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Determine Success Testing Sample Size

Determine Success Testing Sample Size

“How many samples do we need?” is a very common question. It is one you will receive when planning nearly any kind of reliability testing. It is a great question.

Having too few samples means the results are likely not useful to make a decision. Too many samples improve the results, yet does add unnecessary costs. Getting the right sample size is an exercise starting in statistics and ending with a balance of constraints.

There are six elements to consider when estimating sample size. We will use the success testing formula, a life test with no planned failures, to outline the necessary considerations. [Read more…]

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A Proposed Product Life Cycle Process

A Proposed Product Life Cycle Process

In my previous article we covered the advantages of a phase and gate structure for new product development.  Now we can discuss some proposed phase names for a new product development or product life cycle (PLC) process.

An organization may have an existing PLC process ‘baked-in’ to their culture and process documentation.  Accordingly, there’s a wide range of PLC phase names, all of which are likely acceptable and based on solid reasoning.

[Read more…]

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Are You an Indispensable Engineer?

Are You an Indispensable Engineer?

#AskAsh – 004 – How to become an Indispensable Engineer

Question

Hi Ash,

What are your best tips for safeguarding your job, but also rise to the top to score your dream position?

As a recent graduate, I have this fear that if the economy turns or my company starts doing poorly that I’ll be the first one cut. What can you do to be indispensable at work?

Thanks,

Erica, New York

[Read more…]

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Process Capability VI – Non-Normal Variables

Process Capability VI – Non-Normal Variables

The Situation

You have a process that is not capable because sample measurements or SPC data indicate that some characteristics have too much variability. The calculated Cpk’s are too small. What do you do?

Assuming the data is correct, a course of action is to review the assumption is that the measurements are normally distributed. For most situations, this is a reasonable assumption, but other statistical distributions may provide a better description of the data variation. 

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Test to pass & Test to Improve

Test to pass & Test to Improve

In many program cases I see teams “testing to pass” when they should be “testing to improve”.  Testing to pass is putting your best foot forward.  There is a “mark” and you are going to hit it so you can advance to the next stage.  Testing to Improve is looking for defects and response to inputs. The motivation for each is very different.  The risk for leaders is overseeing teams who view their role objectives to be in line with “testing to pass.”

[Read more…]

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The Basics of Planned and Deferred Maintenance

The Basics of Planned and Deferred Maintenance

We can plan to do more than we are capable of accomplishing. The remaining items, if they warranty accomplishing become deferred. They roll over to the next’s day’s list of actions to take.

Of course, in practice, the process to plan, execute, and defer maintenance activities is a bit more complex than described above. The ability to maintain equipment in working order along with minimizing downtime and costs is in large part the balance between resources available to conduct maintenance and the increased risk of system failure due to deferred maintenance. [Read more…]

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Phase and Gate Structure for New Product Development

Phase and Gate Structure for New Product Development

In previous articles we defined an element of lean as a phase and gate structure for new product development.  This assumes a waterfall approach to the project (versus agile product development).

A new product life cycle phase gate structure might entail, for example: “Definition, Concept, Design, Verification, Qualification, Production and End-of-Life”.  (Your organization might decide on different phase names.)

There’s an apparent contradiction in using a waterfall project approach and calling it lean project management, however.  A goal of any lean process is to work toward ‘single piece’ or continuous flow: agile product development is more like ‘single piece flow’ of information, versus waterfall which is more like ‘batch processing’ of information.

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Incemlpote dtaa set anaysils

Incemlpote dtaa set anaysils

Iideytinnfg pantrtes in dtaa is why we pforrem stsiattaicl aalisnys. It is not an ecaxt sicncee but iarmitofonn can be exeaaltpotrd eevn if the dtaa is nsoiy or inmptcolee.
The Rseaon Wuleibl asaynlis is ieeeptmnlmd as a tool is to look for pntertas and tehn cetare a charisotairceatn of a cmomon boeihvar. Taht charcoeatistairn can tehn be uesd to unsretadnd uocnpimg silimar pntarets. The raoesn you hvae been albe to raed tihs alirtce is beusace yuor biran fgriued out taht eevn tuhogh teh wodrs are samerbcld the frsit and lsat leettr and the wrod lgnteh areare corcert.
Uisng tihs prttean and the sceentne coxnett and rninaemig ltrtees and cmipanrog taht asnaigt yuor vbualrcaoy you can qulikcy dremtinee the menanig of the sectnnee.
It’s spimly a mteatr of aniaslys, pteratn chractrsaoietian, and tehn precdoitin by aiplnypg taht chariocatestrian to a new dtaa set.
Wlel Dnoe !
-Aadm

 

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It’s Time To Bring Back Skilled Trade Apprentice Programs!

It’s Time To Bring Back Skilled Trade Apprentice Programs!

As I work with teams of operators and skilled trades people performing RCM analyses at companies around the world at some point in time as we are discussing the failure modes and effects I might ask the question; how does your company ensure that the skilled trades people working on your assets are actually qualified to work on the equipment?

This question is often met with a look of confusion. [Read more…]

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Fail Fast – Fail Small – Learn and Move On

Fail Fast – Fail Small – Learn and Move On

Guest Post by Joseph Paris (first posted on CERM ® RISK INSIGHTS – reposted here with permission)

Fail Fast – Fail Small – Learn and Move On

Nobody likes to fail. Failing causes us embarrassment. Failing bruises our ego. Failing might be a dark spot on our performance assessments. All we have to do is reflect on our childhood for when we failed and how poorly we felt. Even if our parents did give us encouragement, we still felt bad about failing. Let’s face it – failing sucks. [Read more…]

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Tools to Focus on Plant Reliability

Tools to Focus on Plant Reliability

The focus of maintenance has changed from repairing equipment to keeping it running for longer between breakdowns. This requires more consideration of how to get longer running life between repairs, i.e. higher reliability, on a machine. To accomplish this a number of ‘tools’ have been invented and developed to allow maintainers to pinpoint problems and fix them. In this article three of the most effective ‘tools’ will be introduced. Root cause analysis, Weibull analysis and lifecycle simulation can be used to help organisations achieve proactive approaches to maintenance or adopt a “reliability based approach” to maintenance.  [Read more…]

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Data Outliers and Questions

Data Outliers and Questions

When looking at a pile of data, sometimes there is a data point that is not like the others. It attracts attention as it is different than the rest of the data.

When I spot something odd in a dataset, I wonder if there is something to learn here. Is this an opportunity to make a discovery or improve a process?

All too often it is tempting to remove the outlier as a mistake. Or to drop the outlier as it doesn’t make any sense and ‘messes up’ the analysis. [Read more…]

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Lean Project Management for Product Development

Lean Project Management for Product Development

My last article covered a scalable model for lean product development depending on the number of projects and technical objectives.

Let’s start with the foundational elements from this model:

 

  • Facilitate a lean project
  • Understand customer needs (requirements validation and/or agile product development)
  • Maximize customer (product) value (product value estimation)

[Read more…]