on Product Reliability

We like to think we make decisions based on information. We don’t. We make decisions based on emotions. And the most important emotion we rely upon for decision-making is confidence. We can be provided all the information in the world, but if we can’t understand it, trust it or believe it, we look for confidence in other ways. Often to disastrous outcomes. 

The number of ‘well-funded’ production efforts full of ‘very smart people’ that routinely generate expensive but unreliable products is sadly, very high. And it all comes down to the wrong types of confidence that well-paid decision-makers chase. 

[Read more…]

What does it mean to be a ‘visionary leader’? It starts with being different to most people. You can’t just become a visionary leader by completing a leadership course, being mentored by someone awesome, or by compiling an impressive curriculum vitae (although these can help people with the potential to become visionary leaders get there).

One of the first things that the then United States Army Chief of Staff (General George C. Marshall) did at the outbreak of World War II was to fire the majority of his officers who had climbed the ladder of military ranks throughout the previous 20 years of relative peace.

[Read more…]

Boeing is really having a bad stretch. Or more specifically, the passengers flying in its 737 MAX aircraft are.

Most recently a ‘plug’ flew off the side of Boeing 737 MAX 9 plane in flight, leaving a refrigerator sized hole next to startled (but mercifully still living) passengers. A ‘plug’ is a panel that seals up a hole in the fuselage that is included during manufacture to allow an optional emergency exit to be installed. 

This failure is not a good look … especially for a three-month-old plane. Lots of manufacturers of different machines throughout history have been able to successfully bolt panels to cover holes of a similar size to that of an aircraft emergency exit. It is not hard to do. Nor is it hard to have systems in place to make sure it is done right.

[Read more…]

Apple new iPhones will be somewhat different to those of the past. They will now have a USB-C charging and data port, and not Apple’s lightning cables. Why? Because the European Union said so. And they said so because they are not happy with the number of different charging cables we all now need for our various devices. Having a single cable that can charge an iPhone, Samsung smartphone, and virtually every other small electronic consumer product makes sense. It means fewer cables, smaller carbon footprints, less electronic waste, and prices will come down as less and less products assume that they need to provide a charging cable in their packaging. I have at least 20 power cables in my office that have been provided with various electronic gadgetry over the years.

[Read more…]

It looks like 2023 will be the hottest year on record. Along with all the cyclones, hurricanes, floods and bushfires we have already had. Those who study and take climate change seriously unanimously agree that man-made changes to the environment are causing the climate to change so fast that mother nature will struggle to keep up. 

And for the minority (yes, it is a minority as has been confirmed by many surveys and studies across the world), their arguments against climate change go something like this …

It might not be because of us …

… so it’s definitely not because of us.

[Read more…]

Climate change is universally accepted. And when I say ‘universally,’ I mean that the only people who think it is not a thing are fringe elements of society who are predisposed to specific interpretations of religion or commercial greed that would be harmed by any attack on fossil fuels and the energy we derive from them.

The good thing about this is that organizations who are serious about being successful and profitable can’t do so by sharing the ideology of a small minority. More and more people (including younger humans who will be the decision makers of tomorrow) are demanding more and more from the organizations they buy services and products from – especially when it comes to environmental concerns.

So to be successful, you need to take this stuff seriously.

[Read more…]

I was recently asked by a product design engineer why their organization struggles with reliability even though they have a very ‘robust’ design process that seemingly has lots of different ‘good’ reliability engineering activities embedded in it. And when I say ‘good’ reliability engineering activities, I mean activities that have (in the past) shown to have a really good impact on reliability.

When I looked at some of this engineer’s processes as summarized by a ‘process flow chart,’ the reason his organization struggled with making reliable products was quite obvious. 

The process was so complex that it became the ‘product.’ 

[Read more…]