The Culture of Design for Reliability

The way we think and act concerning creating a reliable product or system defines the reliability culture of an origination. I trust your organization doesn’t complete the design then ask the reliability folks to ‘add the reliability element’ or ‘test to prove it’s reliable enough’.

Another ineffective approach is to perform many reliability-related tasks, like a design FMEA, HALT, ALT, derating, margin and environmental testing, life testing, demonstration testing, etc More is not better. If the focus is just doing the list of tasks, with little information acted upon, then this approach is little more than a waste of resources.

So, what is it that makes a wonderful design for reliability program? It’s not expecting the reliability team to do it on their own, nor is it checking off a long list of tasks. It is the focus across the organization, inside and outside the design and development team, that each decision made has an impact on reliability performance. As such, the work of the DfR program is to enable each decision to be well informed concerning the potential impact to reliability involved with the pending decision. [Read more…]

How One Person Can Change the Reliability Culture

Nicholas W. Eyrich, Robert E. Quinn, and David P. Fessell published in the Harvard Business Review an article titled “How One Person Can Change the Conscience of an Organization”, dated December 27, 2019. In the article, they discuss how corporate transformations, while assumed to occur from the top-down, actually it is the middle managers and first-line supervisor that can make significant change happen.

They look at what it takes for one person to make a significant change within an organization. As reliability or quality professionals, we often have the opportunity to spot needed changes. It is then up to us to tackle those challenges to make the change happen. [Read more…]

Best Practice for Dealing with Field Failures

A common practice I’ve seen in organizations is to deal with field failures when they occur. This may occur when the mistaken assumption that no failure will occur due to ‘such an excellent design.”

Ben Franklin may not have been thinking about future product failures, yet his quote:

By failing to prepare you are preparing to fail.

implies we need to prepare ourselves and our organization to deal with field failures. Having clear processes to deal with field failures is a best practice. [Read more…]

Improving Reliability with Good Judgment

At an early concept meeting discussing the technical strategy for the new product, the engineering teams were at an impasse. The decision matrix balanced out with three distinct options. Product reliability differed slightly with each option yet presented risks just as the considerations of cost, complexity, feature set, and time to market.

The project manager, the leader of the development program, asked a few questions, asked for input from the director of engineering, and selected a path forward.

The team accepted the decision. The project went well. Yet, I’ve often wondered how did she know which option to select. I also learned to trust her judgment on difficult decisions. [Read more…]

Is Making Assumptions Similar to Making Mistakes

Over the past week, I received a couple of interesting questions. One concerned assuming a Weibull beta value for an accelerated life test plan. The second involved assuming expected life models for elements within a reliability block diagram.

In both cases, we faced incomplete data and uncertainties, yet felt the need to assume some values in order for the math to work out. We do make assumptions in order to solve problems. We also can make mistakes that lead to unwanted consequences. [Read more…]

Lessons Learned via Golden Nuggets

One of the enjoyable parts of reliability engineering work is the consistent need to learn. We learn how new materials, designs, applications, and systems work, and fail. Sometimes we learn through proactive characterization studies, sometimes via unwanted field failures.

Failures will occur, it is what we learn from them that matters. The ability to gather and remember the lessons learned is a common and ongoing need for every organization. We are not very good at it, in general. [Read more…]

Dealing with Reliability Related Uncertainty

Uncertainty is another word for risk. Reliability uncertainty or risk is neither good nor bad, it just a bit unknown. Until we know the outcome, the eventual reliability performance, we will not know the impact.

So, how do we deal with reliability uncertainty? Will our product or system work as expected over time, or will it fail? Let’s examine a few of the common approaches in use and when and why the approach is effective. [Read more…]

A Two-Step Approach to Get Better at What You Do

How is it that some people continue to get better at managing meetings, designing complex test plans, making presentations, or solving problems? How in general do people improve their performance over time at something? [Read more…]

One Does Not Simply Do Reliability

Some time ago when talking with someone I just met, the conversation turned to what we did for a living. I mentioned being a reliability engineer, and his response: “Oh, yes, we do reliability”. Curious, as I’m not sure that I ‘do reliability’, we then talked about what he meant.

The conversation revealed that they had a list of tasks that they accomplished for each product under development. They did tests and reviews of the results. A lot of testing. They did FMEA and HALT. He believed the engineers did derating or stress/strength calculation. He didn’t know about process stability with vendors or internal manufacturing lines.

They did stuff, which meant they did reliability.

[Read more…]

The Value of a Great Question

Some time ago, earlier in my career, I worked for a wonderful boss. She would stop by my office on occasion and ask ‘what’s new?’ or “how’s it going?’ Just a check-in. I often let her know about the current vexing problem I was struggling with at the moment.

The funny thing is she never directly solve the problem for me. She certainly could have. Instead, she would ask a couple of questions that always helped me to find the solution. This happened with problems concerning dealing with a difficult person, strange material properties, motivating change within a group, or finding someone that could design and run a computational fluid dynamic model for me.

It was her questions the helped. She did this in meetings, in presentations, and when she swung by my office for a chat. [Read more…]

Infrastructure Is Not a One Time Investment

In a recent blog post, Seth Goin discussed the need for ongoing investment to maintain infrastructure. Whether a road or building or even your own skills, it takes regular care to avoid system failures or obsolesce. [Read more…]

Is SPC Part of the Reliability Toolkit?

Statistical process control, SPC, is a set of tools to enable monitoring the stability of a process. SPC is also the first step to checking process capability with measures such as Cpk. Many consider SPC a quality or manufacturing tool. Yet, having and maintaining a stable process is also essential to creating a reliable product. Let me explain why. [Read more…]

Reliability Questions and Decisions

Very few reliability decisions are made by reliability engineers. Yet, reliability engineers are asked many questions concerning reliability. How reliable will this design be for customers? How will the system likely fail? How many failures should we expect next month?

How you answer these and the many other questions received does impact the reliability of your product or system. The information provided those that ask reliability related questions, with useful and practical information, can make better decisions which improves reliability performance.

[Read more…]

The Purpose of Reliability Engineering Work

An immediate purpose is to earn a living. You also may suggest the work is to improve the reliability of the product or system. Reduce downtime, reduce warranty, increase profit, etc.

That is fine for the overall purpose of reliability engineering work, yet in the day to day work, the specific task level, what is the purpose behind what we do?

[Read more…]

The Design for Risk Idea

Yesterday had the chance to review the long list of Design for X topics. Assembly, environment, maintainability, and of course reliability, plus about a dozen other areas of focus. How is a design team to navigate all these different sets of constraints and objectives along with crafting a solution that works?

With a little creativity, you could relate every Design for X topic to reliability. Easier to assembly, fewer assembly errors leading to field failures, for example.

Another way to think about the Design for X space is to consider a superset instead. What are all these design considerations really about? What is common, including the design for reliability topic? With a little thought, it seems clear to me that we all are really considering how to identify and manage risk. [Read more…]