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

Standards and Regulations Abstract Kirk and Fred discussing the role and relationship of meeting standards and making a reliable product. Key Points Join Kirk and Fred as they discuss how passing standard test requirements doesn’t mean you have made a reliable product. Topics include: Standards are very critical to have useful interfaces such as IEEE 802.11 standard for Wi-fi so that we have easy interoperability between devices. Standards committees take years to complete them and many times they are technologically obsolete by the time they are finished. This is especially true with electronics technology. Standards have been driving safety improvements in cars with requiring air bags, back up cameras, and other systems as the new technologies come to market. Many of the safety standards for cars will not be necessary when we have 100% autonomous cars on the roadways. The market drives innovations and most safety systems in vehicles became available many years before the systems became required standards. 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 Click on this link to access the article from the US ARMY and CALCE titled  “Reliability Prediction – A 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 645 Standards and Regulations appeared first on Accendo Reliability.

Dealing with Failures that Destroy Abstract Kirk and Fred discussing the challenge of understanding the root cause of failures for products that are hard to retrieve from the field or have other reasons that make failure analysis almost impossible. Key Points Join Kirk and Fred as they discuss different situations and conditions where the products failure analysis can’t be done after its failure in the field Topics include: Some products have self destruct mechanisms to prevent fraud in a secure system which prevents tampering but also prevents failure analysis Weapon or ordinance that fails to detonate in the field is generally still very dangerous and not worth risking retrieval and analysis Isolation of subsystems or components and measuring the most likely driving mechanism progressing the product to failure using potential causes through fault tree analysis. Safety or thermal shutdown interlocks are limitations have to be disabled during HALT. In HALT the goal is finding the designs operational limits and not preset trigger points to protect itself or others in the field from damage. In some cases replacing a component destroyed in a HALT evaluation to a higher power component can improve reliability without knowing the complete root cause of the destroyed device. 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 Click on this link to access the article from the US ARMY and CALCE titled  “Reliability Prediction – A 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 644 Dealing with Failures that Destroy appeared first on Accendo Reliability.

Maintenance FMEAs Abstract Carl and Fred discussing the application of FMEAs in support of asset maintenance. Key Points Join Carl and Fred as they discuss the subject of FMEAs and Maintenance; and difference between FMEAs done in support of product development (Design FMEAs) and FMEAs done in support of maintenance or Reliability Centered Maintenance (RCM) programs. Topics include: Design for Maintainability; Design for Service Causes in Design FMEAs are taken to the level of potential design deficiencies Causes in Maintenance FMEAs are taken to maintenance actionable level Recommended actions in Design FMEA support design improvements Recommended actions in Maintenance FMEA support maintenance improvements How should Design FMEAs and Maintenance FMEAs be connected? RCM Decision Logic Diagrams in Maintenance FMEA vs Effect descriptions in Design FMEA Reliability professionals should understand both product development and operations Be aware of failure rate handbooks, and the assumptions that go into the information Put an asterisk on failure rate data that is from handbooks 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 643 Maintenance FMEAs appeared first on Accendo Reliability.

What Price Reliability? Abstract Carl and Fred discussing the reliability of the Texas electric grid debacle, and what can be learned from a reliability point of view. Lessons learned from this problem can be applied to other industries. Key Points Join Carl and Fred as they discuss the cost of reliability in the electric grid. Should electrical system providers communicate the price of long-term reliability, so customers can make an informed choice? Topics include: Lack of feedback loop on the long term reliability of electrical generation and transmission equipment Deferred maintenance creates reliability problems Life cycle costing, budgeting and modeling, from beginning to end Applying reliability tools throughout product life cycle Customers want low cost electricity; are they willing to pay for the maintenance that avoids shut downs during rare events? Is part of our job as reliability professionals to inform customers about long term reliability? How can we ensure preventive maintenance is priced into the product? There is no incentive to maintain electrical grid equipment; same with highways Incentivizing for quarterly results does not support long-term 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 642 What Price Reliability? appeared first on Accendo Reliability.

How to Become a Reliability Engineering Consultant Abstract Chris and Fred discuss how to become a reliability engineering consultant. This is a very natural question for a lot of us. It might be easy to visualize what you want to achieve. But it can be daunting to get there. Key Points Join Chris and Fred as they discuss how you go about becoming a reliability engineering consultant. It is Topics include: It’s not about what you can do. It’s about how you can help. A lot of prospective consultants simply see themselves as having a lot of tangible skills that relate to specific things they can deliver. It might be data analysis. Or FMECAs. Or plotting data. But clients are after how you can help. How can you help improve profit, reduce costs, reduce TTM and so on. The people who are going to hire you aren’t likely to know what these activities do. Do you want to be Consultant #1 – Contractor or ‘pair of hands.’ This works really well for certain people. This sort of consultant usually has ‘year long’ contracts that when that contract expires, you find another one. Cash flow is usually good … except between contracts. Do you want to be Consultant #2 – Trusted advisor. This is not so much being a luminary in the field, but clients (for whatever reason) become trusted and seen as an otherwise impartial source of help. Do you want to be Consultant #3 – Visible Expert. You need to be known. You need to be visible. You need to be blogging. You need to be presenting at seminars. You need to be doing webinars. And … you need to be doing this for a while before you become visible. Just having a website is not enough. But … do you really want to be a consultant? Some people can’t handle not having a salary. That’s OK … but don’t pretend you are someone you are not. Not having a salary can be a source of great mental stress. Sometimes you will have a number of clients. Sometimes you will have none. It is a roller coaster … especially early. Is this really what you want? … don’t underestimate the change in ‘human interaction’ lifestyle. Consultants don’t work in teams the way other employees do. This might work for you. But you might be surprised how much you miss it. You also need to be able to work by yourself and in your basement. This is not great. It is one of the costs of becoming a consultant. How can you start? Become a consultant for the organization you work with. Make proposals to VPs. Try and gain business from the CEO. Start behaving like a consultant before you do. You might be surprised about what you learn about yourself … or how people regard you! 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 641 How to Become a Reliability Engineering Consultant appeared first on Accendo Reliability.

How Reliable Does My System Need to Be? Abstract Chris and Fred discuss how you go about setting a reliability goal. We got asked by someone who was responsible for a ‘complex’ system … How reliable does our system need to be? Unfortunately … you need to tell us that! Hopefully this webinar will help you start asking the right question to work it out for yourself. Key Points Join Chris and Fred as they discuss Topics include: It is about your business or operational need. What are your profit margins? How many missions do you need to launch? How big does your fleet of vehicles need to be? This depends on how your organization generates value. Things like warranty reliability goals change from industry to industry. So you need to look within first. And if you are able to link reliability performance to the main purpose of your organization, you have automatically motivated your employees by linking their effort to rewardable outcomes. … and let’s be sure that reliability is the thing that matters. If you are designing a complex system … then perhaps availability is your key metric. Maybe you can include lots of hot-swappable components and assemblies to make sure your system keeps working. And there are lots of other examples of getting this wrong. Are you after reducing weekly mean preventive maintenance time, or improving operational availability? There is a difference, and getting it wrong means you get poor outcomes. Measuring the past shouldn’t be a goal for the future. Doing a Weibull plotting course, working out what your preliminary tests suggest, and then setting the results of your analysis as your goal is not setting a requirement. You are … by definition … concluding that wherever you are now is wherever you need to be when it comes to reliability. Reliability is one thing. The perception of reliability is perhaps more important. Fred talked about a medical device that was reliable, but was also designed to be lightweight. This meant its case was thin and prone to cosmetic damage. The device worked fine, but because it was lightweight and quickly looked damaged, customers believed it wasn’t reliable. If in doubt … ask your customers! They will obviously say they want it to be 100 % reliable. Ask them if they are happy to pay for it? They will say no. So start a conversation, and perhaps (for example) you might be able to come up with an agreed goal for 2 years from now. If asking your customers is too hard … ask your marketing team! They should be able to at least give you some thoughts on how customers value reliability, and how much it influences their decision to purchase. 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 640 How Reliable Does My System Need to Be? appeared first on Accendo Reliability.

Ready to Teach Reliability Abstract Philip and Fred discussing the general need to be able to teach reliability all the time. Key Points Join Philip and Fred as they discuss teaching reliability at all levels from the short explanations, to presentations, and via courses. Topics include: Be prepared so the learning experience works for the audience A great way to master a topic is to teach reliability Different methods of learning and being adaptable 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 639 Ready to Teach Reliability appeared first on Accendo Reliability.

How Much Do You Need to Know About Reliability? Abstract Philip and Fred discussing the journey of learning reliability engineering. Key Points Join Philip and Fred as they discuss the need to know enough to solve problems and to know when you do not know enough. Topics include: The need to learn a little bit every day How to continue to learn after you read the one book Know enough to know if the solution is appropriate or correct 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 638 How Much Do You Need to Know About Reliability? appeared first on Accendo Reliability.

Electrical Power Reliability in Texas Abstract Kirk and Fred discussing the failures of the electrical grid due to a extreme cold and snow in Texas that was a very rare weather condition in February 2021. Key Points Join Kirk and Fred as they discuss the failure of the Texas electrical grid in Texas this past February 2021 due to a rare sustained cold front hitting central and southern Texas. Topics include: A major difference for the weather event in Texas was the below freezing temperatures lasted for several days, causing the electrical grid to fail and subsequent water supply and plumbing problems . Texas had identified some of the weakness due to past severe weather events but had taken no action to improve the grid with the excuse that it is a rare event. The fundamental question is how much can you spend and prepare a system for a very rare environmental stress condition that may never happen. Is this a question we may have for a consumer electronics product that is rarely abused by the customer, such as dropping a smartphone in 100 ft of water. Cost tradeoffs always require compromise on how robust we can build a system to withstand rare stress conditions. 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 Click on this link to access the article from the US ARMY and CALCE titled  “Reliability Prediction – A 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 637 Electrical Power Reliability in Texas appeared first on Accendo Reliability.

ALT Samples and HALT Limits Abstract Kirk and Fred discussing two questions from a listener on HALT and ALT. Key Points Join Kirk and Fred as they discuss two common questions regarding ALT (Accelerated Life Testing) which is to quantify a component or systems time to wear out failure and when do you stop improving a design with HALT. Topics include: The number of samples needed for ALT depends on the question you are trying to answer. ALT is most relevant for mechanical systems such as gears, switches and relay’s and requires multiple samples and multiple stress levels to properly model expected lifetimes. Enough samples from different build lots need to be used to account for variation in manufacturing. To do an ALT the wear out endpoint or measurable change must be reached to make a life-use time model and this can take long test periods to complete. Few electronic assemblies and components have a life entitlement that is shorter than its technological obsolescence, and for the majority of electronics will not wear out with normal use during its technological usefulness of 10 years or more. Our second question is when do you stop changes to make a product more robust using HALT? The basic point of stopping improvement is when the product strength and capability cannot be improved with standard materials and techniques, which Gregg Hobbs Ph.D. called the “Fundamental Limit of the Technology”. Experience with HALT helps set a benchmark of what electronics are able to perform to. Different industries have different stress requirements as the down well oil drilling instruments require use to 185 degC or more. 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 Click on this link to access the article from the US ARMY and CALCE titled  “Reliability Prediction – A 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 636 ALT Samples and HALT Limits appeared first on Accendo Reliability.