Introduction to R & M Management
Fred SchenkelbergFMS Reliability
Reliability Engineering and Management Consultant
Carl S. CarlsonReliaSoft Corporation
Senior Reliability Consultant
2014 RAMS – Tutorial 2A - Schenkelberg
Reliability Engineering & Management Consultant
Fred SchenkelbergReliability Engineering
& Management Consultant
FMS Reliability
(408) 710-8248
Carl S. CarlsonSenior Reliability Consultant
ReliaSoft Corporation
[email protected]@effectivefmeas.com
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Tutorial Objectives
To introduce an outline to guide management of an effective reliability program.
To make you think about how to integrate reliability engineering within an organization.
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First Challenge as Reliability Engineer
New heating cable design
How long will it last?
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What did I need to know?
Timeline
Budget
Samples
What else?
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How long should it last?Is this a 1 or 5 year problem?
What is the goal?
How does your organization state reliability goals?
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First Assignment as Reliability Engineer
Put together a reliability plan for new vehicle programLesson learned: select the vital few tasks
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Outline of topics
Requirements Tasks Risk Reduction Tasks Assurance Tasks Organizational Tasks Primary Steps to Achieving High Reliability
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Requirements TasksSet Reliability Targets
Function
Environment
Duration
Probability
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Balance with other objectivesFeatures or functions of the product
Cost of the product
Time to market
Reliability
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Cable part of a larger system• Cable, sensor, power supply,
controller, and connectors
• Materials, processes, assembly, design, transportation, and installation
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Story of 50% field failure rate
All elements met reliability goal.
Field data agreed
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Apportion the goal
Sys
Sub 1 Sub 2 Sub 3 Sub 4 Sub 5
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Apportion the goal
Sys
Sub 1 Sub 2 Sub 3 Sub 4 Sub 5
With series system, product of sub system reliabilityis system reliability.
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Apportion complete goal
Function
Environment
Duration
Probability
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Story of “you need to improve reliability”No goal
No field data
No Pareto of issues
Just make it better, as warranty expenses too high
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Communication of Reliability Goals
Where should they reside?
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Requirements TasksIdentify Reliability Data Needs
Reliability data supports measuring and assuring reliability requirements are attained.
Data can take the form of test failures, field failures, degradation measurements, test or analysis successes, and other forms.
Focus on data integrity and correct measurements.
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Two basic questions
What will fail?
When will it fail?
Information to permit appropriate product development decisions
2014 RAMS – Tutorial 2A - SchenkelbergTesting to Pass
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Outline of topics
Requirements Tasks Risk Reduction Tasks Assurance Tasks Organizational Tasks Primary Steps to Achieving High Reliability
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Risk Reduction TasksDesign-in reliability This step involves selecting the “Design for
Reliability” tools that can be executed in the design and manufacturing stages of product development process
Such as Failure Mode & Effects Analysis, Derating, Design Margin Analysis, Highly Accelerated Life Testing, etc.
The focus of the DFR tools should be on high risk areas, such as new technology and new applications
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• Understand stress• Understand strength• Separate stress from strength
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Henry Petroski Design Paradigms
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Discovery
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Discovery ToolsDiscovery Tools
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Prediction of early life failures
Not commonly possibly for unknown variation
Design in some margin
Derating
Safety factor
Determine margin
If variation is known, determine probability of failures – still difficult to know when though.
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Risk Reduction TasksAchieve supplier reliability Incorporate reliability specifications and tasks into
supplier bid packages Select suppliers who are capable of achieving
reliability objectives Identify critical supplier parts Review and approve supplier tasks for critical parts
before shipment
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Extra tasks for critical suppliersDue care tasks for all other suppliers
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Risk Reduction TasksImplement reliable manufacturing Manufacturing Reliability is essential to ensuring the
manufacturing and assembly operations do not reduce the inherent design reliability of products.
Steps must be taken to control manufacturing processes so they are both stable and capable.
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Outline of topics
Requirements Tasks Risk Reduction Tasks Assurance Tasks Organizational Tasks Primary Steps to Achieving High Reliability
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Assurance TasksVerify Reliability Requirements Met Develop and use reliability tests that use physical
testing methods, as well as analytical modeling techniques.
Focus needs to be on proper analysis and accelerated life testing.
Supplier reliability requirements for critical parts must be verified before shipment.
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When will it fail?
Everything Fails at some point.
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Typical early life failures
Product does not meet design specifications
Material or component characterization
Process characterization
Assembly characterization
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Hit by a big hammer
Some stress is too large to accommodate
Lightening
Vehicle accident
Meteor strike
Hurricane
Possibly foreseen or expected, and not economical to design the ability to withstand
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Prediction of overstress
Not commonly possibly
Design errors
Environment
Unexpected use
When significant adverse consequence may occur explore mitigation or fail safe approaches
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Wear out and related
Everything fails – eventually
Understand failure mechanisms and environment
The race to cause a failure
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Prediction of wear out
Guesses
Estimates
Predictions
Previous products
Models
Testing
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Life testing
Standards
Set levels
Environmental extremes
Single stress and model for acceleration factor
Determine the model and acceleration factor
Physics of failure modeling/testing
Pick one that fits risk, resources, and time
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Is it good enough?
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Is it good enough?
How do we know?
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Is it good enough?
How do we know?
We understand thefailure mechanisms& business objectives
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Assurance TasksContinuously Improve Reliability The value of physical testing should be enhanced
through use of appropriate Reliability Growth Models and Life Data Analysis.
A Failure Review system (FRACAS) should be instituted.
Reliability improvement methods throughout product life cycle must be maintained.
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FRACAS
A method to keep it all together
Triage
Prioritization
Closure
Grey area of when to stop fixing and ship
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Assurance TasksMaintain High Reliability Throughout Life Establishing and implementing proper service and
maintenance procedures will extend product life and help ensure safe and trouble-free usage.
Understanding and addressing customer issues during field usage is important.
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Maintenance Considerations
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Value
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Outline of topics
Requirements Tasks Risk Reduction Tasks Assurance Tasks Organizational Tasks Primary Steps to Achieving High Reliability
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Organizational TasksEstablish organizational resources
Organizational resources include personnel, training, procedures, and business processes.
Will help move the organization to higher stages in the Maturity Matrix
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Organizational TasksInstitutionalize Reliability Tasks
It is the responsibility of engineering to achieve reliability objectives.
Reliability methods must be integrated into ongoing engineering procedures and tasks, including design reviews, supplier selection, work instructions, design procedures, etc.
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Achieving reliability objectivesis an organization-wide endeavor.
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Organizational TasksAdvance up the Maturity Matrix Maturity Matrix represents stages of “maturity” of
a company with respect to Product Requirements Engineering Feedback Process Management
There are 5 stages of maturity that represent increasing levels of organizational and engineering capability
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Primary Steps to Achieving High Reliability
Step 1: Develop Reliability Strategic Vision
Step 2: Perform Reliability Gap Assessment
Step 3: Develop Reliability Program Plan
Step 4: Execute Reliability Program Plan
Step 5: Assess Program Lessons Learned
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Step 1: Develop
Reliability Strategic Vision
Step 2: Perform
Reliability Gap Assessment
Step 3: Develop
Reliability Program Plan
Step A: Set reliability
targets
Step B: Identify
reliability data needs
Step C: Design-in Reliability
Step D: Achieve supplier reliability
Step E: Implement
reliable manufacturing
Step F: Verify
reliability reqmts met
Step G: Continuously
improve reliability
Step H: Maintain
high reliability
thru-out life
Step I: Establish
organizational resources
Step J: Institutionalize
reliability tasks
Primary Steps to Achieving High Reliability(High Level)
Step 4: Execute
Reliability Program Plan
Step 5: Assess Prgm
Lessons Learned
Step K: Advance Up
Maturity Matrix
Requirements Tasks Risk Reduction Tasks
Assurance Tasks Organizational Tasks
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Step 1: Develop Reliability Strategic Vision
In the words of American educator Steven Covey, “begin with the end in mind.”
The Reliability Strategic Vision outlines the overall vision for Reliability for the organization or program.
It should be developed with full management support, understood by all employees, and integrated into work activities.
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Step 2: Perform Reliability Gap Assessment
A Reliability “Gap” Assessment is:
A comprehensive analysis of the specific “gaps” between a company’s vision for reliability and current reliability capability
It begins with developing or understanding the company’s reliability vision, and then analyzes the specific shortcomings to achieving that vision.
The “gaps” are those issues or shortcomings that if closed or resolved would move the company in the direction of achieving its reliability vision. It is input to the Reliability Program Plan.
“Gaps” include both organizational capability and application of reliability methods.
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Step 3: Develop Reliability Program Plan
A Reliability Program Plan (RPP) is a document that defines the entire set of tasks that need to be accomplished on a project or program, including responsibility for execution, timing and resources, in order to achieve the program reliability objectives.
The objective is to design and manufacture a highly reliable product, on time, and in a cost effective manner.
Includes Steps A thru K
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Step 4: Execute Reliability Program Plan
Reliability Program Plan execution requires management buy-in and support
Reliability plan tasks should be integrated into company project planning and execution mechanisms
Provide a Work Break-Down Structure and schedule for the RPP (who, what, when, where, etc.)
Empower reliability to raise the red flag when needed
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Step 5: Assess Program Lessons Learned
No reliability program is flawless Maintain record of issues with development and
execution of reliability plan Move the organization up the maturity matrix
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Conclusions
Developing and executing an effective Reliability Program Plan is essential to achieving high reliability for products and processes
By following the information in this tutorial, companies can develop effective Reliability Program Plans that achieve reliability objectives, while staying within budget and timing constraints.
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