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USING TRIZ TO MAKE 
                    SYSTEMS MORE 
                       RELIABLE
                                  Jack Hipple
                           ©2011 ASQ & Presentation Jack Hipple
                             Presented live on Dec 09th, 2010




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USING TRIZ TO MAKE
 SYSTEMS MORE RELIABLE

WNY Society of Reliability Engineers

               Jack Hipple
             Innovation-TRIZ
                Tampa, FL
              813-994-9999
         www.innovation-triz.com
        jwhinnovator@earthlink.net
Agenda

•  TRIZ : What is it and how does it apply
   to improving reliability?
•  TRIZ Principles
  •  Ideal Final Result
     •  Trimming and resource use
     •  Separation principles
  •  TRIZ in reverse: Predictive Failure Analysis™
•  Recommendations and resources
•  Q/A
What is TRIZ ?

         A Russian acronym:
Theoria Resheneyva Isobretatelskehuh
                Zadach



    (Theory of Solving Inventive Problems)
               What are these?
The History of TRIZ
•  Result of work by a brilliant patent examiner for the Russian navy,
   Genrich Altshuller, late 1940 s to early 1950 s
•  Originated from the study of thousands of the world s most
   inventive patents--now in the millions
•  Methodology emigrated to the west after Perestroika (~1990)
•  Recognized that development of technological systems followed
   predictable patterns that cut across ALL areas of technology--the
   speed of technical evolution can be accelerated. Invention and
   problem solving are learnable sciences and not governed
   solely by genetics and being in the shower! There is an
   algorithm!
•  Established schools to teach after a Stalin 5+ yr. prison term--
   deceased in 1999 at age 71
Algorithms:
Generalizing Problems in Math

         It s Rome, 1100 A.D…


 Specific problem   Specialized solution
  3x2+5x+2 = 0          x = ????

 ALGEBRA DOES NOT EXIST--HOW DO
           WE SOLVE?
Generalizing Solutions
          Problem Solving Principle Example
Abstract problem               Abstract solution
ax2+bx+c = 0                   x=(-b [+/-]!b2-4ac)/2a



Specific problem             Specialized solution
3x2+5x+2 = 0                 x= -1, -2/3

    TRIZ DOES FOR PROBLEM SOLVING AND
    FORECASTING WHAT ALGEBRA DOES FOR
        EQUATION PROBLEM SOLVING!
TRIZ: What is it?

•  A left brained problem solving process
  •  Based on the study of the inventive patterns in the
     breakthrough global patent literature
  •  40 Inventive Principles
  •  Algorithm (as in algebra)
     •  Vs. “brainstorming”, psychology, and “quantity”
     •  Effort spent in problem definition vs. evaluating large
        quantity of irrelevant solutions
  •  Generalized problem models and solutions
     •  Su-Field, cause and effect
Visualizing Contradictions

                                       Normal Design Tradeoff or Current
           Good                        Performance Barrier Curve
                                       Constant Design Capability

    Parameter A
                                                TRIZ Moves Performance
                                                Barrier Curve away from
                                                the origin




             Bad

                         Parameter B
                   Bad                       Good
Examples

•  Reflux ratio on distillation column
•  Safety factors
•  Amount of ice melting salt
•  Number of wheel bolts
•  Surface active agents
•  Organizational communication
•  Safety inspections
TRIZ Contradiction Table
                                                                                           •  Possible contradictions
     Undesired            1        2             14              38 39                        represented in 39 x 39 table

                        Nonmoving Object
      Result             Moving Object
         (Degraded
                                                                                           •  Intersections of contradicting




                                                                            Productivity
                                                               Automation
                           Weight of
                           Weight of




                                                 Strength



                                                                Level of
            Feature)
                                                                                              rows and columns are
 Feature                                                                                      references to 40 inventive
 to Improve                                                                                   principles for contradiction
        Weight of                              28, 27,                                        elimination
1     Moving Object                            18, 40
        Weight of
2    Nonmoving Object




         Level of
                                                                                           28 Replace a mechanical system with
38      Automation                                                                            a non mechanical system
                                                                                           27 An inexpensive short-life object instead
39     Productivity
                                                                                              of an expensive durable one
                                                                                           18 Mechanical vibration
                                                                                           40 Composite materials


                                       ®Ideation International, used by permission
                                                                                           Proposed Solution Pathways:
Contradiction Table

•  Contradiction table
     •  http://www.triz40.com,
        http://www.innovation-triz.com,
        http://www.aitriz.org
        •  Has been updated in the past 5 years to a 48X48 table


  •  Useful for simple contradictions that are
     obvious

•  Modeling and software tools available for
   complicated systems
How Does This Apply to
Reliability?

•  Great emphasis in TRIZ on elegant simplicity in
   product, system, or service design
  •  “Ideal Final Result”
  •  Something performs its function and doesn’t exist
     •  If something doesn’t exist, it is 100% reliable
     •  Doesn’t require maintenance or monitoring
  •  A function controls “itself”
  •  A resource that is totally reliable and predictable
     •  Ex: gravity
The Boeing Corporation


 What s the Best Way to
 Hoist Seats up into the
   Body of a 757 Jet?
Hoists and Chains?
Maintenance and Reliability?




  If you re a MechE, don t you just love to
        design this stuff? Maintain it?
Lean Times: With Airbus on Its Tail , Boeing Is Rethinking How It Builds
Planes Old Hay Loaders, New Resins Play Roles as Firm Tries To Build
Faster, Cheaper
Hitting a `Rescue Me' Button
By J. Lynn Lunsford

09/05/2001 The Wall Street Journal (Copyright (c) 2001, Dow Jones & Company, Inc.)

RENTON, Wash. -- Not far from the steady blatt-blatt of the rivet guns on its 757 assembly line just
outside Seattle sits what Boeing Co. calls its moonshine shop: The people here distill work-saving
ideas into contraptions that make it easier to build jets.
Consider the hay loader next to an almost-completed 757. Normally, this cross between a ladder and
                                                      But to
a metal-spiked conveyor belt would be dumping bales of hay onto waiting trucks .
veteran mechanic Robert Harms, the hay loader is the perfect
way to get bulky passenger seats from the factory floor up 13 feet
to the door of a plane without having to use an overhead crane.
"It might look funny, but when you see it work, you wonder why
we didn't do it this way all along," he says.
Mr. Harms, the 52-year-old mechanic who led the effort to modify the hay loader to
move seats, recalls the day when he arrived for work and found a note attached to
his contraption. It read: "Idiots running amok."

"That sign kind of serves as our inspiration because once it started running, that
loader has made believers out of people," he says.

Gordy Laborde, a 48-year-old mechanic who has been installing interiors in Boeing
757s for 13 years, counts himself among the converted. "I looked at that hay loader
from every angle and I could not see how it was going to work. You do
something for so many years one way, and something like this
really takes you out of your comfort zone."
Using triz to make systems more reliable
Using triz to make systems more reliable
Boeing Discovers Hay Loaders…
Reliability vs. Overhead Crane Systems?




   Question: If you were a Boeing engineer,
   would you ask and would your boss let you
   go to an agricultural equipment show?
Ball Bearings:
 They have to work!

 You are in the ball bearing
business and want some new
  ideas for monitoring and
   controlling quality and
uniformity—where would you
            look?
Ball Bearings:
How Inspected?
Caviar Eggs
Caviar and Bearings
Inspecting Caviar Egg Hardness
(Used Since 1945)

                  Eggs




                          The real hard
                         eggs bounce up
                            and over
Two Key Questions


 1.  How reliable is gravity?

 2.  Does it require any
     maintenance or Inspection?
Gravity is Discovered…..Again
MACHINE REPLACES MAN
                            CASE STUDY

A robot was brought to a plant to operate a machine. After it was rigged up and switched
on, the elderly worker who had operated the machine for years was amazed at seeing the
nimble iron man performing all the necessary steps.

A half an hour later, however, the robot came to a standstill, to the bewilderment of the
service team of electronic engineers. What happened? As it turned out, some chips had
fallen from the workpiece into the moving elements of the machine. This situation where
a human worker would simply flip the chips away with a broom and continue working
brought the robot to a deadlock. The engineers cleaned the machine with a broom,
switched on the robot…only to see the robot stop again. How could this problem be
solved? Obviously, one cannot attach a human worker with a broom to the robot……

Source: TRIZ: The Right Solution at the Right Time, p3, used with permission
System Oscillation:
Phones and Remote Controls


Complexity                  TRIZ: Trimming
                                Phones that
                                only
                                receive calls
             Add useful
             complexity :
             features

                            Time
Trimming

•  Arbitrarily removing a physical or functional part
   of a:
   •  Process
   •  System
   •  Product
•  How its function can be replaced
•  Most useful in systems that have grown complex
   over time but useful at any time as a simple
    brainstorming concept
The Keyboard Performs its
Function and Doesn t Exist
Flash Drive: Ever Lost a Cap?
Who Needs Steps?
Black and Decker Paint Stick™:
Where is the Bucket? Ladder? Spill?
Trimming a Restroom Entrance

      Doors are cumbersome for
         people with luggage.


               RESTROOM




    Function of the door – privacy
   Use geometric shape to replace
       FUNCTION of the door.
         Door is eliminated.
Classical Approach to Design

•  Optimize and minimize pain
•  Ex: Number of bolts on a tire
  •  More: more secure wheel
  •  Less: Easier to change tire
The Tire Bolt Optimization:
Minimizing the Pain of
Maintenance and Reliability




      Number of
      Bolts Used
      to Hold the
         Wheel
                                               Minimal Loss
                                                of Wheels



                    Likelihood of Wheel Loss
The TWEEL from Michelin:
 Trimming the Tire
TiroGage™: The Stem is the Gage
TRIZ Separation Principles to
Eliminate Contradictions

•  Separate in time, space, system/super-
   system, and upon condition
•  Separation frequently improves reliability
   when multi-tasking is required
McDonald s Drive Through:
Reliability in Orders
Separate in Space:
Sacramento vs. Santa Maria
Predictive Failure Analysis™:
TRIZ in Reverse
•  Normal approach to failure prediction/
   analysis is checklisting of possibilities
  •  Asking “what could go wrong?”
  •  Slowly get better as the list gets longer from
     experience
     •  Our brains normally can’t see beyond a list
•  Alternative: How to make it go wrong?
  •  Make sure a system fail?
  •  Mis-schedule something?
  •  Make sure we install the wrong part?
Predictive Failure Analysis™
Algorithm

•  State the desired result
   •  “I want the webinar to go smoothly”
•  Invert the desired result
   •  “I want the webinar to go poorly”
•  Exaggerate the inverted result
   •  “I want this webinar to be the worst ever hosted by ASQ and
      chapter charter is revoked and Dave Auda is blacklisted on
      Facebook and Plaxo
•  How would we make this happen?
•  What resources would we need?
   •  Are they available? Can they be synthesized?
Using triz to make systems more reliable
Areas Used
•  Chemical plant control and releases
   •  Vs. HAZOP
      •  How to make sure we have a release
•  Software coding
      •  How to make sure coding never works
•  Food safety
      •  How we make sure everyone is poisoned
•  Mechanical failures
      •  How to make sure it never runs
•  Emergency and military communications
      •  How to make sure communication is never received and/or
         misinterpreted
TRIZ Learnings and
Recommendations
•  Always balance and question the addition of what is
   believed to be useful complexity
   •  Useful to user or repair person?
•  Arbitrarily trim a system
   •  Force/assign the rest of the product or system to perform the
      function
   •  One less part to maintain, monitor
•  Separate conflicting requirements
   •  Space, time, system/super-system, upon condition
•  Minimize energy conversions
   •  Every one loses energy and uses a system to convert and
      requires maintenance
   •  Invention history teaches that energy conversions are minimized
•  Use of a reverse algorithm can identify failure points
   difficult to find with check listing
RESOURCES
•  Altshuller Institute for TRIZ studies (www.aitriz.org)
      •  Annual meeting, fall 2011, location and date TBD
•    On line TRIZ Journal (www.triz-journal.com)
•    www.innovation-triz.com, newsletter available
•    European TRIZ Association (www.etria.net), fall 2011 meeting, location TBD
•    Mexican TRIZ Association (www.ametriz.mx), fall, 2011 meeting, location TBD
•    Books:
      •    “And Suddenly the Inventor Appeared” (Altshuller)
      •    “Hands on Systematic Innovation” (Mann)
      •    “TRIZ: The right Solution at the Right Time” (Salamotov)
      •    “Simplified TRIZ” (Rantanen/Domb)
      •    “Engineering of Creativity” (Savransky)
•  Chemical Engineering Progress (CEP)
    (April, May, June 2005)
•  3 Day Intro TRIZ courses for ASME and AIChE
    •  http://www.innovation-triz/events
      •  Las Vegas (3/21-23/2011)
      •  San Francisco (5/9-11, 2011)
      •  Other courses at http://www.triz-journal.com

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Using triz to make systems more reliable

  • 1. USING TRIZ TO MAKE  SYSTEMS MORE  RELIABLE Jack Hipple ©2011 ASQ & Presentation Jack Hipple Presented live on Dec 09th, 2010 http://reliabilitycalendar.org/The_Reli ability_Calendar/Webinars_‐ _English/Webinars_‐_English.html
  • 2. ASQ Reliability Division  English Webinar Series One of the monthly webinars  on topics of interest to  reliability engineers. To view recorded webinar (available to ASQ Reliability  Division members only) visit asq.org/reliability To sign up for the free and available to anyone live  webinars visit reliabilitycalendar.org and select English  Webinars to find links to register for upcoming events http://reliabilitycalendar.org/The_Reli ability_Calendar/Webinars_‐ _English/Webinars_‐_English.html
  • 3. USING TRIZ TO MAKE SYSTEMS MORE RELIABLE WNY Society of Reliability Engineers Jack Hipple Innovation-TRIZ Tampa, FL 813-994-9999 www.innovation-triz.com jwhinnovator@earthlink.net
  • 4. Agenda •  TRIZ : What is it and how does it apply to improving reliability? •  TRIZ Principles •  Ideal Final Result •  Trimming and resource use •  Separation principles •  TRIZ in reverse: Predictive Failure Analysis™ •  Recommendations and resources •  Q/A
  • 5. What is TRIZ ? A Russian acronym: Theoria Resheneyva Isobretatelskehuh Zadach (Theory of Solving Inventive Problems) What are these?
  • 6. The History of TRIZ •  Result of work by a brilliant patent examiner for the Russian navy, Genrich Altshuller, late 1940 s to early 1950 s •  Originated from the study of thousands of the world s most inventive patents--now in the millions •  Methodology emigrated to the west after Perestroika (~1990) •  Recognized that development of technological systems followed predictable patterns that cut across ALL areas of technology--the speed of technical evolution can be accelerated. Invention and problem solving are learnable sciences and not governed solely by genetics and being in the shower! There is an algorithm! •  Established schools to teach after a Stalin 5+ yr. prison term-- deceased in 1999 at age 71
  • 7. Algorithms: Generalizing Problems in Math It s Rome, 1100 A.D… Specific problem Specialized solution 3x2+5x+2 = 0 x = ???? ALGEBRA DOES NOT EXIST--HOW DO WE SOLVE?
  • 8. Generalizing Solutions Problem Solving Principle Example Abstract problem Abstract solution ax2+bx+c = 0 x=(-b [+/-]!b2-4ac)/2a Specific problem Specialized solution 3x2+5x+2 = 0 x= -1, -2/3 TRIZ DOES FOR PROBLEM SOLVING AND FORECASTING WHAT ALGEBRA DOES FOR EQUATION PROBLEM SOLVING!
  • 9. TRIZ: What is it? •  A left brained problem solving process •  Based on the study of the inventive patterns in the breakthrough global patent literature •  40 Inventive Principles •  Algorithm (as in algebra) •  Vs. “brainstorming”, psychology, and “quantity” •  Effort spent in problem definition vs. evaluating large quantity of irrelevant solutions •  Generalized problem models and solutions •  Su-Field, cause and effect
  • 10. Visualizing Contradictions Normal Design Tradeoff or Current Good Performance Barrier Curve Constant Design Capability Parameter A TRIZ Moves Performance Barrier Curve away from the origin Bad Parameter B Bad Good
  • 11. Examples •  Reflux ratio on distillation column •  Safety factors •  Amount of ice melting salt •  Number of wheel bolts •  Surface active agents •  Organizational communication •  Safety inspections
  • 12. TRIZ Contradiction Table •  Possible contradictions Undesired 1 2 14 38 39 represented in 39 x 39 table Nonmoving Object Result Moving Object (Degraded •  Intersections of contradicting Productivity Automation Weight of Weight of Strength Level of Feature) rows and columns are Feature references to 40 inventive to Improve principles for contradiction Weight of 28, 27, elimination 1 Moving Object 18, 40 Weight of 2 Nonmoving Object Level of 28 Replace a mechanical system with 38 Automation a non mechanical system 27 An inexpensive short-life object instead 39 Productivity of an expensive durable one 18 Mechanical vibration 40 Composite materials ®Ideation International, used by permission Proposed Solution Pathways:
  • 13. Contradiction Table •  Contradiction table •  http://www.triz40.com, http://www.innovation-triz.com, http://www.aitriz.org •  Has been updated in the past 5 years to a 48X48 table •  Useful for simple contradictions that are obvious •  Modeling and software tools available for complicated systems
  • 14. How Does This Apply to Reliability? •  Great emphasis in TRIZ on elegant simplicity in product, system, or service design •  “Ideal Final Result” •  Something performs its function and doesn’t exist •  If something doesn’t exist, it is 100% reliable •  Doesn’t require maintenance or monitoring •  A function controls “itself” •  A resource that is totally reliable and predictable •  Ex: gravity
  • 15. The Boeing Corporation What s the Best Way to Hoist Seats up into the Body of a 757 Jet?
  • 16. Hoists and Chains? Maintenance and Reliability? If you re a MechE, don t you just love to design this stuff? Maintain it?
  • 17. Lean Times: With Airbus on Its Tail , Boeing Is Rethinking How It Builds Planes Old Hay Loaders, New Resins Play Roles as Firm Tries To Build Faster, Cheaper Hitting a `Rescue Me' Button By J. Lynn Lunsford 09/05/2001 The Wall Street Journal (Copyright (c) 2001, Dow Jones & Company, Inc.) RENTON, Wash. -- Not far from the steady blatt-blatt of the rivet guns on its 757 assembly line just outside Seattle sits what Boeing Co. calls its moonshine shop: The people here distill work-saving ideas into contraptions that make it easier to build jets. Consider the hay loader next to an almost-completed 757. Normally, this cross between a ladder and But to a metal-spiked conveyor belt would be dumping bales of hay onto waiting trucks . veteran mechanic Robert Harms, the hay loader is the perfect way to get bulky passenger seats from the factory floor up 13 feet to the door of a plane without having to use an overhead crane. "It might look funny, but when you see it work, you wonder why we didn't do it this way all along," he says.
  • 18. Mr. Harms, the 52-year-old mechanic who led the effort to modify the hay loader to move seats, recalls the day when he arrived for work and found a note attached to his contraption. It read: "Idiots running amok." "That sign kind of serves as our inspiration because once it started running, that loader has made believers out of people," he says. Gordy Laborde, a 48-year-old mechanic who has been installing interiors in Boeing 757s for 13 years, counts himself among the converted. "I looked at that hay loader from every angle and I could not see how it was going to work. You do something for so many years one way, and something like this really takes you out of your comfort zone."
  • 21. Boeing Discovers Hay Loaders… Reliability vs. Overhead Crane Systems? Question: If you were a Boeing engineer, would you ask and would your boss let you go to an agricultural equipment show?
  • 22. Ball Bearings: They have to work! You are in the ball bearing business and want some new ideas for monitoring and controlling quality and uniformity—where would you look?
  • 26. Inspecting Caviar Egg Hardness (Used Since 1945) Eggs The real hard eggs bounce up and over
  • 27. Two Key Questions 1.  How reliable is gravity? 2.  Does it require any maintenance or Inspection?
  • 29. MACHINE REPLACES MAN CASE STUDY A robot was brought to a plant to operate a machine. After it was rigged up and switched on, the elderly worker who had operated the machine for years was amazed at seeing the nimble iron man performing all the necessary steps. A half an hour later, however, the robot came to a standstill, to the bewilderment of the service team of electronic engineers. What happened? As it turned out, some chips had fallen from the workpiece into the moving elements of the machine. This situation where a human worker would simply flip the chips away with a broom and continue working brought the robot to a deadlock. The engineers cleaned the machine with a broom, switched on the robot…only to see the robot stop again. How could this problem be solved? Obviously, one cannot attach a human worker with a broom to the robot…… Source: TRIZ: The Right Solution at the Right Time, p3, used with permission
  • 30. System Oscillation: Phones and Remote Controls Complexity TRIZ: Trimming Phones that only receive calls Add useful complexity : features Time
  • 31. Trimming •  Arbitrarily removing a physical or functional part of a: •  Process •  System •  Product •  How its function can be replaced •  Most useful in systems that have grown complex over time but useful at any time as a simple brainstorming concept
  • 32. The Keyboard Performs its Function and Doesn t Exist
  • 33. Flash Drive: Ever Lost a Cap?
  • 35. Black and Decker Paint Stick™: Where is the Bucket? Ladder? Spill?
  • 36. Trimming a Restroom Entrance Doors are cumbersome for people with luggage. RESTROOM Function of the door – privacy Use geometric shape to replace FUNCTION of the door. Door is eliminated.
  • 37. Classical Approach to Design •  Optimize and minimize pain •  Ex: Number of bolts on a tire •  More: more secure wheel •  Less: Easier to change tire
  • 38. The Tire Bolt Optimization: Minimizing the Pain of Maintenance and Reliability Number of Bolts Used to Hold the Wheel Minimal Loss of Wheels Likelihood of Wheel Loss
  • 39. The TWEEL from Michelin: Trimming the Tire
  • 40. TiroGage™: The Stem is the Gage
  • 41. TRIZ Separation Principles to Eliminate Contradictions •  Separate in time, space, system/super- system, and upon condition •  Separation frequently improves reliability when multi-tasking is required
  • 42. McDonald s Drive Through: Reliability in Orders
  • 43. Separate in Space: Sacramento vs. Santa Maria
  • 44. Predictive Failure Analysis™: TRIZ in Reverse •  Normal approach to failure prediction/ analysis is checklisting of possibilities •  Asking “what could go wrong?” •  Slowly get better as the list gets longer from experience •  Our brains normally can’t see beyond a list •  Alternative: How to make it go wrong? •  Make sure a system fail? •  Mis-schedule something? •  Make sure we install the wrong part?
  • 45. Predictive Failure Analysis™ Algorithm •  State the desired result •  “I want the webinar to go smoothly” •  Invert the desired result •  “I want the webinar to go poorly” •  Exaggerate the inverted result •  “I want this webinar to be the worst ever hosted by ASQ and chapter charter is revoked and Dave Auda is blacklisted on Facebook and Plaxo •  How would we make this happen? •  What resources would we need? •  Are they available? Can they be synthesized?
  • 47. Areas Used •  Chemical plant control and releases •  Vs. HAZOP •  How to make sure we have a release •  Software coding •  How to make sure coding never works •  Food safety •  How we make sure everyone is poisoned •  Mechanical failures •  How to make sure it never runs •  Emergency and military communications •  How to make sure communication is never received and/or misinterpreted
  • 48. TRIZ Learnings and Recommendations •  Always balance and question the addition of what is believed to be useful complexity •  Useful to user or repair person? •  Arbitrarily trim a system •  Force/assign the rest of the product or system to perform the function •  One less part to maintain, monitor •  Separate conflicting requirements •  Space, time, system/super-system, upon condition •  Minimize energy conversions •  Every one loses energy and uses a system to convert and requires maintenance •  Invention history teaches that energy conversions are minimized •  Use of a reverse algorithm can identify failure points difficult to find with check listing
  • 49. RESOURCES •  Altshuller Institute for TRIZ studies (www.aitriz.org) •  Annual meeting, fall 2011, location and date TBD •  On line TRIZ Journal (www.triz-journal.com) •  www.innovation-triz.com, newsletter available •  European TRIZ Association (www.etria.net), fall 2011 meeting, location TBD •  Mexican TRIZ Association (www.ametriz.mx), fall, 2011 meeting, location TBD •  Books: •  “And Suddenly the Inventor Appeared” (Altshuller) •  “Hands on Systematic Innovation” (Mann) •  “TRIZ: The right Solution at the Right Time” (Salamotov) •  “Simplified TRIZ” (Rantanen/Domb) •  “Engineering of Creativity” (Savransky) •  Chemical Engineering Progress (CEP) (April, May, June 2005) •  3 Day Intro TRIZ courses for ASME and AIChE •  http://www.innovation-triz/events •  Las Vegas (3/21-23/2011) •  San Francisco (5/9-11, 2011) •  Other courses at http://www.triz-journal.com