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Speaking Of Reliability: Friends Discussing Reliability Engineering Topics | Warranty | Plant Maintenance
Speaking Of Reliability: Friends Discussing Reliability Engineering Topics | Warranty | Plant Maintenance episodes
- Is There a Standard for HALT?Is There a Standard for HALT?Abstract
Kirk and Fred discussing the use of HALT and whether there is a standard that is used for HALT and the use of test standards in general.
Key PointsJoin Kirk and Fred as they discuss a topic that has been an ongoing discussion since they began the Speaking of Reliability series started many years ago.
Topics include:- Standards are many times used to get specific test procedures completed by vendors. Making vendors contractually complete HALT is the worst way to have a vendor discover and understand the usefulness of HALT methodology.
- Kirk has observed that at least one sample of an Arduino microprocessor has demonstrated operation without failure for hours at 200 deg C.
- Standard test methods remove much of the engineering judgement, or actually thinking about what and why a test process is being performed.
- Fred provides an example of using a standard test procedure that has never failed and caused much waste without thinking about the reasons the test should be performed.
- At some point HASS becomes a poor return on investment, and should not be continued on a mature manufacturing process.
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.
SOR 618 Is There a Standard for HALT?Kirk GrayshareSocial:Link:Embed:" readonly />https://episodes.reliability.fm/sor/sor-618-is-there-a-standard-for-halt.mp3Download AudioDownload Audio RSSShow NotesClick 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.
0 min - Engineering JudgementEngineering JudgementAbstract
Kirk and Fred discussing the use of “engineering judgement” in analysis of reliability testing and the results.
Key PointsJoin Kirk and Fred as they discuss the many aspects of the benefits of experience in seeing failure mechanisms and understanding reliability risks.
Topics include:- How do you protect against those that may know or assume the cause of failures and could be wrong ?
- How do we deal with management that doesn’t agree with a large MTBF reliability predictions, even though most prediction cookbooks have little supporting data for the field relevance of the methodology?
- Relying on current textbook reliability predictions is for the most part is throwing out engineering judgement. The way to understand how to make reliable electronics and systems is to study the cause actual manufacturing test and field failures. Reliability can only be improved by understanding the causes of unreliability.
- Kirk recalls finding a failure mechanism and the wild belief of the company owner had for the cause of a rare failure mechanism.
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 RSSShow NotesClick 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 617 Engineering Judgement appeared first on Accendo Reliability.
0 min - Teaching Reliability Part 2Teaching Reliability Part 2Abstract
Carl and Fred continuing to discuss how to teach reliability. This is part 2 of the podcast series “Teaching Reliability.”
Key PointsJoin Carl and Fred as they discuss more teaching principles, drawing on their personal experiences.
Topics include:
- Aspire to teach complex subjects in a simple manner
- The skills of teaching has its own body of knowledge and it can be learned
- Good teachers connect with their students
- Tell a story that conveys the message your are teaching
- Use questioning to enhance learning
- Don’t lead with your credentials
- Talk to the audience; don’t read the slides
- Tap into your personal interest and passion
- Preparation for your classes
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 RSSShow NotesThe post SOR 616 Teaching Reliability Part 2 appeared first on Accendo Reliability.
0 min - Teaching ReliabilityTeaching ReliabilityAbstract
Carl and Fred discussing the principles of teaching reliability, whether it is sharing knowledge to a small number of people or formally instructing a larger group of engineers.
Key PointsJoin Carl and Fred as they discuss what makes for effective teaching.
Topics include:
- Teaching is one way of influencing others
- Teaching has its own body of knowledge
- The importance of knowing your audience
- You have to understand the subject yourself
- Don’t be afraid to teach
- Ask audience what they expect to get out of the class
- Teaching to different learning styles
- VARK (visual, auditory, reading, kinesthetics)
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 RSSShow NotesThe post SOR 615 Teaching Reliability appeared first on Accendo Reliability.
0 min - Why Leadership‘Why’ LeadershipAbstract
Chris and Fred discuss ‘why’ leadership. Not why leadership is important (we know it is). But the sort of leadership that focuses on the ‘why’ of an organization or group of people. ‘Why’ people who work at these organizations get out of bed in the morning. ‘Why’ customers purchase products or services from an organization. And if we get the ‘why’ right … everything becomes a lot easier. Especially reliability.
Key PointsJoin Chris and Fred as they discuss the ‘why’ of organizations. What that organization does or stand for. What it is
Topics include:
- Why. If you don’t know where you are going, then anywhere you land is fine. Simon Sinek says that “people don’t buy what you make, they buy ‘why’ you do it.” What does success look like? Apple’s ‘why’ is to essentially use computer technology in ways that no one has previously thought of. The Apollo Program’s ‘why’ was to land humankind on the moon. What was the ‘why’ of the Space Shuttle Program? Which program was more successful.
- Value. If the ‘why’ of your organization isn’t valuable, then it is a hobby organization. Which might be OK. But if you want commercial success, then your ‘why’ needs to be valuable to customers and create value for beneficiaries and other stakeholders.
- How. This is how your organization operates. Your operating model. Does it support the ‘why?’ Do you have helpful processes and procedures … or crippling bureaucracy?
- Create. You have the ‘why.’ It is ‘valuable.’ You have worked out ‘how’ you are going to do it. Now your people create something. A service. A product. A system. This is essentially the main effort of your organization. This is the act of people doing stuff.
- What. This is the outcome of your creation effort. And if you have done it right, it is a reflection of the ‘why.’ Which means you will be valuable.
- It goes wrong #1 … when ‘value’ becomes the ‘why.’ Jack Welch said the concept of ‘shareholder value’ … where every decision is based on how it improves things like share price. Which means you stop focusing on the main reason your organization is there and you chase short term money. Like Enron.
- It goes wrong #2 … when the ‘what’ replaces the ‘why.’ Think of BlackBerry. They made smartphones with physical keyboards that made writing emails really easy. And this was what customers wanted. But their tastes changed when more and more functionality with large touch screens. But BlackBerry didn’t change. The phone with a keyboard was the most important thing for them. Which means they no longer exist.
- It goes wrong #3 … when the ‘why’ becomes fuzzy, and the ‘creation’ becomes most important. Which means that people do what they personally value. Which tends to be stuff that people think is cool. Think of the Space Shuttle Program … multiple reviews kept saying things like ‘trying to do too much with too little.’ Again … was the Space Shuttle Program a success?
- It goes wrong #4 … when there is bad leadership. Having a great ‘why,’ ‘vision’ or ‘mission’ is great – but if this isn’t constantly reinforced by leadership then the framework fails.
- And Reliability? If reliability is not part of your organization’s ‘why’ then you are in trouble. So what can you do?
- What is yours and your reliability teams’ ‘why’? If you can’t articulate the ‘why’ of you and your reliability team … then who is at fault? What can you say to your CEO to demonstrate that your team has been successful within your larger organization one, two, five or ten years from now?
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 RSSShow NotesThe post SOR 614 ‘Why’ Leadership appeared first on Accendo Reliability.
0 min - Focus on Problem Number 5Focus on Problem Number 5Abstract
Chris and Fred discuss ‘Problem #5.’ What is problem #5? Well … technically it isn’t a problem at all. Which is what we want to be doing as reliability engineers. Preventing problems from occurring. Most people look at reliability engineers as (perhaps at best) addressing field failures or failures in the hands of the customers. But reliability engineering is much more valuable than that. Reliability engineering prevents you from not meeting budget or not achieving scheduled milestones. In fact … field failures (which are what we call ‘Problem #1’) are incidental to good reliability engineering. Want to learn more?
Key PointsJoin Chris and Fred as they discuss the five problems that reliability engineering is trying to address. But if you focus on just one, you miss all the benefits that you can potentially achieve.
Topics include:
- Problem #1 – Failure (disaster). This is the worst, most horrific type of problem that good reliability engineering is trying to avoid. Problem #1 is disastrous and potentially unrecoverable. These are the problems that most people think reliability engineering is supposed to address
- Problem #2 – Issue uncovered during manufacture (crisis). Perhaps you find out that tolerances don’t line up between components. Or a material you thought was going to work doesn’t. Or a particular shape your design team was hoping your production line could achieve – but turns out they can’t. This is a crisis. Perhaps you have already advertised that your product is going to launch – but now it can’t. Either way, resolving this problem is a crisis in terms of budget, schedule, brand and so on.
- Problem #3 – Issue uncovered toward the end of design (expensive). Finding a problem or issue toward the end of your design cycle is expensive. You have already gone through a number of design reviews. Perhaps you have already issued documents for suppliers to work toward. So resolving this problem is expensive. And ignoring this issue means it becomes Problem #1 or #2.
- Problem #4 – Issue uncovered early (cheap). Think Highly Accelerated Life Testing (HALT). Testing that is designed to push your product toward the edge of its operating limits to rapidly work out where its weak points are. Because we are looking for them at the start of the design process – it is relatively easy to resolve. Great!
- And finally … Problem #5 – making your first design a reliable design. Think FMEAs or other activities that make sure we think about how our product can fail before we start designing. If people can design something that works, then we should know the likely ways our thing will fail. So making our first design a reliable design means that Problem #5 is never really a problem. We prevent issues before they ever happen.
- So this is about budget, schedule … oh and by the way, fewer failures. Perhaps in that order! But beware … making our first design a reliable design means we have no fire-fighting heroes, everything goes well, and perhaps we think it is because we are great engineers and not focusing on making our first design a reliable design.
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 RSSShow NotesThe post SOR 613 Focus on Problem Number 5 appeared first on Accendo Reliability.
0 min - Balancing Reliability Into Your OrganizationBalancing Reliability Into Your OrganizationAbstract
Philip and Fred discussing the difference between doing tasks and using the results to make decisions.
Key PointsJoin Philip and Fred as they discuss
Topics include:- To get the ROI you have to actually use the results of a task
- How do you select the right tools/tasks for your program?
- Understanding the business and customer needs then balance reliability activities
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 RSSShow NotesThe post SOR 612 Balancing Reliability Into Your Organization appeared first on Accendo Reliability.
0 min - Vendor MTBF ClaimVendor MTBF ClaimAbstract
Philip and Fred discussing a listener question about how to verify vendor claims about reliability.
Key PointsJoin Philip and Fred as they discuss
Topics include:- Assumptions and which party may benefit.
- Statistical approaches and a few tips
- Are standards and textbooks failing 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 RSSShow NotesThe post SOR 611 Vendor MTBF Claim appeared first on Accendo Reliability.
0 min - Public Perception and ReliabilityPublic Perception and ReliabilityAbstract
Kirk and Fred discussing the public’s perception of reliability after having a product with poor reliability or one with impressive robustness and how the online sharing of information can affect that in sales, or lack of.
Key PointsJoin Kirk and Fred as they discuss
Topics include:- The recent post of CNET doing an informal drop test on an IPhone 12-mini showing how very strong and robust the ceramic shield glass on the front is. Consumers will most likely expect this new level of robustness for all smartphone touch screens.
- Technological progress has made smartphones much more robust, even though some older technologies cannot be used with the new technology (wired versus Bluetooth headphones)
- Companies generally will never disclose how much stress and environment margins components or systems are capable of even though they may know them through HALT results as they have different margins for different markets and product lines and customers may use it up to that limit.
- The Boeing 737 Max will have challenges getting the public’s confidence in its reliability and safety. It will be critical to disclose the details of the fix and other airlines to understand the changes and agree to the solutions, even though it may take awhile for the public trust to come back.
- Briefly discussion of the RAMS 2021 and that the committee is still planning on holding the event in Florida in January despite the ongoing world wide pandemic.
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 RSSShow NotesHere is the link to CNET’s video: “iPhone 12 Mini drop test: Ceramic Shield rose to the challenge”
Here is the link to CNET’s article on the recall of the Ring smart Doorbell system
Click on this link to access the article “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 610 Public Perception and Reliability appeared first on Accendo Reliability.
0 min - Demistifying DeratingDemistifying DeratingAbstract
Kirk and Fred discussing the reasons and practice of derating components for the purpose of improving the reliability of electronics products, as Kirk’s experience has shown most causes of unreliability are due to mistakes and overlooked errors in design, use, or manufacturing
Key PointsJoin Kirk and Fred as they discuss the need and benefits or lack of benefit in the classic methods of derating components for the purpose of improving reliability.
Topics include:- Most electronics made have more intrinsic fatigue life than will ever be needed as technological obsolescence typically comes long before electronic components wear out. Even most mechanical parts as in buttons, relays, have extensive use life.
- It is agreed that creating larger operational margins in electronics improves reliability, but using blanket derating guidelines may add cost versus finding the one component through HALT of the system and increasing the strength of component.
- Finding the root cause of a component failure is important, but sometimes you just increase the limiting component and applying HALT to verify increase in stress-strength margins.
- If you cannot trust the component manufacturers ratings, why would you use that component.
- Component manufacturers all have margins in the component specifications to allow for variation in manufacturing, but there is no standard and most never will disclose the actual margins that the component design has.
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 RSSShow NotesHere is a link to Kirk’s article “There is a drain in the Bathtub Curve” , still relevant 8 years after it was first published
Click on this link to access the article “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 609 Demistifying Derating appeared first on Accendo Reliability.
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