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Home » Articles » on Tools & Techniques » Page 2

on Tools & Techniques

A listing in reverse chronological order of articles by:



  • Dennis Craggs — Big Data Analytics series

  • Perry Parendo — Experimental Design for NPD series

  • Dev Raheja — Innovative Thinking in Reliability and Durability series

  • Oleg Ivanov — Inside and Beyond HALT series

  • Carl Carlson — Inside FMEA series

  • Steven Wachs — Integral Concepts series

  • Shane Turcott — Learning from Failures series

  • Larry George — Progress in Field Reliability? series

  • Gabor Szabo — R for Engineering series

  • Matthew Reid — Reliability Engineering Using Python series

  • Kevin Stewart — Reliability Reflections series

  • Anne Meixner — Testing 1 2 3 series

  • Ray Harkins — The Manufacturing Academy series

by Michael Keer Leave a Comment

13: Controlled Introduction. Part 4 Customer Trials

13: Controlled Introduction. Part 4 Customer Trials

By Mike Freier

In the last blog, we discussed the importance of business systems including the perils of manual processes, common business systems used for an agile hardware product lifecycle, optimizing data flows, managing product data across systems, and tips for success. 

Now, in this final blog in the controlled Introduction series, we discuss the importance of customer trials, identifying and developing trial customers, running the trials and how to leverage the learnings resulting from these trials to benefit your business.

[Read more…]

Filed Under: Articles, on Tools & Techniques, The Hardware Product Develoment Lifecycle

by Ray Harkins Leave a Comment

The Fixed Capability Technique

The Fixed Capability Technique

A Practical SPC Method for High-Capability Processes

By Ray Harkins and Michael J. Vella

Manufacturing professionals who regularly apply Statistical Process Control (SPC) methods, such as X̄ and R charts, know the power of SPC to maintain control of both quality and cost. The standard practice emphasizes attention to variation, with operators trained to take corrective action whenever a process signals an out-of-control condition. Typically, this means adjusting a process input, verifying the correction, and resuming production.

However, not every out-of-control signal requires intervention, especially in processes where inherent variation is extremely small and product quality is consistently high. In some cases, such as tooling wear or small material variations, process center shifts may occur outside of the operator’s ability to correct. Responding to these shifts with standard SPC rules can lead to overcorrection, lost productivity, and increased variation.

[Read more…]

Filed Under: Articles, on Tools & Techniques, The Manufacturing Academy

by Hemant Urdhwareshe Leave a Comment

Maintainability and Availability Introduction

Maintainability and Availability Introduction

Dear friends, we are happy to release this video. In this video, Hemant Urdhwareshe briefly discusses various concepts such as on maintainability and availability, MTTR, MTBMA, Availability trade off, maintenance time distributions etc.. Hope you find the video useful.

[Read more…]

Filed Under: Articles, Institute of Quality & Reliability, on Tools & Techniques

by Michael Keer Leave a Comment

12: Controlled Introduction. Part 3

12: Controlled Introduction. Part 3

By Mike Freier

In the last blog, we discussed how to navigate the various mechanical tooling options and the advantages and trade-offs for volume production. We learned that considering factors such as lead times, cost, quality, and control over development processes is essential to selecting the most appropriate tooling option tailored to your specific product requirements.

Now, let’s continue to our next blog series, which will focus on business systems. Business systems are critical for supporting agile product realization, optimizing your processes, meeting regulatory compliance, and scaling your business. So let’s explore business systems strategies, flows, usage throughout the product life cycle, and tips for success.

[Read more…]

Filed Under: Articles, on Tools & Techniques, The Hardware Product Develoment Lifecycle

by Hemant Urdhwareshe Leave a Comment

Reliability Block Diagrams (RBD)

Reliability Block Diagrams (RBD)

Dear friends, we are happy to release our video on this important topic of reliability block diagrams! In this video, Hemant Urdhwareshe explains basics of series and parallel logic in RBDs. Hemant also explains application of Bayesian theorem and conditional probability to estimate reliability in special cases. Hope you find this useful and interesting!

[Read more…]

Filed Under: Articles, Institute of Quality & Reliability, on Tools & Techniques

by Carl S. Carlson Leave a Comment

Quality Objective 6: TECHNICAL RISK ANALYSIS

“Risk analysis is the art of turning uncertainty into actionable insight.” — Anonymous

In this article, I will outline how to evaluate an FMEA against the FMEA Quality Objective for Technical Risk Analysis.

By definition, “risk analysis” is “the systematic process of identifying, evaluating, and estimating the levels of risk involved in a situation, process, or system, in order to inform decision-making. [Read more…]

Filed Under: Articles, Inside FMEA Tagged With: FMEA Quality Objectives

by Michael Keer Leave a Comment

11: Controlled Introduction, Part 2

11: Controlled Introduction, Part 2

Article by Mike Freier

In our last blog post, we delved into the journey of transitioning from engineering and beta units to high-volume production. We explored the crucial steps of choosing a reliable contract manufacturer (CM), negotiating a mutually beneficial agreement, and providing comprehensive documentation to support the product assembly process.

Now, let’s dive into our next blog piece, where we’ll uncover the world of mechanical tooling options that will support your product’s successful development and scale-up into high-volume production. We’ll be exploring 3D printing, soft tooling, and hard tooling, each offering unique advantages and trade-offs. By understanding these differences, you’ll be empowered to make better informed decisions and select the best strategy to support your business.

[Read more…]

Filed Under: Articles, on Tools & Techniques, The Hardware Product Develoment Lifecycle

by Ray Harkins Leave a Comment

What is Acceptance Sampling?

What is Acceptance Sampling?

In manufacturing and quality assurance, we rarely have the time—or budget—to inspect every single part in a batch. That’s where acceptance sampling comes in. It’s a statistical tool that helps us decide whether to accept or reject a lot of material based on a random sample. But more than just a shortcut, acceptance sampling is a structured decision-making process that balances quality expectations with efficiency and risk.

[Read more…]

Filed Under: Articles, on Tools & Techniques, The Manufacturing Academy

by Hemant Urdhwareshe Leave a Comment

DFMEA Application Case Studies

DFMEA Application Case Studies

FMEA Part-3

Dear freinds, we are glad to release this part-3 of our series on FMEA. In this video, Hemant Urdhwareshe illustrates two application case studies in using DFMEA.

[Read more…]

Filed Under: Articles, Institute of Quality & Reliability, on Tools & Techniques

by Michael Keer Leave a Comment

10: Controlled Introduction, Part 1

10: Controlled Introduction, Part 1

Article by Mike Freier

In the last blog post, we discussed how to validate your product and cover some of the important testing that your engineering teams should plan on to ensure your product meets all the requirements outlined in the engineering design specification.

Transitioning from engineering and beta units to high volume production involves finding a contract manufacturer (CM) as well as sub-tier volume suppliers, signing a deal with the CM, and handing off the set of data and instructions to make your product. Read on to learn what to lookout for in each step in the process of scaling your product into volume manufacturing.

[Read more…]

Filed Under: Articles, on Tools & Techniques, The Hardware Product Develoment Lifecycle

by Hemant Urdhwareshe Leave a Comment

How to use DFMEA form and Rating Guidelines

How to use DFMEA form and Rating Guidelines

Dear friends, we are happy to release this FMEA Part-2 video. In this video, Hemant Urdhwareshe explains how to use the DFMEA form. He also explains briefly the guidelines for Severity, Occurrence and Detection rating as per AIAG VDA first edition and logic for setting priorities for action plan.

[Read more…]

Filed Under: Articles, Institute of Quality & Reliability, on Tools & Techniques

by Michael Keer Leave a Comment

9: Validation

9: Validation

Article by Mike Freier

In the last blog post, we discussed how incorporating Agile principles can improve your hardware product development process. Not only will you be able to accelerate your schedule, but you can also develop higher quality products with lower costs and reduced risks. Furthermore, Agile frameworks and techniques can fit into your existing new product introduction (NPI) and stage gate process, so your high-level standard operating procedures do not have to change.  

Once you have engineering and beta units in hand, validation and verification can begin. In this stage, engineering teams should test your product against the engineering design specification to verify that your product meets the performance, reliability, regulatory, manufacturing test, and safety goals.

[Read more…]

Filed Under: Articles, on Tools & Techniques, The Hardware Product Develoment Lifecycle

by Larry George Leave a Comment

Estimate Reliability Functions Without Life Data

Estimate Reliability Functions Without Life Data

ASQC Reliability Review, Vol. 13, March 1993

This paper shows how to estimate field reliability functions from ships and returns. It offers to estimate field reliability functions from your data. It suggests how you can use these estimates to improve service and inventory management. [Links to Google Sheet and user guide follow the paper.]

You can estimate field reliability functions without life data. You don’t need to know each part’s time to failure. In fact, if you don’t know times to failures, you have to estimate field reliability functions from ships and returns, unless you have a sample of times to failures, and some of the sample failed.

[Read more…]

Filed Under: Articles, on Tools & Techniques, Progress in Field Reliability?

by Hemant Urdhwareshe Leave a Comment

Planning and Preparing for DFMEA

Planning and Preparing for DFMEA

FMEA Part-1

Dear friends, we are happy to release this DFMEA Part-1 video. In this video, we have tried to explain how to plan and prepare for DFMEA. Hope you find it interesting and useful. Your feedback welcome!

[Read more…]

Filed Under: Articles, Institute of Quality & Reliability, on Tools & Techniques

by Ray Harkins 1 Comment

What is Design of Experiments?

What is Design of Experiments?

If you work in manufacturing, quality, or engineering, you’ve probably heard the term “Design of Experiments,” or DOE. Maybe you’ve even helped collect data for one without fully understanding what was going on behind the scenes. That’s okay. DOE is a sophisticated statistical method, but even if you’re not the one crunching the numbers, understanding the big ideas behind it can make you a more effective technician, engineer, or manager.

At its core, Design of Experiments is a structured statistical approach to testing. It helps us understand how different inputs (or factors) affect an outcome (or response). Whether you’re adjusting a process to improve tensile strength, dialing in machine settings to reduce defects, or figuring out which supplier provides the most consistent material, DOE helps answer one big question: What settings or conditions will give me the result I want?

[Read more…]

Filed Under: Articles, on Tools & Techniques, The Manufacturing Academy

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