Carl S. Carlson — Thought Leader

Author of Inside FMEA articles, FMEA Resources page, and multiple books, and a co-host on Speaking of Reliability.

This author's archive lists contributions of articles and episodes.

Getting to Consensus

Getting to Consensus with the FMEA Team

“A genuine leader is not a searcher for consensus but a molder of consensus.”
Martin Luther King

One of the challenges for any team leader is bringing the team together and agreeing on decisions and actions going forward.

Consensus building is the best practice for all of the FMEA team decisions. This means the FMEA team takes the time to understand all sides of an issue and finds a solution or determines a course of action that is supported by all team members. Facilitating is a consensual activity.

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Pugh Analysis and FMEA

“Once you make a decision, the universe conspires to make it happen.” – Ralph Waldo Emerson

There are times when an FMEA facilitator has difficulty arriving at consensus with the FMEA team. This sometimes happens when there are two or more competing ideas or solutions and members of the team feel strongly about their personal idea or solution. One tool that can be used to solve this problem is called Pugh Analysis, a type of decision matrix.

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SOR 783 A Facilitator’s Role

A Facilitator’s Role

Abstract

Carl and Fred discussing the essence of a facilitator’s role in leading meetings and reliability methods. This role is discussed from the viewpoint of reliability applications.
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SOR 782 A PFMEA Use Question

A PFMEA Use Question

Abstract

Carl and Fred discussing an interesting question from a subscriber to the Inside FMEA series. The question has to do with selected process steps on a Process FMEA, and the efficacy and value of the occurrence rating being verified later in pilot assembly or trial production.
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To Scribe or Not to Scribe

Mediocrity can talk, but it is for genius to observe. – Benjamin Disraeli

The Inside FMEA series has completed the primary facilitation skills. The next few articles will cover special facilitation topics.

This article talks about the pros and cons of using a “scribe” to help with facilitation. [Read more…]

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SOR 777 We Are All Consultants

We Are All Consultants

Abstract

Carl and Fred discussing how much of what we do as reliability professionals falls into the role of consultants. Learning how to be better consultants will enhance the results of our day-to-day work.
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SOR 776 Transferring Knowledge

Transferring Knowledge

Abstract

Carl and Fred discussing the process of knowledge transfer from one person to others. This process is at the core of influencing others to achieve reliability objectives.
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Managing Time

“Most of us spend too much time on what is urgent, and not enough time on what is important.” – Steven Covey

FMEAs take time and cost money. If time is wasted, FMEAs will be unsupported and ineffective.

In this article, I’ll lay out some tips to keep FMEA in-meeting time as short as possible, without reducing the quality of results. Many of these tips are based on lessons learned from doing FMEAs the wrong way. This is not a complete list. I’m sure you have other lessons learned to save time, and would love to hear from you.

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SOR 766 What Matters in a Demonstration Test

What Matters in a Demonstration Test?

Abstract

Carl and Fred discussing a listener question about how which failures to count in demonstration testing. Specifically, what about maintenance induced failures, supply chain failures and other types of failures, not typically part of the product design.
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SOR 765 Fast vs Thorough

Fast vs Thorough

Abstract

Carl and Fred discussing the need to be fast in smaller or startup companies. Reliability engineering can adapt to a fast culture and support lean product development, without compromising essential tasks.
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Unique Challenges When Facilitating FMEAs

“Interdependent people combine their own efforts with the efforts of others to achieve their greatest success.” Stephen Covey

If you’ve been reading the FMEA facilitation series, by now you understand the primary facilitation skills. Studying and applying these skills will help you achieve excellent results in FMEA applications. [Read more…]

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SOR 753 Catching Up with Questions

Catching Up with Questions

Abstract

Carl and Fred summarizing and discussing the latest questions received from readers and listeners.
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Creativity and FMEA

“Creativity is an ability to respond adaptively to the needs for new approaches and new products.” Frank Barron

Creativity is an essential ingredient to achieving excellence in FMEAs. Excerpts from the book Effective FMEAs will be used throughout the article.

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SOR 752 Bringing Back Old Plant Equipment

Bringing Back Old Plant Equipment

Abstract

Carl and Fred discussing a listener question about the use of FMEA when ramping up equipment in a plant. In this case, the equipment had been sitting dormant for a number of years.
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SOR 747 Celebrating Reliability Success

Celebrating Reliability Success

Abstract

Carl and Fred discussing a listener question about when it is OK to celebrate reliability successes. Specifically, how long you have to wait to feel comfortable you have a successful product when nothing bad happens.
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