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

Where is Reliability Training Going? Abstract Chris and Carl discuss where reliability engineering training is going … noting that Chris and Carl do a lot of it. Key Points Join Chris and Carl as they discuss where reliability engineering training, where it is at, where it is going … and where it should be going. Both Chris and Carl do a lot of reliability engineering training … so what do they think? Topics include: The ‘traditional’ way? … is perhaps the stereotypical ‘dot point’ lesson where the instructors go through information one step at a time, and it is then up to the students to write down that information, in their own time review that information, and otherwise try to memorize that information. There are many problems with this, starting with the fact that people will very, very quickly forget stuff they memorize just to demonstrate ‘compliance’ with learning objectives. Why? … because this training is not fun, and it doesn’t come with a story or narrative. What have we learned? Carl in particular has decades of experience in delivering training for things like Failure Modes and Effects Analyses (FMEAs). This can be a dry topic! But the trick is to interact and engage. We need students to think about what they are learning. And a good way of doing that is to try and make the student apply what they are being learned to what they do and how it can help them. Where are we going? Chris in particular is working on developing avatar-based training … where scriptwriters work iteratively on improving the ‘perfect’ way of explaining what can be sophisticated topics. The benefit is that the narrative can be perfected iteratively. But the problem is that it is not truly interactive. But … this is where experience comes in. We need to be able to understand and anticipate the likely questions and ways to engage students to unlock the potential of fully online ‘avatar’ training. … but you need to keep learning … to teach other people have to learn. You can’t ever beat having the right ‘personality’ to teach. Do you have any experiences (good/bad/indifferent) regarding teaching and learning? … feel free to share with us! 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 893 Where is Reliability Training Going? appeared first on Accendo Reliability.

Where are FMEAs (and their standards) Heading? Abstract Carl and Chris discussing the future of FMEA, sharing their vision for where this method is headed. Key Points Where are FMEAs (and their standards) Heading? Abstract Carl and Chris discussing the future of FMEA, sharing their vision for where FMEA as a method is headed, as well as where we think it should be headed. Key Points Join Carl and Chris as they discuss the standards and methodology of FMEA, and analyze the trends that impact its use and value. What are the trends that affect FMEAs:? Are they positive of negative? The two types of FMEA users Should you follow FMEA standards exactly, or can they be tailored to your application? Understanding the fundamentals of FMEA is essential to properly use FMEA standards The role of Corrective Actions in applying FMEAs Next generation of FMEA standard is SAE 1025 Keep your eye on the ball: reduce risk to acceptable level We don’t need both acronyms FMEA and FMECA; both have a criticality analysis. FMEAs that are done early in the product development process are usually qualitative. Future is to use specific selection criteria to select when FMEA is used; preliminary risk assessment Future is to balance automation of selective portion of FMEAs, with team involvement on high-risk areas. Future is an integration of Model-Based Engineering with FMEA procedure 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 892 Where are FMEAs (and their standards) Heading? appeared first on Accendo Reliability.

Last Minutism Abstract Greg and Fred discussing why do folks wait to the last minute to get important things done.  We go beyond procrastination to understand the basics of last minutism. Key Points Join Greg and Fred as they discuss practical tips and tools to avoid last minutism. Topics include: What is last minutism behavior? Why do we all do this? What can you go to accept, avoid, or even control your last minutism? 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 891 Last Minutism appeared first on Accendo Reliability.

Hero Syndrome Abstract Greg and Fred discuss why heros who fly in to fix a failing project or product recall get all the attention, praise and promotions.  But, the folks who maintain the systems day in and day out are often neglected, forgotten, or even dismissed. Key Points Join Greg and Fred as they discuss fire fighting Hero Syndrome found in many companies. Topics include: What is the Hero Syndrome? Why do companies reward Hero behavior and dismiss daily system improvement and project results behavior? How can you become a Hero maintaining systems and improving processes? 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 890 Hero Syndrome appeared first on Accendo Reliability.

Becoming a Consultant Abstract Chris and Fred discuss how to become a reliability engineering consultant. Is this something you are interested in? Key Points Join Chris and Fred as they discuss how you go about becoming a reliability engineering consultant. There are lots of consultants out there … so surely it is easy to do … right? Topics include: Consulting is like parenthood. Everyone knows what parenthood technically entails before you become one. But until you become a parent, you don’t really understand what it is like. Same with consulting. You might be able to technically understand what a consultant does and how they earn money, but until you take the plunge and become used to not having money coming in between clients, spend more time on marketing yourself than your actual work and so on, you can’t understand precisely what it takes. If consulting was easy, then everyone would be doing it. Some people like the idea of being a consultant (being your own boss, setting your own schedule, answering to no one et cetera). But you need to be extroverted, engaging, and able to communicate how you can change the life of your potential clients. You might be the world’s best reliability engineer, but if you can’t seek out and make connections with prospective clients, it won’t matter. Not having a good resumé means you won’t get hired. Only having a good resumé also means you won’t get hired. A lot of ‘wannabe’ consultants believe that all they need to have is a set of qualifications and experience that dominates everyone else. These same ‘wannabe’ consultants get angry and frustrated when consultants they deem inferior get more work than they do. Resumés don’t tell clients how you are good at solving problems. This comes from your communication and messaging. I’m not going to share my knowledge through articles and podcasts and webinars … people need to pay me for that! Consulting is based on Karma. The more you share, the more you get back. If you don’t share at least some of your knowledge, and how you are skillful at implementing the tools and skills contained within your knowledge … then how does anyone else know how good you are? You have to share lots of knowledge and be prepared to help lots of people without the guarantee of reward in order to convince people that you are the right person for the job. 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 889 Becoming a Consultant appeared first on Accendo Reliability.

The Role of Regulations Abstract Chris and Fred discuss the role of regulations … good, bad and ugly. Key Points Join Chris and Fred as they discuss how regulations can help, hinder and delude us when it comes to making things safe and reliable. Regulations without a doubt have contributed to the saving of many lives over the years by preventing things from failing. Regulations have also been used (and abused) to try and find the cheapest, nastiest, and ugliest solutions to problems that have been disastrous. So what gives? Topics include: Let’s think of aircraft … like Cessnas. Cessnas are reliable aircraft. However, there is no motivation to continually improve the design and manufacture of these machines that were originally conceived in the 1950s. Why? Because that would require full re-certification (which is costly and time-consuming). So there is a financial disincentive to make anything better. Even moving from hand welding to machine welding is out. In isolation … this is not OK. For the bigger picture where we have this blanket need to recertify to ensure only good changes are made? … what do you think? … then there is Boeing. Who essentially hijacked the regulatory process and perverted it in the lead-up to the Boeing 737 Max aircraft disasters, where substantially new aircraft were argued as being ‘minor’ changes to an already certified airframe and did not need full recertification. This did not have a good outcome. So what are ‘regulations’ anyway? They are nothing more than rules decreed by human beings. They are as perfect as the humans making them. Which means that they are not perfect. They do not ‘precede’ technology. For example, regulated safety features in motor vehicles such as seatbelts, airbags, and ABS braking systems only became regulations after manufacturers made them standard in at least some of their models (which is why autonomous vehicles feel like they are perpetually ‘stalled’ in regulatory compliance). So the bottom line? Don’t outsource critical thinking. Make sure that your products are reliable AND comply with regulations. Just because something complies with regulations doesn’t mean it is reliable. And vice versa. 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 888 The Role of Regulations appeared first on Accendo Reliability.

Changing Customer Expectations Abstract Kirk and Fred discussing a recent product failure that Kirk had with the manufacturer of his e-bike, and the positive outcome. Key Points Join Kirk and Fred as they discuss Kirk’s e-bike user caused failure and how the company had a major spare part that they no longer manufacturing. Topics include: The manufacturer of the e-bike had opened a sales and service store locally since Kirk had purchased it in per-pandemic 2020, which made it easier to get service. The e-bike service center not only had the part, but when a secondary component had a failure the company not only replaced the component, which required a significant disassembly, they also did some other adjustments and did not charge extra for the repair. The same company previously replaced a AC charging module for the battery, due to a FET melting an adjacent inductor’s insulation,  at no charge. Both Fred and Kirk have worked for companies that have products that have a 50% failure rate, yet their customers tolerate it and they are still profitable. The decision to replace or repair a product is affected by the evolution of the pace of the particular technology, as smartphones are difficult to repair and rapidly improve in performance, where as e-bikes and washing machines have a much slower path to obsolescence. 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 887 Changing Customer Expectations appeared first on Accendo Reliability.

Making Assumptions Abstract Kirk and Fred discuss the use of assumptions in the reliability models, testing, and predictions Key Points Join Kirk and Fred as they discuss how assumptions are used in reliability engineering and how they can be misleading or very limited in making reliability assessments. Topics include: Assumptions must be made about potential stresses and environments the product will be used when creating reliability testing or evaluations. The assumption that all supply chains will always be capable and never have a process “excursion” is optimistic and process variations do lead to latent defects Kirk once was a part of a committee organized to determine why the reliability predictions made by the “reliability engineering” organization were not correlating to actual field failure rates. They seemed to not question that they were using industry accepted standard failure rates (i.e. MIL HNBK 217F) that were derived from technology many years before and that they were not aware of what was failing in the field nor the root causes. Some companies continue to require reliability predictions using models that have little to no correlation to actual field failure mechanisms, because that’s what has always been done. There are some mechanical wear out mechanisms, such as a magnetic tape wear to the read/write head glass surface,  that can be measured and the rate of wear can be reasonably known and valid estimates of life can be made. The life entitlement in solid state electronics for nominally built devices is almost always well beyond the systems technological obsolescence, and most failures are due to errors in design or manufacturing, or customer abuse. 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 886 Making Assumptions appeared first on Accendo Reliability.

Naked Mole Rat Abstract Chris and Fred discuss the naked mole rat … an animal that doesn’t appear to age at all! Ever! And they are ugly … Want to know why we are talking about these animals and what that has to do reliability? Listen to this podcast! Key Points Join Chris and Fred as they discuss the naked mole rate, which is one of the very few things in the world that appears to never age. Why are we talking about this? Well … many textbooks and reliability engineers assume that all of their machines and products are ‘naked mole rats.’ Confused? Topics include: Things that have a constant hazard or failure rate are like naked mole rats. Naked mole rats do die, but this is mainly from predation, injuries and other environmental stresses that cause death. So this means that a 40-year-old naked mole rate is just as likely to die today as a 5-year-old naked mole rat. And this is alien to our understanding of life, entropy and everything else. … and many textbooks and engineers simply assume that machines and products have constant hazard rates. This also happens if people only use the MTTF or MTBF to characterize the reliability of something. So every time a reliability engineer or textbook assumes a constant hazard rate or use the MTTF or MTBF and nothing else … they are essentially saying that the product or machine in question is a naked mole rat. Do you really think that your product, machine, vehicle, plant et cetera is a ‘naked mole rat’? Well … you do if you only ever use the MTTF or MTBF, or assume a constant hazard rate. Please don’t do this. 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 885 Naked Mole Rat appeared first on Accendo Reliability.

Allocating Reliability – Conundrum Abstract Chris and Fred discuss one of the challenges of allocating reliability … in response to a question from one of our listeners. Might you be able to learn something as well! Key Points Sam wrote in asking about how we go about allocating reliability targets to a system with 10 subsystems, each with 50 to 100 components. Some components are continuously operating, and some are ‘on demand.’ The system availability needs to be at least 90 %, including 15 days of planned maintenance over 2 years, along with no more than 5 days of unplanned downtime (on average) per year. How do we do this? Topics include: Keep things flexible for your design teams by not being too specific early. For example … the requirements above are all about availability … and not reliability. So resist the urge to convert things into MTBF and MTTR at the highest levels and then allocate goals because this constrains your design teams tremendously. If it is easier for a design team to come up with something that fails less often (high MTBF) but takes a long time to repair (high MTTR) as opposed to something that fails more often (low MTBF) but can be quickly repaired (low MTBF), let them make the call! If you have already come up with high-level MTBF and MTTR targets, you might have just unnecessarily ruled out a cheap and fast design solution! Then learn how to allocate goals to make it easy on yourself. Ever heard of allocation factors? Get these right and you ensure that the most ‘complex’ parts of your system have the most ‘flexibility’ when it comes to allocated reliability (and availability) targets. Check out our Reliability Allocation webinar at this link. It is way more important to manage reliability than set it in stone. No targets should be fixed in stone as you simply don’t know which components will have the most challenges. Sometimes one component that works perfectly well, doesn’t ‘like’ working with another component that also works perfectly well … then what? If you do reliability allocation well, you will have some ‘design reliability margin’ that leaders and managers can use to solve crises without any additional cost or delay. 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 884 Allocating Reliability – Conundrum appeared first on Accendo Reliability.