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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
- SOR 518 The Folly of Reliability PredictionsSOR 518 The Folly of Reliability PredictionsAbstract
Kirk discusses the continued reliance on the misleading approach of using reliability prediction for reliability development.
Key PointsJoin Kirk as he discusses MIL Handbook 217 and its prodigy, the Arrhenius equation, and the reality of early electronics components (tubes, discrete transistors) being a major factor overall reliability of a system
Topics include:
- Kirk learned about reliability as a technician in a calibration lab and then a field service engineer troubleshooting complex high vacuum semiconductor processing equipment.
- Kirk was made Manager of the new ESS (Environmental Stress Screening) Processes after Dr. Gregg Hobbs had demonstrated the benefits of HALT and HASS to Storage Tek on a small tape drive loader. Gregg had demonstrated that Storage Tek could find 90% of the reported field failure mechanisms in a 15 minute combined stress screen.
- At a ESS conference in Oregon Kirk met Charlie Leonard, a key development engineer from the Boeing Commercial Aircraft Company. Charlie believed that most of the cooling of electronics on aircraft did not improve reliability and was costly and wanted to learn more about HALT and HASS. To learn more Charlie Leonard brought four other Boeing Engineers developing the Boeing 777 aircraft to Storage Tek in Louisville, Colorado for two days to learn more about HALT and HASS and observe its application and data supporting it.
- Charlie also introduced Kirk to Professor Michael Pecht, the founder and leader of CALCE (Center for Advanced Life Cycle Engineering) Consortium at the University of Maryland and that led to Professor Abhijit Dasgupta from the CALCE joining the trip with Boeing to Storage Tek.
- Almost 20 years later Kirk co-wrote a paper with Professor Pecht, published in the IEEE Design and Test of Computers on an experiment of long term overstressing of PC’s. Professor Pecht asked Kirk to include his association with CALCE as a Senior Collaborator in his public credentials.
- Reliability engineers are still following the old models and predictions that are misleading because real field reliability data is extremely sensitive and most times difficult to find even in companies that you work in. For those reliability engineers who do see actual causes of field failures, they probably will see that most are due to errors in design margins, manufacturing processes, or misuse by the user, not semiconductor wear out modes.
- Please download and read the very important US ARMY and CALCE paper linked in the notes below, “Reliability Prediction – A Continued Reliance on a Misleading Approach”
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 the US ARMY/CALCE PAPER presented at the 2013 RAMS conference event mentioned in this podcast– “Reliability Prediction – A Continued Reliance on a Misleading Approach” . This is a government document that is in the public domain and should be distributed a read by any engineer that believes failure prediction methodology is useful or beneficial during product development.
Here is a link to Kirk’s book co-authored with John J. Paschkewitz available from Amazon “Next Generation HALT and HASS: Robust Design of Electronics and Systems”
The post SOR 518 The Folly of Reliability Predictions appeared first on Accendo Reliability.
0 min - SOR 517 ComplianceSOR 517 ComplianceAbstract
James discusses the struggle to implement a program when access to the equipment being limited.
Key PointsJoin James as he discusses the need to understand motivations to help with PM compliance.
Topics include:
- Assigning the appropriate metrics in order to encourage the appropriate behavior.
- PM Compliance owned by operation managers helps improve access for PMs
- Understanding the motivations – helps to align metrics and KPIs that help everyone
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 517 Compliance appeared first on Accendo Reliability.
0 min - SOR 516 Understand Failure MechanismsSOR 516 Understand Failure MechanismsAbstract
Fred discusses the need to fully understand failure mechanisms in order to make meaningful reliability improvements.
Key PointsJoin Fred as he discusses the difference between a failure mode and a failure mechanism.
Topics include:
- The basic difference between symptoms (failure modes) and the physical or chemical specific cause of a failure (failure mechanism)
- Can you describe the failure based on deep understanding of how it happens?
- A few issues when you don’t know enough about the failure mechanisms.
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 516 Understand Failure Mechanisms appeared first on Accendo Reliability.
0 min - SOR 515 Reliability Security BlanketsSOR 515 Reliability Security BlanketsAbstract
Chris discusses ‘reliability security blankets.’ You know what security blankets are – the things that parents offer young children to make them feel safe and comfortable. Not because these blankets actually offer warmth, comfort or safety – but rather because the children associate feelings of warmth and safety with that object because it is ‘always there’ when they are at home or go to be. A reliability security blanket does the same thing – it calms the leaders, managers, bosses, and directors of an organization. But – that is it! There is no reliability to be found. Want to learn more? Listen to this podcast!
Key PointsJoin Chris as he discusses ‘reliability security blankets.’ A security blanket is often a small, portable blanket parents give to their children every night when they go to sleep, or otherwise relax in a safe environment. And the child quickly associates feelings of safety and warmth with that blanket. So in unfamiliar situations, we can give that security blanket to that child to make them feel safe and warm. But the security blanket offers no actual protection. They are small – so they don’t offer a lot of warmth. They can’t prevent harm.
The same things apply to ‘reliability security blankets’ that we see in many organizations across the world.
Topics include:
- What is a ‘reliability security blanket?’ Anything (like frameworks, activities, posters, policies, departments and so on) that offers the feeling of reliability that is then projected on the world around them – without actually going through the process of achieving reliability. And these security blankets can be quite expensive! Like funding an entire ‘data analytics’ team – whose outputs have never actually improved design.
- Reliability security blankets cost time/money/resources with no meaningful outputs (beyond the feeling of reliability). Because the cost of the reliability security blanket is less than the cost of actually achieving reliability.
- Any good examples? Yes. Plenty. Like organizations that follow a (sometimes exhaustive) checklist of tests and procedures that perhaps align with standards or guidebooks without taking the time (or expending the mental effort) to take a first-principles look at the weak points of the system design and do something useful about them.
- What makes reliability security blankets really bad? When they permeate all the way to the top. If the CEO or the directors seek security blankets – then this need to feel reliabiltiy quickly spreads across the entire organization.
- So what do I do? Find your reliability security blankets. Look at things you do that are associated with feelings and not outputs. And then … go back to first principles.
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 515 Reliability Security Blankets appeared first on Accendo Reliability.
0 min - SOR 514 Planning for FailuresSOR 514 Planning for FailuresAbstract
Carl discusses the importance of understanding how things fail, during product development.
Key PointsJoin Carl as he discusses the following topics:
- What do we know if we have high field warranty, even though tests were passed?
- Transitioning from pass-fail tests to testing-to-failure
- The role of accelerated life testing in generating and understanding failure data
- Understanding and modeling mechanisms of failure is essential to achieving reliable designs
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 514 Planning for Failures appeared first on Accendo Reliability.
0 min - SOR 513 The Idea of Use Case 7SOR 513 The Idea of Use Case 7Abstract
Adam discusses how the Use Case 7 concept can rapidly improve product design
Key PointsJoin Adam as he discusses how the Use Case 7 concept can rapidly improve product design
Topics include:- Use Case 7 (UC7) is somewhere between HALT and stress margin testing
- The method does not’ dissociate stresses to use cases like HALt but does go beyond what the intended user will expose the product to
- UC7 also explores ways a product may be used that could lead to a new market or product line. the benefits are plentiful with UC7
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 513 The Idea of Use Case 7 appeared first on Accendo Reliability.
0 min - SOR 512 Learning From Any FailureSOR 512 Learning From Any FailureAbstract
Kirk discusses the many times his home appliances failing and doing his own failure analysis and the limitations.
Key PointsJoin Kirk as he discusses his own experiences with unreliable appliances and possible causes.
Topics include:- What limits did the designs such a kitchen blender have for possible loads (Ice, small pebbles?)
- What amount and size of broken or hard pieces of debris was a considered by designers in a automatic dishwasher
- Market acceptance of the high cost limits us from developing a robotic dishwasher that could really scrub dishes.
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 the US ARMY/CALCE PAPER presented at the 2013 RAMS conference event mentioned in this podcast– “Reliability Prediction – A Continued Reliance on a Misleading Approach” . This is a government document that is in the public domain and should be distributed a read by any engineer that believes failure prediction methodology is useful or beneficial during product development.
Here is a link to Kirk’s book co-authored with John J. Paschkewitz available from Amazon “Next Generation HALT and HASS: Robust Design of Electronics and Systems”
The post SOR 512 Learning From Any Failure appeared first on Accendo Reliability.
0 min - SOR 511 ChangeSOR 511 ChangeAbstract
James discusses the need to focus on change management in order to implement something new in your program
Key PointsJoin James as he discusses the frustration when trying to implement changes,
Topics include:- Focus on technical elements of building an asset management program
- Individuals just didn’t want to change even when presented with the benefits
- The need to execute the change management aspects to be successful
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 511 Change appeared first on Accendo Reliability.
0 min - SOR 510 Measurement ErrorSOR 510 Measurement ErrorAbstract
Fred discusses the importance of minimizing measurement errors.
Key PointsJoin Fred as he discusses the oft-overlooked practice of checking for measurement error.
Topics include:
- What is measurement error
- How poor measurements impact reliability
- What you can do about minimizing measurement error
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 510 Measurement Error appeared first on Accendo Reliability.
0 min - SOR 509 Reliability Engineering Report WritingSOR 509 Reliability Engineering Report WritingAbstract
Chris discusses reliability engineering report writing (yuck). Pretty boring topic. But not nearly as boring as some of the reliability engineering reports. I will (try to) make this as entertaining a podcast as possible. And I will explain the golden rule of engineering report writing – make it a ‘reverse thriller.’ Keen to learn more? Then please listen!
Key PointsJoin Chris as he discusses some of the key things to consider when writing an engineering report. Engineers often dedicate a lot of time, effort and emotion into running tests, doing analyses and so on. BUT … we must resist the temptation to take our readers on the same journey we went through. They are focused on your destinations and conclusions – not your journey and rationale.
Topics include:
- Golden rule … write reliability engineering reports like a REVERSE THRILLER! Thrillers are books and movies that incrementally build suspense until some incredible secret or unsuspecting murderer is revealed in the last few pages or scenes. But our book and movie audience wants the suspense to build. Not the readers of your report. You must start with the ‘incredible secret’ so the reader of your report knows why they should keep reading.
- Don’t forget why we write reports – decision-making! We don’t write reports to generally inform people – or to satisfy requirements. The reader of your report is looking for information to make a decision. Not suspense.
- Reliability engineering reports (and their reading) are not fun. Don’t fight this.
- The first thing in your report should be the point you are trying to make. If your report supports a recommendation or decision to (for example) extend the warranty period for a product … then say this first. This motivates your reader. They know why they should keep reading.
- But I need to have rigor and detail to show that I know what I am talking about! This is very true. But your explanation and rationale need to come after the point you are trying to make. Your decision-maker will typically not have the time to decipher your conclusion for themselves. Have the main point up front – and then your decision-maker (or your decision-makers staff) can check that you know what you are talking about with the supporting data and analysis in the following pages and appendices.
- Don’t write your report as a journal of your study or analysis. Don’t write a report that takes the reader on a journey from ‘day 1,’ through tests A – Z, detailed descriptions of all the issues you came up against before FINALLY revealing the main point of the analysis. Your audience has already put your report down by this stage! Remember, these reports aren’t entertainment. No one is paying to ‘enjoy’ your report. They want the report to help their decision-making.
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 509 Reliability Engineering Report Writing appeared first on Accendo Reliability.
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