Your Reliability Engineering Professional Development Site
A listing in reverse chronological order of articles by:
Why do so many avoid failure?
In product development of plant asset management, we are surrounded by people that steadfastly do not want to know about or talk about failures.
Failure does happen. Let’s not ignore this simple fact. [Read more…]
Everything varies.
Your vendors provide components with a range of values. Your production process varies, too.
Creating, monitoring, and maintaining process stability enhances your product reliability performance.
When I started my professional life as a manufacturing engineer, a senior engineer told me we take a product design and can only make it worse.
He said if we could make every unit exactly according to the nominal values of the drawing, every unit would work well. [Read more…]
The trite answer is just as many samples as you need and not one more.
A better answer is enough samples to make the right decision. The realistic answer is you will not enough samples.
“How many samples?” is an oft-asked question when planning for quality or reliability testing. [Read more…]
A break from the normal format.
Reliability.fm is a podcast network focused on reliability engineering topics.
Starting with three shows. Speaking of Reliability and Dare to Know described below, along with recorded Accendo Reliability webinars. [Read more…]
Failures happen. Sometimes product failures happen quickly.
You just bought a new feature rich computer and discover it doesn’t work. Right out of the box, it will not power up. Conversations with the tech support and it’s a trip back to the store.
The failures that occur early the in the life of a product tend —
this ‘tend’ really is just a vague ‘in general’
…tend to occur because of manufacturing errors or shipping/installation damage.
Not always, though. [Read more…]
Your customers are your best testers for your next product. They will explore the features. Expose the product to use conditions in unconscious ways. And, they will let you what they consider failures without needing the specification document.
During the development process, you and team may work to understand what customer may want or expect for the new product. You may even conduct focus groups or review past product field failures and call center records. [Read more…]
Mechanical systems wear out and fail eventually. The ability of a structure to support a load, move through the specified range of motion, or spin degrades with use and time. Even our joints eventually wear out.
Accelerated life testing (ALT) has plenty of literature concerning the failure mechanisms unique to electronic components and materials. This is partially due to the limited number of unique electronic components compared to the often custom mechanical designs. ALT also has value as it provides information about a system’s reliability performance in the future.
Let’s explore an example of mechanical reliability testing (an ALT) in order to outline a basic approach to ALT design and analysis. [Read more…]
Suppliers often include reliability information along with performance specifications.
We look for reliability statements as one part of the selection process to ascertain if the component is likely to have sufficient reliability.
When the vendor’s data is clearly stated and meaningful, that information saves us from potentially having to conduct our own reliability evaluations. [Read more…]
If you buy more than one of an item used in your product, you will have to deal with variability. In general, the variability from part to part is minimal and expected. Occasionally, the variability is large and causes reliability problems. [Read more…]
It was late Friday afternoon and the phone rang. Which is rarely a good thing.
There seems to a significant spike in field failures due to one component. The initial failure analysis work reveals the issue started with a batch of parts received about two months ago and the flaw continues to appear in subsequent batches. [Read more…]
The communication between suppliers or vendors and their customers is often using a mix of specifications and requirements.
Customers set requirements and suppliers offer specifications. When they match, or when a supplier component specifications meet the customer’s requirements, we have the potential for a transaction. [Read more…]
“Keeping the end in mind”, “working toward a common objective” and “providing a vision” are all convention management wisdom based on setting goals.
Seeing a reliability goal is one of the first tasks when creating a reliability plan.
“How good (reliable) does it have to be?”
That is answered with a reliability goal statement.
There is a lot of uncertainty concerning a reliability goal. [Read more…]
My introduction to reliability engineering was my boss asking me to sort out how long a new product will last in use.
The expectation was it would last for 20 years or more buried in Italian mountain concrete bridges.
My first thought was about living in the Dolomites for 20 years monitoring the performance of the product.
That was quickly dashed as my boss explained he wanted an answer in about 6 months.
Now this was a problem. How do you cheat time to learn about the expected lifetime of a something? Thus started my career in reliability engineering.
Life testing for reliability engineering helps us answer the question how long till failure occurs. Specifically, we find the chance of failure over some duration. [Read more…]
If nothing was uncertain we would not need statistics.
Since nearly everything varies in some fashion, we need a way to describe and work with that variability.
We already know this and we know about statistics as being the right set of tools. Yet we hesitate, avoid, and refuse to pick up the appropriate tool. [Read more…]
In the poem by Oliver Wendall Holmes, The One Hoss Shay, a deacon is confounded by the various parts of his carriage the fail.
And, he decides to do something about it.
But the Deacon swore (as Deacons do,
With an “I dew vum,” or an “I tell yeou,”)
He would build one shay to beat the taown
‘n’ the keounty ‘n’ all the kentry raoun’;
It should be so built that it couldn’ break daown:
“Fer,” said the Deacon, “t’s mighty plain
Thut the weakes’ place mus’ stan’ the strain;
‘n’ the way t’ fix it, uz I maintain, Is only jest T’ make that place uz strong uz the rest.”
Translating from old English, it basically means he wanted to craft a carriage using the best materials and techniques. Later, he built a very sound carriage where every part is just as strong as all the other parts. [Read more…]
