Selecting Tests
Abstract
Dianna and Fred discuss the critical process of selecting appropriate reliability tests, maximizing value while avoiding the common pitfalls of over-testing or testing the wrong parameters.
Key Points
Join Dianna and Fred as they discuss selecting tests, maximizing value while avoiding the common pitfalls of over-testing or testing the wrong parameters.
Topics include:
- Determine Value: Learn how to focus testing by linking activities to critical decisions, ensuring that a test costing $100K yields information worth $1M.
- Challenge the “Why”: Discover why the vital questions for reliability testing are who needs the results and for what purpose, rather than simply deciding what to test.
- Use Analysis to Prioritize: Explore how tools like Hazard Analysis and FMEA highlight critical or unknown areas, allowing you to prioritize the “vital few” tests that will make the biggest difference to the product.
- Beyond the Lab: Consider alternatives to destructive or time-consuming tests, such as engineering estimates, simulations, Finite Element Analysis, or using simple tools like infrared cameras for thermal mapping.
- Test Timing Matters: Understand why testing at the end of the project is often useless, as the only decision left may be whether to issue a recall, emphasizing the need to inform decision-making early
Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques to field data analysis approaches.
Show Notes
In this episode of Speaking of Reliability, Fred and Dianna tackle the common dilemma faced by engineers: balancing the risk of insufficient testing against the expense and time sink of over-testing.
They stress the importance of grounding every testing activity in value. If a test costs a significant amount of money (e.g., $100,000), the information gained should be worth significantly more (e.g., $1 million). When designing test plans, engineers must challenge themselves and their teammates to revisit the “why” of testing. Focus on who needs the results and for what purpose. This helps distill complex issues down to obvious priorities.
The hosts caution that testing is frequently conducted too late in the design cycle, often during the last round of prototypes. If test results arrive after shipping has started, the information often fails to influence the current design. This means the only major decision remaining is whether to implement a recall. Therefore, testing must be connected to decision-making, such as a go/no-go assessment or informing vendor selection. Given the perennial constraints of limited time and budget, it is critical to prioritize, focusing resources on the “vital few” tests that will yield the maximum value.
To aid in prioritization, analysis tools such as Hazard Analysis or FMEA are highly beneficial, as they highlight critical components or areas where unknowns exist. Furthermore, testing is not the only option for gathering necessary information. Engineers should explore alternatives like simulations, engineering estimates, or non-destructive analytical methods such as Finite Element Analysis or thermal mapping using infrared cameras. Ultimately, effective test selection requires relating testing to customer requirements and project goals. And ensuring that effort is spent creating information that is valuable and timely enough to inform decisions.
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