many of are labeled by the book titles they have written and yet we know many other important analysis techniques that we know and use. Topics include: HALT evaluations require a lot of thinking about what needs to be tested, what stresses to apply to what parts of the systems, and what will be defined as a failure In a nutshell, HALT is a methodology of applying environmental stress in a step-wise controlled function to electronic and electro-mechanical systems while operating, The stresses are applied to the point failure, then analysis of the potential weakness,  then improving the weakness and repeating to the point that the design has reached the fundamental limit of standard technologies. Kirk recalls discussing a component change with a manager who argued that a component failure that happened at a wide range of temperatures would never occur in the field, but with the change and a HASS process on the product reduced the warranty return rate from 5% to 0.5% return rate. The most important step in the HALT process is when a weak link is found that is well below the fundamental limit of technology is to improve it. HALT is a waste of time for those companies who want to reduce failures as opposed to telling customers that they do HALT, for marketing purposes. HASS is unnecessary if every unit is manufactured with little or no variations, but that is rare for most industries. Latent defects can be introduced into the supply chain at anytime in the manufacturing life cycle. 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 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. 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” 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 905 A HALT Plan Question appeared first on Accendo Reliability.

Good Reliability Requirements Abstract Carl and Fred discuss the essence of well-written reliability requirements. They are much more than reliability numbers. Key Points Join Carl and Fred as they discuss how to ensure reliability requirements are proper and adequate. This builds from the definition of reliability. Topics include: What are the four key elements of the definition of reliability? How can each of these four key elements be used to develop effective requirements for reliability? What makes for good reliability requirements and bad reliability requirements? Reliability requirements need to be incorporated into technical specifications and measurable in the right timeframe. What is difference between warranty policy and reliability requirements? Requirements should encourage the right behaviors to achieve the organization’s goals. Beware of merely passing tests. Quality objectives for reliability requirements. Don’t forget the intended functions. The four elements have to be specific to the item being specified. Technical specifications should be reviewed to see if the reliability requirements are properly specified. If reliability requirements are properly specified in purchased parts, suppliers can more easily develop and ship reliable parts. 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 During the podcast Carl mentioned a list of objectives regarding reliability requirements. Here is the list. ReliabilityRequirementsObjectives The post SOR 904 Good Reliability Requirements appeared first on Accendo Reliability.