Fundamentals of Reliability Testing

By Fred Schenkelberg

November 13, 2018 / 9am Pacific time

Testing is expensive. Reliability testing is often complex. Let’s break down the basic of planning and conducting reliability testing the provides meaningful results in a cost-effective and timely manner. Let’s do testing right.

Reliability testing includes a broad category of product testing. Generally, it includes evaluations that attempt to determine if an item functions as expected over some duration under some set of conditions or stresses. Reliability testing may include out of box or installation activities, environmental testing, testing to failure, or accelerated life testing.

The core of any reliability testing is a question to answer. Often the work is focused on determining if a design is robust or durable enough for the intended use and market. Keep in mind when preparing to conduct testing that the results provide information to inform a decision.

Let’s discuss an approach to reliability testing that focused on creating results that are useful and meaningful, thus enabling making correct decisions concerning the product and its future performance. For any testing, and especially reliability testing, there are a few basic steps to ensure the testing will meet the needs of those making decisions based on the results.

We will also discuss when it is appropriate to not conduct testing and how to appropriately characterize the risks surrounding the testing itself and interpreting the results. Join this lively and interactive webinar and learn how to improve your reliability testing program.

Bring your questions and favorite reliability testing tips, best practices, and disasters for this interactive and hopefully fun event.

Why Equipment Fails

By Terry Harris

November 13, 2018 / 8am Pacific Time

$50

A Reliable Process Solutions 1-hour webinar event focused on providing you practical content to improve your reliability program today.

This webinar will include presentation and discussion on:

• 5 Main Reasons Equipment Fails
• Design, Fabrication, Installation, Operations, and Maintenance
• What are the percentages of these 5 areas in relation to your plant
• What can maintenance do about the 70 – 80% failures that come with the equipment and processes

Sign up is direct with Reliable Process Solutions. After payment they will forward the link for the GotoWebinar event or provided access to the recording. There are also options to buy bundles of webinars (3 for $105, 6 for $179 and all 12 in 2018 for $299. You determine which 3 or 6 topics yould like to include in your bundle.

Big Data Analytics – Telematics Data Analysis

By Dennis Craggs

November 8, 2018 / 9am Pacific time

Engineers conduct tests to verify that product meet engineering standards. These standards were developed with customer surveys, duplication past standards, or relying on expert opinions. Modern technology provides a new tool to validate standards by measuring product usage by the customer. An automotive example will be discussed, but the methods have much broader application.

Automobile companies installed telematics modules on fleet vehicles, with the consent of the owner, to collect and store usage and environmental data. The volume of data was enormous. Different analytic methods were required for different data types but there were only a few data types to consider. The raw data needed to be standardized for different vehicle miles or time. Then counting data, like trips/day, were analyzed with simple probability distributions. State data, like switch setting, need to be analyzed for transitions and time duration in states. Continuous measurements are more difficult. Engineers frequently use bar histograms, but bar histograms quickly become unreadable when two or more data sets were combined in the same graphic. Methods were developed that allowed many histograms to be analyzed fleet usage patterns and develop the 5th, 50th, and 95th customer percentiles. The standards can then be validated using the customer data.

The Catalyst for Change: GE Appliances’ Journey To Improve Reliability

By Mary Jo Cherney

November 1, 2018 / 9am Pacific time

In this presentation you will learn about GE Appliances’ strategic improvement initiative and our journey towards reliability excellence. Making our operations more reliable has always been at the heart of our quest. One of the biggest challenges we encountered during this endeavor was changing our culture. Based on this we looked for a holistic way for the corporation to become more reliable. Along the way we learned that changing certain processes at the plant level and clearly defining roles and expectations was vital to helping everyone understand how to connect their daily work to the company’s goal of reliability excellence.

Content: The Missing Ingredient in the Recipe for Producing Great Asset Information

By Tracy Smith

November 6, 2018 / 9am Pacific time

Free for members / $35 non-members

This presentation is focused on the importance of EAM/CMMS master data and coding structures in helping to create rich and actionable asset management information. Industry accepted naming conventions, taxonomies, WO codes, problem-failure code sets, etc. are discussed, with sample codes provided to all meeting attendees.

Reliability Program Implementation Case Study

By Patrick Parker

November 7, 2018 / 8am Pacific time

Free for members / $35 non-members

This webinar will walk through the formation and implementation of a reliability program within a customer facility. From brainstorming to execution, project management to change management, and pilot selection to roll out, we’ll discuss what did and did not work, as well as what we’ve learned in the process.

Understanding Shock and Vibration

By Alec Feinberg

November 7, 2018  / 8:30-12pm Pacific time

$350

This 3.5-hour course will start with the basics, defining such terms as “G”, “g”, “GRMS” and “G-Force”. We will explain the physics of shock and vibration in understandable terms. At the end of this course the student will be able to clearly understand shock and vibration, its terms, how tests are specified, and have the capability to apply software as a test aid. This course provides excel based software to aid the student in quickly learning shock and vibration fundamentals. With the DfRSoft Shock and Vibration Software, the student will be able to specify shock tests and perform a number of analyses. Every section below will have many examples to aid the student.

• Shock Test and Analysis
• Constant Acceleration
• Sine Vibration
• Random Vibration

Changes to Electrolytic Capacitors – More Reliable?

By Greg Caswell

November 8, 2018 / 11am Eastern time

Electrolytic capacitors have long been identified as a weak link for long term high reliability applications. However, capacitor manufacturers have made significant improvements to the materials and manufacturing processes to enhance their reliability. This webinar will discuss those changes, provide insight into the various failure mechanisms for electrolytic capacitors and describe appropriate accelerated tests to validate performance.

We will take a deeper dive into the methodologies utilized to improve capacitor performance, e.g. foil purity and electrolyte volume. We will also discuss, from a reliability perspective, the impact of changing to a higher temperature electrolyte (from ethylene glycol to DMF, DMA and GBL) and also changes in the bung material (from butyl to EPDM).

There are several environmental factors involved in the aging of electrolytic capacitors. Electrolyte loss due to drying out and leakage current due to oxide degradation are thermally related as is the self-heating associated with ripple current. The impact of the applied voltage level is also a driver as it can cause leakage current increases as well. All of these issues result in a capacitance decrease, an increase in ESR, and a change to the dissipation factor. Many other failure mechanisms associated with manufacturing will also be discussed.

Examples of calculations for life expectancy will be shown to demonstrate the effects of applied voltage, rated temperature, ripple current, and the endurance factor coupled with the application usage profile.

Where do you Slice the Cheese? Leveraging the Real Value of the Swiss Cheese Model to Drive Down risk

November 9, 2018 / 8am Pacific Time

The Swiss cheese model of accident causation is a conceptual model that visually represents how a high severity problem is comprised of a system of breakdowns within an organization. Its value lies in its ability to demonstrate that a problem must pass through “layers of protection” that organizations have already designed and built into their systems and processes. This webinar will explain the important lessons within the model, address criticism, and highlight the most important takeaways that are often overlooked. We will demonstrate how to leverage the valuable lessons the model reveals on risk and reliability into real world application for your organization.

Introduction to Reliability Based Asset Management

November 13, 2018  / 5:30-6:30am Pacific Time

This webinar is the first of a multi-part series covering Reliability Based Asset Management. The objective of this presentation is to introduce the attendees to the foundational elements covered in this webinars series. The course details the six sequential elements of the RbM process. Beginning with discussion of key reliability concepts, the presentation moves rapidly through:

* Asset Data Identification / Organization / Classification
* Failure Identification – Failure Modes, Effects, and Indicators
* Asset Care Strategy Optimization
* Work Management
* Continuous Improvement

The Two Most Important Root Cause Analysis Tools – and How to Use Them

By Duke Okes

November 13, 2018  / 10am Pacific Time

$199

Root cause analysis (RCA) is a powerful way to identify systemic causes and prevent recurrence of the issue. Yet it often fails to achieve the expected results. But using the right tools and techniques can prevent this – and significantly increase the effectiveness of problem diagnosis. And while there are many tools and techniques for performing root cause analysis, none are so powerful as the flowchart and the logic tree.

This presentation by industry expert Duke Okes will show you when and how to use each of these two tools to conduct a more logical root cause analysis. You will learn how to quickly eliminate many potential causes at a time; use flowcharts to search for causes in six different ways; create a logic tree level using six different approaches; and use both the tools interactively. You will discover how the flowchart supports other cause identification methods; why you can’t rely on the fishbone diagram to diagnose complex cause and effect problems; and how the use of flowchart and logic tree is quite different from brainstorming a long list of possible causes to figure out which to test. You learn how the system engineering approach covered in this webinar applies to both single and repetitive
problems, and performance versus incident type situations, while visually describing the system/process/device being analyzed.

You will discover why none of the tools and techniques used for root cause analysis are as powerful as the flowchart and the logic tree. Both the tools provide a visual display of how the failed system/process/device is supposed to work from a sequential and structural standpoint. You will learn how these powerful tools allow you to quickly eliminate a large number of potential causes at a time, and support the iterative 5-whys thinking process to identify the physical and root causes – related to both the failure to prevent and the failure to detect the problem.

After attending this session, you will be able to conduct more powerful root cause investigations, reduce the number of causes that must be considered at a time, and provide a systems analysis perspective for analyzing any type of problem. Plus, you’ll understand the options for the use of each tool.

The ABC’s of Simulation

By Allen G. Greenwood

November 13, 2018  / 11am Pacific time

Since simulation is becoming widely used in process improvement projects, it is imperative that all stakeholders have a fundamental understanding of simulation.

Correlating HALT & HASS in Lean Product Development & Manufacturing

By John Paschkewitz

November 14, 2018 / 8:30-11:30am Pacific Time

$300

This 3-hour webinar introduces the basic elements and tools of lean product and production process development with emphasis on the opportunities they provide for ensuring product reliability. These methods focus on knowledge based product development with up front learning and reduction of variation. The emphasis is on applying accelerated tests like HALT and HASS effectively during lean product and process development.

During the upfront learning phase, analytical tools are used to enhance understanding of customer needs, modeling of the product and its margins in the operating environment, and Design Review Based on Failure Modes (DRBFM). With this knowledge in place, test planning to include Design of Experiments, HALT and Quantitative Accelerated Life Test are used enhance Design for Reliability. Design Review Based on Test Results (DRBTR) is used to capture learning from testing and identify corrective actions needed.

The lean methods also emphasize integrated product and process design to facilitate the transition to production. DRBFM can again be used to ensure issues in the production processes are identified and corrected. This leads to effective application of HASS and HASA to screen production and ensure variation is minimized. Finally, field return data is subjected to failure analysis and life data analysis to provide correlation with design and test data for further improvement as well as knowledge capture for re-use in follow-on product development.

Printed Circuit Cards and Modeling System Effects

By Gil Sharon

November 15, 2018 / 11am Eastern Time

Printed circuit cards are often connected to a housing or a protective shell. These objects interact with the board in various ways when the temperature changes. Some boards may have stiffeners or heat sinks that could also change the way that the board warps with a change in temperature. Modeling system level effects can be useful to predict the performance of the board and components subjected to temperature variations. This webinar shows examples of boards attached to housings, large heat sinks and other interesting configurations.

Introduction to Reliability Based Asset Management

November 15, 2017 / 8am Pacific Time

This webinar is the first of a multi-part series covering Reliability Based Asset Management. The objective of this presentation is to introduce the attendees to the foundational elements covered in this webinars series. The course details the six sequential elements of the RbM process. Beginning with discussion of key reliability concepts, the presentation moves rapidly through:

* Asset Data Identification / Organization / Classification
* Failure Identification – Failure Modes, Effects, and Indicators
* Asset Care Strategy Optimization
* Work Management
* Continuous Improvement

Introduction to Cause Mapping – Effective Root Cause Analysis

November 15, 2018 / 8am Pacific Time

Learn how to become better at solving problems in your job in just 45 minutes. During this FREE live webinar, we’ll demonstrate the Cause Mapping method, as well as answer your specific questions about our approach to root cause analysis. The Cause Mapping method is evidence-based cause-and-effect, and can be used on day-to-day issues as well as catastrophic incidents. Anyone wanting to become a more effective manager or team member can benefit from this discussion. Participants will take away practical tips that can be implemented immediately.

Process Reliability Modeling (PRM): Increase Profits by Improving Process Effectiveness, Efficiency & Reliability

By Dr. Michael Abitz

November 15, 2018 / 10am Pacific Time

$199

Traditional process improvement methods demonstrate high failure rates: Business Process Reengineering (BPR) 50% – 85%, Total Quality Management (TQM) 75%, and Six Sigma 90%. According to peer reviewed research, the average Sigma Score for organizations is approximately 3 – meaning that 25-40% of sales are lost to waste in manufacturing and transactional processes. They cost the industry billions of dollars in nonproductive time, cost overruns, and project delays – and are probably hurting your operations more than you realize.

Learn how the proactive methods used in Process Reliability Modeling (PRM) can help you to identify organizational issues before they result in loss of revenue. This session by industry expert Michael Abitz will bring you up to speed with PRM, show you how to reduce the cost of doing business – and increase profits/sales by 25 to 40% – by improving the effectiveness, efficiency and reliability of your processes. The great thing about PRM is that you can use in any medical, transactional, engineering, manufacturing, marketing, sales, quality, documentation, education, and government process. You will learn about data mining and critical process metrics, including how to baseline your organization’s Sigma Score; why you come to wrong conclusions; and the most effective management tool you may still not be using.

Abitz will provide valuable insight on other specific areas, such as: the fishbone diagram; manufacturing and transactional yield; how to apply reliability statistics through Weibull analysis; how to identify root causes of process variation before they occur; how to convert information into measurable data; and how process variation costs you money. You will learn how to eliminate the 5-Cs in manufacturing and transactional processes (confusion, conflict, complexity, chaos and cost); a new lens to view organizations; as well as the failure rate of change management programs and consultants. Abitz will bring you up to speed with the Pareto principle; explain why you need process owners; discuss statistical process control techniques; show you how to locate root causes with reality charting software; discuss process and problem repair, and how to interpret results from different tools and methods.

After attending this webinar, you’ll know how to use Process Reliability Modeling (PRM) to identify hidden process issues that are responsible for 25-40% loss in sales, and increase your organization’s process effectiveness, efficiency, and profits.

Hand Soldering & De-Soldering with Lead-Free Solder

By Bob Willis

November 19, 2018 / 6:30-8am Pacific Time

$25 for members / $95 non-members

Hand soldering and de-soldering with lead-free solders does requires higher process temperatures. This material change can impact on the printed circuit board and components used. It can also impact on the tooling leading to increased cost and maintenance in your facility. Soldering with lead-free can be simpler than you think if staff are provided with the correct procedures and a better understanding of the process and the type of joints they will be producing. Changes to material and processes in your factory is an ideal time to eliminate poor practices that have been used for many years leading to extra rework and cost.

Each delegate will receive a copy of all of the slides presented plus a set of posters on soldering to print on site for future training.

Condensation Testing – Initial Results from a Round Robin Project

November 20, 2018 / 6:30-8am Pacific Time

In preparation for the event and to ensure you are equipped to get the maximum benefit from the event, please read our simple Webinar Guidelines https://www.bobwillis.co.uk/wp-content/uploads/2017/01/WebinarAttendance2017.pdf

NPL has been working with 11 industrial partners to develop a test methodology for condensation testing to enable relative performance of conformal coatings to be determined. Details will be given of the test vehicle which has been designed incorporating components to provide a tougher coating challenge. A short term test methodology has been devised using three increasing levels of condensation over a 24 hour period. Initial test results using the methodology with a range of common coatings will be given including a discussion of how the results are analysed. Recent work on developing a method for condensation testing of double sided assemblies will also be give

The webinar will cover:

Condensation testing of coated assemblies
Test methodology development for condensation testing
Double sided assembly condensation testing

The webinar will run for between 45-60min with question and answer session. The webinars are limited to 100 delegates/companies. A copy of each of the slides presented and links to NPL reports will be provided after the webinar

ESD Electrostatic Discharge Guide for Everyone

By Jeremy Smallwood & Charles Cawthorne

November 26, 2018 / 6:30-8am Pacific Time

$25 members / $95 non-members

When handling most of today’s electronic components, printed circuit assemblies (PCAs) or equipment that contains electronics, special consideration must be given to the potential damaging consequences resulting from static electricity. Electrostatic discharge (ESD) can result in PCAs or higher level equipment failing test in the factory, or worse still, it can result in latent defects that can cause subsequent failure in the field. So what is electrostatic discharge and how is electrostatic discharge damage prevented?

This webinar provides an elementary guide to the principles of ESD control, looking at the basic theory behind the subject and the practical methods that can be adopted used to enable components, PCAs and equipment to be handled without the risk of incurring electrostatic related damage. The webinar is aimed at personnel who are new to the industry, including design and process / manufacturing engineers, technicians, trainers and also at those who support manufacturing indirectly (i.e. purchasing, account managers, sales staff, etc.)

Topics include:

• What is ESD and why is it important
• How static charges are generated
• How static charges can be transferred to electronic components
• Illustration of the damage that can be sustained by electronic components following electrostatic discharge
• What is an Electrostatic discharge Protected Area (EPA)
• How to set up an EPA within a factory
• What practical controls are required to prevent electrostatic damage
• How to store / transport electrostatic sensitive components / PCAs
• How to handle electrostatic sensitive equipment out in the field

Analysis of Large Heterogeneous Repairable System: Reliability Data in Big Data Environment

By Xiao Liu Ph.D.

November 29, 2018 / 11am Pacific Time

In the age of Big Data, one pressing challenge facing engineers is to perform reliability analysis for a large fleet of heterogeneous repairable systems with covariates.

Forget Human Error. Focus on this instead…

November 30, 2018 / 8am Pacific Time

We are all human and therefore must acknowledge that as humans, we are prone to making mistakes. Labeling a problem simply as a case of “Human Error” is self-evident and shortsighted. Most concerning is that it misleads you from the ultimate purpose of your investigation. Instead we are stuck with generic action items such as “Don’t mess up”, “Be more careful”, or “Follow the procedure” that do little to reduce risk. If you have seen any of these as an output from an investigation then you are all too familiar with this shortcoming.

During this webinar, we will challenge some of the conventional methods used to investigate human error that tend to focus on the human condition and leave you little to work with. Instead, we will demonstrate what to focus on during your investigation so that you can improve reliability in spite of the fact that we as humans err.

Outsourcing a Part of Physical Asset Management – How to Decide

By William (Bill) Mercer

November 30, 2018 / 9am Pacific Time

Asset-intensive industries have changed radically because of regulatory and technological changes. This has allowed many new investors to enter existing markets and forced established companies to consider new markets for growth. Simultaneously, new technology has levelled the playing field as high efficiency changes economies of scale and market dynamics.

To manage their risks and uncertainties associated with new technology, while still focusing on improving profits, many asset owners look to outsourcing part of the physical asset management responsibility to specialized operations and maintenance companies. The owners gain advantages through the transfer of non-core activities to the supplier to reduce costs or to reduce risk. Whatever the rationale for outsourcing, the owner requires a method to evaluate outsourcing options to determine which is right for it, given its own internal capacity and strategy. The decision process must be capable of selecting the right type of service level based on a number of tangible and intangible strategic criteria. This type of multi-faceted decision necessitates process based on a sound theoretical foundation that can compare different options against the critical criteria of lifecycle costs, revenue influences, quality, health and safety, and other key drivers.

In this workshop, we’ll look at a case study model using the analytical hierarchy process (AHP) as a tool capable of evaluating this type of diverse multi-levelled decision. AHP is simple and straightforward, and uses an easy-to-understand hierarchical structure to sort criteria based on their relative importance.