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

Restarting Quality Abstract Greg and Fred discuss the future of quality and reliability – which may be ‘back to the future’ of quality. Key Points Join Greg and Fred as they discuss how to restart quality Topics include: What is the current state of quality management, assurance, and control. What changes are occuring in quality. What will be the future of quality. 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 Check out the Ann Jordan interview by Quality Digest on the Future of ASQ and quality: https://www.youtube.com/watch?v=01n0Y58_1Bg Related topics SOR 734 Can Organizations Change(Opens podcast in a new browser tab) The post SOR 785 Restarting Quality appeared first on Accendo Reliability.

Decision Fatigue Abstract Greg and Fred discuss the importance for making smart decisions.  The challenge is that after Covid we are all tired of making decisions.  So, have we lost our perspective and even our sense of humor in understanding context in making smart decisions. Key Points Join Greg and Fred as they discuss decision fatigue. Topics include: Why are we all tired of making decisions. What happens to quality and reliability professionals who continually bring problems not solutions to their bosses. What can we do to alleviate decision fatigue. 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 Check out the Guardian article and see the Australian cartoon below: https://www.theguardian.com/artanddesign/2020/jan/23/its-telling-that-people-are-convinced-theyre-real-the-satirical-signs-of-sydneys-nanny-state Related Topics Post Covid Perfect Storm(Opens article in a new browser tab) The post SOR 784 Decision Fatigue appeared first on Accendo Reliability.

A Facilitator’s Role Abstract Carl and Fred discussing the essence of a facilitator’s role in leading meetings and reliability methods. This role is discussed from the viewpoint of reliability applications. Key Points Join Carl and Fred as they discuss the key elements of the facilitator role. What works? What doesn’t work? What skills are involved? Topics include: What is the role of facilitator? Should a facilitator control the discussion? What does this mean? Facilitator must not impose his/her will. That is wrong type of control. Facilitator has power. How to facilitate without misusing power. Facilitator should listen and guide, controlling or manage to ensure that there is balanced input from all participants to the discussion. People’s time is meetings is highly valuable. Facilitators need ground rules, norms of behavior. Extrovert vs introvert and how to balance input. Higher position people can influence how much people are willing to be open and involved. Create safe place where people can bring up concerns. Are facilitator’s neutral? Should they be? What is the problem with purely neutral facilitators? Facilitators can have a dual role – facilitation plus subject matter expertise. They need to be clear which one they are when they talk. How to get to consensus, where everyone buys in. What are the goals of the meeting? What techniques can be used to get to the best meeting outcomes in the least amount of time? 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 Related Topics Should I Train a Good Facilitator or a Great One?(Opens podcast in a new browser tab) The post SOR 783 A Facilitator’s Role appeared first on Accendo Reliability.

A PFMEA Use Question Abstract Carl and Fred discussing an interesting question from a subscriber to the Inside FMEA series. The question has to do with selected process steps on a Process FMEA, and the efficacy and value of the occurrence rating being verified later in pilot assembly or trial production. Key Points Join Carl and Fred as they discuss whether or not the PFMEA occurrence rating should be verified in trial production. Topics include: Occurrence rating in PFMEA is not usually an objective numerical failure rate. When PFMEAs are done on new or modified processes, the field or plant data is not the only input to occurrence rating. PFMEA occurrence rating is used (along with severity and possibly detection) to prioritize issues for follow-up action. Discussion on how PFMEA occurrence rating is determined and how it is used. Discussion on subjective ratings in an FMEA. Primary purposes of PFMEA include improving the process design and improving the process control plan. One of the outputs of FMEA is to learn where to go look. Linkage between PFMEA and Process Control Plan. Limitations of doing FMEAs on everything 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 Related Topics PFMEAs can Identify Special Process Characteristics(Opens article in a new browser tab) The post SOR 782 A PFMEA Use Question appeared first on Accendo Reliability.

Data and Mechanisms Abstract Chris and Fred discuss how reliability data analysis really doesn’t mean a lot … unless you pair it with a failure mechanism. Why is this? What does that mean? Key Points Join Chris and Fred as they discuss how reliability data analysis by itself doesn’t ‘mean’ a lot. What does this mean? And why is this? Topics include: We are all human. Not computers. Which means if we are asking someone to challenge their own ‘status quo,’ then they need to understand what is going on as opposed to admiring a chart. If something is different to preconceived ideas, then it is natural for our judgment and corporate knowledge to start exploring why your data might be wrong. You need to instead, prove that you know why you are right. Do you want to improve reliability … or measure it? To improve something, you need to do something. We can’t fix data points. But you can fix the root causes that lead to failures (through failure mechanisms). So you need to know (for example) if your product is failing due to fatigue before we start preventing that failure from occurring. Not all data analysis is the same. Why? We can find all sorts of ways to modify data to suit our prejudice. And sometimes we don’t think it through. Think about a manufacturing team who produces products at various rates throughout the year. So if we simply look at ‘number of failures per month’ and ‘number of units produced per month’ … we get the wrong message. A simple reduction in production several months ago will reduce the apparent failure rate today. A simple increase in production today will increase the failure rate today. This is not helpful. 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 Related Topics SOR 516 Understand Failure Mechanisms(Opens podcast in a new browser tab) The post SOR 781 Data and Mechanism appeared first on Accendo Reliability.

Influencing Change Abstract Chris and Fred discuss what it means (as a reliability engineer) to try and change something … even though the organization that thinks they are open to change really isn’t. What can we do? Key Points Join Chris and Fred as they discuss how reliability engineers help organizations actually change … especially when they don’t realize that they aren’t open to change. Perhaps you are asked to reduce downtime on a production line, but the line manager rejects all your recommendations because they only ever wanted you to reduce repair time. Perhaps you are asked to improve supplier reliability, but the organization says there is no time to implement your recommendations. What can we do? Topics include: Sometimes we need to do a better job at relating outcomes with inputs. Reliability engineers can sometimes be guilty of presenting graphs, charts and data that aren’t related to the metric that matters. You might be able to have data that suggests that optimizing the servicing interval increases the MTBF by 10 % … but if the organization is focused on uptime then this is not enough. Instead, try and relate servicing interval directly to uptime (or availability). Sometimes data analysis is not enough. Especially for ‘fire-fighting’ organizations who are so used to being good at responding to field issues and simply aren’t used (comfortable?) with tackling the number of fires that start in the first place. So you need to appear credible. You need to be able to come up with good answers to questions asked by skeptics. Know your audience. It doesn’t matter if you think your amazing report or data analysis is so good that it should stand alone … you need to know what sort of information they value and need to hear. 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 Related Topics Influencing the Organization(Opens article in a new browser tab) The post SOR 780 Influencing Change appeared first on Accendo Reliability.

Dealing with Changing Requirements Abstract Kirk and Fred discussing the dynamics of changing a design during the development process. The longer it takes to develop a new product the longer it allows the competitors to introduce new features and functions, which may have more market appeal than your products features right as your finishing development. Key Points Join Kirk and Fred as they discuss adding and changing features and how it affects the reliability in the long term. Topics include: Getting a product with new features to the market is a big factor in making a new market required feature for competitors, such as making smartphones more water resistant forces other smartphone makers to do the same. Rapid development component technology also makes adding new features, such as electronic cameras once relatively expensive becoming a chip so inexpensive it can be added to many lower costs products. Thermal HALT of high speed digital systems is especially beneficial in signal propagation issues and soft failures, as conductivity is inversely proportional to temperature in most materials. High temperature slows and low temperature speeds up electrical signals. 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” 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. Related Topics SOR 532 Reliability Culture in Product Maintenance(Opens podcast in a new browser tab) The post SOR 779 Dealing with Changing Requirements appeared first on Accendo Reliability.

Connect Activity to Business Objectives Abstract Kirk and Fred discussing a basic question Fred asks in the Reliability Management Class and with new clients, that is “what are you trying to accomplish” with your reliability program, Key Points Join Kirk and Fred as they discuss the objectives reliability and business and connecting those objectives to field reliability and the business case for ROI on the reliability Topics include: First you must understand why products fail in the field to know what failures cost the company, although the difficult to quantify lost sales and reputation for quality will probably be a greater loss in the long term. Looking at the field or final test failures and understanding the failure modes gives guidance on what testing and stresses would have made this mechanisms detectable and corrected before market introduction or shipment to the customer A key necessity in introducing a major change in the reliability program through HALT and HASS methodologies is having upper management understand the new approach and why the change from formulas and predictions to testing to limits. Without this company common understanding the use of HALT and HASS will be an up hill battle and likely not adopted. Many government equipment suppliers have an inherent conflict of interest developing reliable systems when the majority of the profits in the program come from spare parts and  service 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” 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. Related Topics SOR 154 Connecting Reliability, Maintenance, and Business(Opens podcast in a new browser tab) The post SOR 778 Connect Activity to Business Objectives appeared first on Accendo Reliability.

We Are All Consultants Abstract Carl and Fred discussing how much of what we do as reliability professionals falls into the role of consultants. Learning how to be better consultants will enhance the results of our day-to-day work. Key Points Join Carl and Fred as they discuss their experiences as consultants and how they were using the skills of consulting from early in their careers. To a great degree, everyone should be using the skills of consulting to be successful in achieving reliability objectives. Topics include: Teaching reliability engineers to be internal consultants, to improve their engagement with the rest of the organization in achieving reliability objectives. To be a good consultant you don’t merely do what the customer wants. It takes collaboration between consultant and internal customer. Ask “why” when internal customer says they want something done. Make sure it is the right method to use. What problem are they trying to solve? What are you going to do with the information? Soft skills are important to achieving reliability objectives. Role of consultant is teaching as well as performing. Part of the job of every reliability engineer is to provide services to the rest of the organization, and the skills of consulting are essential. Balance your reliability method skills with the softer skills of consulting and communication to expand your roles and be more successful. Always begin with asking what you are trying to achieve. How does it add value? Adding benefit to others is the role of consulting. Identify the decisions that you support. What to do when customer asks you to do something that is misguided. For example, customer asks for MTBF prediction. You can do what the customer asks and also do what adds value, such as Weibull analysis. Look for “win-win.” Exception is if customer asks you to do something which is unsafe or unethical, that should not be done, and has to be redirected into a safe and ethical action. If you are required to do a task that does not add value and do not have opportunity to also do a task that adds value, consider not going forward. Poor job satisfaction. Consider your career strategy to get in position that adds value to the company and provides job satisfaction. 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 One of the references discussed in the podcast is the book “Flawless Consulting,” by Peter Block, published by Pfeiffer and Company in 1981. Related Topics 54 – What Makes a Good Consultant with Fred Schenkelberg(Opens podcast in a new browser tab) The post SOR 777 We Are All Consultants appeared first on Accendo Reliability.

Transferring Knowledge Abstract Carl and Fred discussing the process of knowledge transfer from one person to others. This process is at the core of influencing others to achieve reliability objectives. Key Points Join Carl and Fred as they discuss how to transfer your knowledge to other people, and conversely, how to support knowledge transfer from others. Topics include: How do you transfer knowledge from one person to another? What are the mechanisms for knowledge transfer? The field of reliability influences management and engineering Remote versus onsite meetings and teaching Reading a script does not transfer knowledge Recognizing the knowledge gap is first step to transferring knowledge Use of questioning can be a great tool to address confusion Telling without trying does not necessarily transfer knowledge Deliberate practice is necessary for gaining the skills associated with knowledge Look for guidance and advice from colleagues, essence of coaching Importance of setting a learning environment where people can make safely make mistakes Good place to start learning is “consciously incompetent” Part of learning is making mistakes Plato says to adopt an ignorance mindset Being confused when learning something new can be good indicator; see Confusion Curve in Show Notes Students must realize they need to pose questions as part of learning and instructors need to make it safe to ask challenging question What is objective of teaching? Learning occurs better in smaller classes (under 20 people) due to student-instructor interaction “There may be some question in the room, let’s explore” Even students who are looking for “check box” can learn with the right instruction techniques Knowledge transfer is a two-way street 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 Good instruction engages students and can create temporary confusion, which is a natural part of the learning process: Confusion curve Related Topics SOR 615 Teaching Reliability(Opens podcast in a new browser tab) The post SOR 776 Transferring Knowledge appeared first on Accendo Reliability.