The slides that Carl and Fred present at the 2014 RAMS conference (www.rams.org). An overview of tasks, approaches, and structure to creating a proactive and effective reliability program in your organization.

1. Introduction to
R & M Management
Fred Schenkelberg
FMS Reliability
Reliability Engineering and Management Consultant
Carl S. Carlson
ReliaSoft Corporation
Senior Reliability Consultant

2. Reliability Engineering & Management Consultant
Fred Schenkelberg
Carl S. Carlson
Reliability Engineering
& Management Consultant
Senior Reliability Consultant
FMS Reliability
(408) 710-8248
fms@fmsreliability.com
ReliaSoft Corporation
carl.carlson@reliasoft.com
carl.carlson@effectivefmeas.com
2014 RAMS – Tutorial 2A - Schenkelberg
2

3. 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.
2014 RAMS – Tutorial 2A - Schenkelberg
3

4. First Challenge as Reliability Engineer
New heating cable design
How long will it last?
2014 RAMS – Tutorial 2A - Schenkelberg
4

5. What did I need to know?
Timeline
Budget
Samples
What else?
2014 RAMS – Tutorial 2A - Schenkelberg
5

6. How long1 or 5 year
Is this a should it last?
problem?
What is the goal?
How does your organization
state
reliability goals?
2014 RAMS – Tutorial 2A - Schenkelberg
6

7. First Assignment as Reliability Engineer
Put together a reliability plan for new vehicle program
Lesson learned: select the vital few tasks
2014 RAMS – Tutorial 2A - Schenkelberg
7

8. Outline of topics





Requirements Tasks
Risk Reduction Tasks
Assurance Tasks
Organizational Tasks
Primary Steps to Achieving High Reliability
2014 RAMS – Tutorial 2A - Schenkelberg
8

9. Requirements Tasks
Set Reliability Targets
Function
Environment
Duration
Probability
2014 RAMS – Tutorial 2A - Schenkelberg
9

10. 2014 RAMS – Tutorial 2A - Schenkelberg
10

11. Balance with other objectives
Features or functions of
the product
Cost of the product
Time to market
Reliability
2014 RAMS – Tutorial 2A - Schenkelberg
11

12. Cable, sensor, power supply,
Cable part of a larger system
controller, and connectors
•
•
Materials, processes, assembly,
design, transportation, and
installation
2014 RAMS – Tutorial 2A - Schenkelberg
12

13. Story of 50% field failure rate
All elements met
reliability goal.
Field data agreed
2014 RAMS – Tutorial 2A - Schenkelberg
13

14. Apportion the goal
Sys
Sub 1
Sub 2
Sub 3
Sub 4
2014 RAMS – Tutorial 2A - Schenkelberg
Sub 5
14

15. Apportion the goal
Sys
Sub 1
Sub 2
Sub 3
Sub 4
Sub 5
With series system,
product of sub system reliability
is system reliability.
2014 RAMS – Tutorial 2A - Schenkelberg
15

16. Apportion complete goal
Function
Environment
Duration
Probability
2014 RAMS – Tutorial 2A - Schenkelberg
16

17. NoStory of “you need to improve reliability”
goal
No field data
No Pareto of issues
Just make it better,
2014 RAMS Tutorial
as warranty expenses too –high2A - Schenkelberg
17

18. Where should
they reside?
Communication
of Reliability
Goals
2014 RAMS – Tutorial 2A - Schenkelberg
18

19. Requirements Tasks
Identify 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.
2014 RAMS – Tutorial 2A - Schenkelberg
19

20. Two basic questions
What will fail?
When will it fail?
Information to permit appropriate
product development decisions
2014 RAMS – Tutorial 2A - Schenkelberg
20

21. Testing to Pass
2014 RAMS – Tutorial 2A - Schenkelberg
21

22. Outline of topics





Requirements Tasks
Risk Reduction Tasks
Assurance Tasks
Organizational Tasks
Primary Steps to Achieving High Reliability
2014 RAMS – Tutorial 2A - Schenkelberg
22

23. Risk Reduction Tasks
Design-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
2014 RAMS – Tutorial 2A - Schenkelberg
23

24. • Understand stress
• Understand strength
• Separate stress from strength
2014 RAMS – Tutorial 2A - Schenkelberg
24

25. Henry Petroski
Design Paradigms
2014 RAMS – Tutorial 2A - Schenkelberg
25

26. Discovery
2014 RAMS – Tutorial 2A - Schenkelberg
26

27. Discovery Tools
Discovery Tools
2014 RAMS – Tutorial 2A - Schenkelberg
27

28. 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.
2014 RAMS – Tutorial 2A - Schenkelberg
28

29. Risk Reduction Tasks
Achieve 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
2014 RAMS – Tutorial 2A - Schenkelberg
29

30. Extra tasks for critical suppliers
Due care tasks for all other suppliers
2014 RAMS – Tutorial 2A - Schenkelberg
30

31. Risk Reduction Tasks
Implement 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.
2014 RAMS – Tutorial 2A - Schenkelberg
31

32. Outline of topics





Requirements Tasks
Risk Reduction Tasks
Assurance Tasks
Organizational Tasks
Primary Steps to Achieving High Reliability
2014 RAMS – Tutorial 2A - Schenkelberg
32

33. Assurance Tasks
Verify 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.
2014 RAMS – Tutorial 2A - Schenkelberg
33

34. When will it fail?
Everything Fails at some point.
2014 RAMS – Tutorial 2A - Schenkelberg
34

35. Typical early life failures
Product does not meet
design specifications
Material or component
characterization
Process characterization
Assembly characterization
2014 RAMS – Tutorial 2A - Schenkelberg
35

36. 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
2014 RAMS – Tutorial 2A - Schenkelberg
36

37. Prediction of overstress
Not commonly possibly
Design errors
Environment
Unexpected use
When significant adverse consequence may occur
explore mitigation or fail safe approaches
2014 RAMS – Tutorial 2A - Schenkelberg
37

38. Wear out and related
Everything fails –
eventually
Understand failure
mechanisms and
environment
The race to cause a failure
2014 RAMS – Tutorial 2A - Schenkelberg
38

39. Prediction of wear out
Guesses
Estimates
Predictions
Previous products
Models
Testing
2014 RAMS – Tutorial 2A - Schenkelberg
39

40. 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
2014 RAMS – Tutorial 2A - Schenkelberg
40

41. Is it good enough?
2014 RAMS – Tutorial 2A - Schenkelberg
41

42. Is it good enough?
How do we know?
2014 RAMS – Tutorial 2A - Schenkelberg
42

43. Is it good enough?
How do we know?
We understand the
failure mechanisms
& business objectives
2014 RAMS – Tutorial 2A - Schenkelberg
43

44. Assurance Tasks
Continuously 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.
2014 RAMS – Tutorial 2A - Schenkelberg
44

45. FRACAS
A method to keep it all together
Triage
Prioritization
Closure
Grey area of when to stop fixing and ship
2014 RAMS – Tutorial 2A - Schenkelberg
45

46. Assurance Tasks
Maintain 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.
2014 RAMS – Tutorial 2A - Schenkelberg
46

47. Maintenance Considerations
2014 RAMS – Tutorial 2A - Schenkelberg
47

48. Value
2014 RAMS – Tutorial 2A - Schenkelberg
48

49. Outline of topics





Requirements Tasks
Risk Reduction Tasks
Assurance Tasks
Organizational Tasks
Primary Steps to Achieving High Reliability
2014 RAMS – Tutorial 2A - Schenkelberg
49

50. Organizational Tasks
Establish organizational resources
 Organizational resources include personnel,
training, procedures, and business processes.
 Will help move the organization to higher stages
in the Maturity Matrix
2014 RAMS – Tutorial 2A - Schenkelberg
50

51. Organizational Tasks
Institutionalize 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.
2014 RAMS – Tutorial 2A - Schenkelberg
51

52. Achieving reliability objectives
is an organization-wide
endeavor.
2014 RAMS – Tutorial 2A - Schenkelberg
52

53. Organizational Tasks
Advance 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
2014 RAMS – Tutorial 2A - Schenkelberg
53

54. 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
2014 RAMS – Tutorial 2A - Schenkelberg
54

55. Primary Steps to Achieving High Reliability
(High Level)
Step 1:
Develop
Reliability
Strategic
Vision
Step 2:
Perform
Reliability Gap
Assessment
Step 3:
Develop
Reliability
Program Plan
Requirements Tasks
Step A:
Set reliability
targets
Step B:
Identify
reliability data
needs
Assurance Tasks
Step F:
Verify
reliability
reqmts met
Step G:
Continuously
improve
reliability
Step 4:
Execute
Reliability
Program Plan
Step 5:
Assess Prgm
Lessons
Learned
Risk Reduction Tasks
Step C:
Design-in
Reliability
Step D:
Achieve
supplier
reliability
Step E:
Implement
reliable
manufacturing
Organizational Tasks
Step I:
Step H:
Establish
Maintain
organizational
high
resources
reliability
2014 RAMS –
thru-out life Tutorial 2A - Schenkelberg
Step J:
Institutionalize
reliability
tasks
Step K:
Advance Up
Maturity
Matrix
55

56. 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.
2014 RAMS – Tutorial 2A - Schenkelberg
56

57. 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.
2014 RAMS – Tutorial 2A - Schenkelberg
57

58. 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
2014 RAMS – Tutorial 2A - Schenkelberg
58

59. 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
2014 RAMS – Tutorial 2A - Schenkelberg
59

60. 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
2014 RAMS – Tutorial 2A - Schenkelberg
60

61. 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.
2014 RAMS – Tutorial 2A - Schenkelberg
61