How is Reliability Engineering Changing?

By Fred Schenkelberg

January 14, 2020 / 9am Pacific Time

The reliability engineering discipline, like all fields of endeavor, is changing. The inclusion of risk management, the shift to proactively avoiding field failures, and the increasing use of sensors and models, all make the future fascinating.

Let’s explore a brief history plus the major trends in business and industry that shape the work or reliability professionals. The work to create, assembly, and maintain a reliable system includes many activities and tasks that have given rise to the field of reliability engineering. There is a litany of tools that we and others use to identify risks, design, test, and maintain systems.

Supply chains are more complex and risky. Sensors have become affordable and more powerful. Modeling techniques have improved as well. Terms like physics of failure, prognosis health management, and risk management have become common – if not well understood.

What’s coming to reliability engineering in 2020 and beyond? Let’s explore a few trends and their implications. Let’s prepare and shape the future so we all can enjoy reliable systems and products.

Lubrication for Aging Equipment

By Terry Harris

January 14, 2020 / 8am Pacific Time

$45

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:

• What is aged equipment
• Changing the outdated recommended lubes
• Additive package changes for aged equipment
• What are we seeing in our lab analysis

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 $129, 6 for $209 and all 12 in 2019 for $329. You determine which 3 or 6 topics you’d like to include in your bundle.

Deriving Safety from the Quality and Reliability Disciplines

January 9, 2019 / 9am Pacific Time

Safety is a topic that usually gets lots of attention when it fails. This webinar will discuss Safety, or for the lack of a better term, Unsafety. The objective of the webinar is to clarify the distinctions and dependencies between and among Safety, Reliability and Quality. Material content will include coverage of emerging tools/methodologies intent on improving the prevention of Unsafety in complex systems.

Lubricant Fundamentals 201: Lubricant Composition

By Paul Llewellyn

January 7, 2020 / 8am Pacific Time

Learn how finished lubricants are formulated and the types of base oils, additives and thickeners that are used and why. The pros and cons of a variety of lubricant components are explained, and explanations are given for the selections made as determined by the final use of the lubricant.

Learning Takeaways

1. Primary components of finished lubricants

2. Considerations that go into the selection of base oils, additives and thickeners for different lubricants

3. How the final use and equipment requirements dictate proper lubricant composition

Best Practice Webinar: Preparing your People for Transitioning to Industry 4.0

By Jack R. Nicholas Jr.

January 8, 2020 / 8am Pacific Time

Planning for Industry 4.0? To achieve higher reliability and related goals—such as a better environmental footprint, lower energy costs, sustained or improved product quality, and so on—you need to prepare your people for a smooth and successful transition. In this one-hour webinar, reliability expert Jack Nicholas discusses how to plan for managing assets and people while getting ready to implement next-generation technologies. Why bother with IIoT and related technologies? How to sell your plan to the “C” level. Attend this webinar to hear Jack’s answers to these questions and more.

Deriving Safety from the Quality and Reliability Disciplines

January 9, 2019 / 9am Pacific Time

Safety is a topic that usually gets lots of attention when it fails. This webinar will discuss Safety, or for the lack of a better term, Unsafety. The objective of the webinar is to clarify the distinctions and dependencies between and among Safety, Reliability and Quality. Material content will include coverage of emerging tools/methodologies intent on improving the prevention of Unsafety in complex systems.

Statistical Methods for Quality Improvement

By Steven Wachs

January 9, 2020 / 10am Pacific Time

$150

This webinar introduces important statistical concepts and methods for assessing and ensuring product quality.

The methods include: Statistical Process Control, Process Capability Assessment, Regression Modeling, Design of Experiments, Hypothesis Testing, and Measurement Systems Assessment.

The methods have many applications including:

• Ensuring that I can effectively measure key characteristics
• Determining how well my process/product meets requirements
• Knowing when a process or system is behaving consistently (stable) or differently (unstable) than before
• Uncovering which key inputs to my process affect product performance or customer satisfaction
• Predicting future outcomes using a predictive model
• Comparing groups of data when random (natural) variation is present?
• Ensuring adequate sample sizes for making decisions

How A 5-Why Expands Into a Complete Investigation

January 10, 2020 / 8am Pacific Time

Every investigation, regardless of its complexity, can begin with a simple 5-Why. Bigger incidents will be broken down into more detail. Even as the investigation expands into a larger analysis it does not contradict the initial 5-Why. Smaller incidents have few parts and bigger incidents have more parts, but the cause-and-effect principle doesn’t change. It can be applied consistently to all incidents.

Solder Paste Evaluation & Simple Tricks of the Trade

By Bob Willis

January 13, 2020  / 6:30-8am Pacific Time

$60 for members / $85 non-members

Solder paste quality and performance is significantly important and considerable engineering goes into its production. Selecting the best materials for your product and assembly process is key to high yield and your customers’ satisfaction. Solder paste must be compatible with your equipment and other processes you use like cleaning, coating and electrical test. Working with suppliers to achieve the best performance is vital but so is periodic review of materials used.

There are always improvements being made to printing and jetting technology and it is important that engineers consider whether there are technical or commercial reasons to change. We look at common testing methods and some of the simple shop floor techniques used over the years to understand the different types of process failures.

Root Cause Analysis for CAPA – Myths, Challenges, and Best Practices

By Susanne Manz

January 15, 2020 / 10am-11:30 Pacific Time

$150

This webinar will help you understand the critical ingredients for conducting an effective root cause analysis.

You will learn about FDA expectations, tools and techniques, and tips for conducting and documenting root cause analysis. We will discuss the myths, challenges, and best practices for this critical process. We’ll also cover the essentials of doing a failure investigation.

Valid Statistical Rationales for Sample Sizes

By John N. Zorich

January 15, 2020 / 10am-11:30 Pacific Time

$150

This webinar explains the logic behind sample-size choice for several statistical methods that are commonly used in verification or validation efforts, and how to express a valid statistical justification for a chosen sample size.

The statistical methods discussed during the webinar include the following:

• Confidence intervals
• Process Control Charts
• Process Capability Indices
• Confidence / Reliability Calculations
• MTBF Studies (“Mean Time Between Failures” of electronic equipment)
• QC Sampling Plans

Equipment Validation, Tracking, Calibration and Preventive Maintenance

By Jeff Kasoff

January 16, 2020  / 10am Pacific Time

$150

FDA and EU regulations require that firms have a program for the calibration and maintenance of test and measurement equipment.

The program must include: intervals, scheduling, specific procedures, limits of accuracy/precision, and remedial action in the event that the equipment does not meet established requirements.

Prior to use, however, this equipment must be validated to make sure it produces product that meets its specifications. There are ways, though, to validate equipment already in use.

Areas Covered in the Session:

• Equipment Validation: Installation Qualification, Operation Qualification, and Performance Qualification
• Preventive Maintenance Requirements
• Calibration vs. Maintenance: When to use Which One?
• Remedial Action for Out-of-Calibration Equipment
• Use of Calibration Standards to Save Cost
• Equipment Calibration Requirements: Scheduling, Use of External Services, and Documentation

Introduction to Cause Mapping® – Effective Root Cause Analysis

January 17, 2020  / 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.

The Basics of Oil Filtration

By Peter Smyth

January 21, 2020  / 11am Pacific Time

We will discuss best practices for oil handling, techniques for keeping contaminants out, the dangers caused by not having clean, dry oil, and then different filtration methods for removing contaminants if they find their way in, as well as best techniques for monitoring your oil to ensure that you are meeting your cleanliness goals.

Reliability Prediction Based on Multiple Accelerated Life Tests

By Joseph Bernstein

January 22, 2020 / 8:30-10:30am Pacific Time

$200

To this day, the users of our most sophisticated electronic systems that include opto-electronic, photonic, MEMS device, etc. are expected to rely on a simple reliability value (FIT) published by the supplier. The FIT is determined today in the product qualification process by use of HTOL or other standardized test, depending on the product. The manufacturer reports a zero-failure result from the given conditions of the single-point test and uses a single-mechanism model to fit an expected MTTF at the operator’s use conditions.

The zero-failure qualification is well known as a very expensive exercise that provides nearly no useful information. As a result, designers often rely on HALT testing and on handbooks such as Fides, Telecordia or Mil Handbook 217 to estimate the failure rate of their products, knowing full well that these approaches act as guidelines rather than as a reliable prediction tool. Furthermore, with zero failure required for the “pass” criterion as well as the poor correlation of expensive HTOL data to test and field failures, there is no communication for the designers to utilize this knowledge in order to build in reliability or to trade it off with performance. Prediction is not really the goal of these tests; however, current practice is to assign an expected failure rate, FIT, based only on this test even if the presumed acceleration factor is not correct.

We present, in this tutorial, a simple way to predictive reliability assessment using the common language of Failure In Time or Failure unIT (FIT). We will evaluate the goal of finding MTBF and evaluate the wisdom of various approaches to reliability prediction. Our goal is to predict reliability based on the system environment including space, military and commercial. It is our intent to show that the era of confidence in reliability prediction has arrived and that we can make reasonable reliability predictions from qualification testing at the system level.

Acceptance Sampling Plans for Process Validation and Production Lot Monitoring

By Steven Wachs

January 22, 2020 / 10-11:30am Pacific Time

$150

Personnel involved in process validation and production control often rely on sampling methods to determine the suitability of a process before moving to production (process validation) or for checking production lots for acceptance.

This webinar provides details regarding the generation of sampling plans that meet the desired statistical properties. By attending this webinar, participants will be able understand the key inputs and issues involved in determining acceptance sampling plans.

Although software is generally used to generate sampling plans, the participants will gain useful insight into the methodology and its use in typical applications.

Sampling plans for attribute data are the primary focus although variable acceptance sampling plans are presented as well. The binomial distribution and its use in developing Operating Characteristic (OC) Curves is discussed. The key inputs to determining sampling plans (AQL, RQL, Consumer’s and Producer’s Risks) are described in detail. Key characteristics of the generated sampling plans (such as average outgoing quality) are presented. Double sampling plans are briefly introduced.

Several example applications of acceptance sampling are presented. The use of Statistical Process Control and Process Capability methods are presented as an alternative to variable acceptance sampling plans.

Process Validation: Statistical Justification for Sample Size and the Use of Only 3 Lots

By John N. Zorich

January 22, 2020 / 10am Pacific Time

$150

This webinar explains how to choose and justify a sample-size for Lots that are included in Process Validation studies.

The statistical methods discussed during the webinar include the following:

• Confidence intervals
• Confidence / Reliability Calculations (for variables & attributes)

It then explains how to analyze those samples in such a way that they provide statistically valid final %Reliability for the production Process itself. One example is worked through completely.

Fishbone Diagramming

By Michael Abitz

January 23, 2020 / 10am Pacific Time

$150

Fishbone Diagramming is an analytical approach used to identify and solve problems. Analysis is presented in the Seven Basic Tools of Quality in addition to advanced methods used to increase organizations effectiveness, efficiency and reliability.

Specific areas presented:

• Look for Evidence
  • The Post-it Exercise
  • Pareto Chart
  • Fish Bone Diagramming
  • Process Reliability Modeling
  • Critical Path Analysis
  • Value Stream Mapping
  • Failure Mode Effects Analysis
• Process Improvement and Problem Solving:
  • Reality Charting
  • Model for Improvement

Root Cause Analysis Case Study: Loss of the Space Shuttle Challenger

January 24, 2020 / 8am Pacific Time

On the morning of January 28, 1986, during the tenth flight of Space Shuttle Challenger, NASA experienced its first space shuttle disaster. A mere 73 seconds after liftoff, the space shuttle broke apart over the Atlantic Ocean, taking the lives of all seven crew members. In this webinar, we’ll use this catastrophic event as a case study for understanding how a cause-and-effect based root cause analysis can be applied to complex, catastrophic incidents.

Risk Management in Medical Device Design

By Charles H. Paul

January 24, 2020 / 10am Pacific Time

$150

The webinar will explore the basic principles of risk management and planning as they relate to medical device design and as required by the FDA.

It will present a logical process for risk management from risk identification through evaluation/rating and mitigation.

The secret to preventing medical device recalls or at least to minimizing their impact is sound Risk/Hazard Analysis. Aside from being required, it is absolutely essential and necessary to the development and fielding of medical devices that offer a significant level of protection for patients and manufacturers alike.

The tools and techniques of Risk Analysis and the rating process used to evaluate the risks identified will be presented and discussed – Fault Tree Analysis, Failure Mode Effects Analysis, and Failure Mode Effects and Criticality Analysis.

How to Get Optimal Strategies on Every Asset All the Time

By Jason Ballentine

January 29, 2020 / 8:30-9:30am Pacific Time

Asset Strategy Management (ASM) is a process which allows organizations to capture and review data from all sources and leverage learnings to enhance asset strategies, by identifying pockets of strategy excellence and deploying those strategies across the organization, wherever they are relevant. With ASM, you not only equip the end user with an optimal strategy, but along the way you create a company-wide set of strategies that is housed in one central location, readily available across all sites for use and continuous improvement. Not to mention saving a significant amount of time in the process of developing and deploying those strategies. Implementing an ASM program ensures that optimal strategies are always deployed, quickly and efficiently, resulting in the reduction of failures, downtime and risk, and consequently, a lower cost of operations.

Acccurate Material Properties for Simulation with Digital Image Correlation (DIC)

By Tyler Ferris

January 30, 2020 / 8am Pacific Time

Coefficient of Thermal Expansion (CTE) is one the most important factors affecting solder fatigue. Thus knowing the accurate CTE for your materials is essential when designing electronics and selecting initial parts. With increasingly complex materials and architectures being inserted into complicated simulations, Digital Image Correlation (DIC) can help you to ensure the accuracy of those simulations. DIC is especially critical for capturing the behavior of electronic components and circuit boards when simulating their response to thermal, thermo-mechanical, and mechanical loads.

In this webinar you’ll learn how DIC material testing can be used to accurately measure CTE of components and boards (the key parameter in solder fatigue simulations) as well as how the technique can be used to identify the glass transition temperatures of polymeric materials like pottings, underfills, and coatings, which are often within the operating temperature range of electronics.

Creating Optimal Sampling Plans

By Yuval Shapiro

January 30, 2020 / 10am Pacific Time

$150

A sampling plan is a term widely used in research studies that provide an outline on the basis which of research is conducted.

It tells which category is to be surveyed, what should be the sample size and how the respondents should be chosen out of the population.

The purpose of this webinar is to present to the listener the importance of creating a statistically based sampling plan and, how to present those in viable protocols.

KPI Why: A Case Study in Leveraging Maintenance Metrics to Drive Improvements

By Kris Halland

January 30, 2020 / 11am Pacific Time

This case study will show how we used an analysis of standard work management metrics and a systematic approach to identify opportunities to improve our plant. We’ll provide specific examples of how we developed and implemented the approach and the results we achieved. We’ll also describe the fundamental understanding and steps that could be taken to implement a similar approach at any plant, or for any particular metric.

Topics will include cultural recognition of KPIs as an improvement tool, not a personnel measurement stick; understanding all the various causes and influences on any particular metric; analysis and categorization of deviations; identifying losses as acute one-offs vs. chronic systemic issues; behavioural vs. procedural issues; understanding change/improvement requirements, what can be directly controlled and what can be only influenced; determining corrective actions; and tracking the resulting improvements. Specific examples will be derived from our site’s application of this methodology to schedule compliance, PM/PdM compliance, and emergency work metrics.

Root Cause Analysis Case Study: Super Bowl Delayed by Power Loss

January 31, 2020 / 8am Pacific Time

Super Bowl XLVII in 2013 became a bit more exciting than anticipated when the stadium in New Orleans had a partial loss of power in the third quarter of the football game–delaying the game. In this webinar, we use the Cause Mapping^® method of root cause analysis to better understand why the Super Bowl was delayed and determine possible solutions to prevent such a delay in the future.