Musings on Reliability and Maintenance Topics

Short essays and thoughts (musings) on reliability and maintenance engineering topics.

Let me know your reaction and thought, plus any questions.

ISSN 2329-0080

Reliability Program Structure

A product reliability program is a process. Like any process, it has inputs and outputs, generally some form of an objective, and feedback. Furthermore, the process may or may not be controlled, or even a conscious part of the organization. Reliability may just happen, good or bad. Results may or may not be known or understood.

In some organizations, the reliability program may be highly structured with required activities at each stage along the product lifecycle. In other organizations, reliability is considered as a set of tests (e.g. environmental or safety compliance). In some organizations, reliability is effectively a part of everyone’s role. [Read more…]

by Fred Schenkelberg Leave a Comment

Reliability Goals

The target, objective, mission or goal is the statement that provides a design team with focus and direction. A well-stated goal will establish the business connection to the technical decisions, related to product durability expectations. A well-stated goal provides clarity across the organization and permits a common language for discussing design, supply chain, and manufacturing decisions.

Let’s explore the definition of a ‘well-stated reliability goal.’ First, is it not simple MTBF, “as good as or better than…” or ‘a 5-year product’. These are common ‘goals’ found across many industries, yet none permit a clear technical understanding of the durability expectations for the product.
The common definition for reliability is [Read more…]

by Fred Schenkelberg 2 Comments

HALT Value

It’s always necessary to estimate the value of specific reliability activities. It is needed to justify the investment required to accomplish the task. Prototypes, diagnostics equipment, and environmental chambers are expensive. The difficulty is an inability to know what will be found, before conducting the experiment.

Not doing the test means the certainty of not finding anything. That is often not enough motivation to invest, to learn something about the reliability performance. The following scenario is just one situation, along with a few ideas to help you estimate the value of investments in reliability work. [Read more…]

by Fred Schenkelberg 3 Comments

Derating Value

This example is based on a real situation. After a class on design for reliability, a senior manager declared that every component would be fully derated in every product (electronic test & measurement devices). Within a year the design team redesigned all new and existing products, with strict adherence to the derating guidelines provided in the class. A year after the class the product line enjoyed a 50% reduction in warranty claims. They learned about derating and a manager saw the potential value. [Read more…]

by Fred Schenkelberg 3 Comments

ALT Value

Here is an example of how to determine the future value of a specific reliability task. Many of us face the challenge of how to justify spending product development resources to provide insights and information to the rest of the team. Accelerated life testing (ALT) is particularly difficult: It is time consuming, expensive, and at times statistically complex. Having a clear method to estimate the value serves your career and the organization well, as both benefit from the right investments.

[Read more…]

by Fred Schenkelberg 2 Comments

Reliability Knowledge

A recent forum post included the notion that many engineers and managers developing products or maintaining equipment have knowledge apathy concerning reliability. “They don’t care!” was the poster’s words. Has this happened? Have we lost the ability to care about reliability?

Reliability Understanding

In a course I teach on reliability engineering management I ask my students to find an advertisement using reliability as a central theme or claim. This isn’t very hard to do, and I’ve regularly been surprised at the range of uses advertising finds around the concept of reliability. ‘Reliable Movers’ claims to reliably and safely move your belongings to your new home. A reliable shotgun ammunition-loading device suggests each shell will fire reliably. And, many other advertisements use the basic concepts of consistent, repeatable, safety, and trustworthy via the term reliable or reliability. There is a common and good association with reliability. [Read more…]

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Reliability Predictions

If only we had a crystal ball or another device to predict the future. From the general wondering about the enemies next move, to the soldier hoping their equipment will work. In the corporate boardroom estimating the competitions next move, to the maintenance manager ordering spare parts, we have many uses for knowing the future.

We often look to past performance to provide an indication of the future. Has this mutual fund regularly provided adequate returns? If so, we predict it will going forward. And anyone that has reviewed mutual fund performance also has read or heard the admonishment to not use past performance to estimate future returns. Mutual funds, markets, business and battlefields all change and respond in sometimes unforeseen ways. [Read more…]

by Fred Schenkelberg 3 Comments

Reliability Value

What is reliability management? Reliability Engineering? Would a product design or an organization benefit with a focus on reliability management and engineering? What is the value of a focus on reliability?

Any organization, that develops and produces products, has resource limits. It may be talent, capabilities, time, funding, or some combination of these. Yet, the goal to create a product that meets customer expectations includes the concept of product reliability. The product should provide the expected functions over time, without failure. This expected product reliability occurs, even if the design requirements and advertising do not explicitly mention product reliability. [Read more…]

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Reactive and Proactive

Do you let events happen to you, or do events follow your designs and expectations? Are you a spectator or actor? Do you wonder about your product’s future or do you control your product’s future? Are you reactive or proactive?

Every reliability and maintenance program is a system. Every program has inputs, such as product testing results and field returns. Every reliability program has outputs, such as product design and production. In the most basic terms, a reliability program includes product specifications for functionality including expected durability. The program includes some form of design, verification, production and field performance. Given this basic lifecycle description, it is possible for two types of approaches to executing the product lifecycle. [Read more…]

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Reliability Culture

Years ago I had the opportunity to assess the reliability programs of two organizations. They made similar products for different segments of the market, and they both had about the same size an organization. Two years previously, both organizations lost the reliability professional from their staffs. Furthermore, both teams were located in one building, one upstairs and the other downstairs, which made scheduling the assessment interviews convenient.

[Read more…]

by Fred Schenkelberg 1 Comment

Musings on Reliability and Maintenance Topics

I write quite a bit about reliability and have plans to write quite a bit more. I have looked to prolific authors in our field with admiration and respect: Wayne Nelson, Patrick O’Connor or Terrence O’Hanlon, they all share so much knowledge. They make the subjects and material clear and accessible. They have in large part helped me all throughout my career by enabling my ability to solve problems and create value.

Of course, there are many others that have contributed to my career and my approach to engineering. My colleagues, managers, and mentors have each helped to educate and develop my skills and approach. Every single client has also contributed. As many of you have heard from me, I learn from every encounter and feel very fortunate to have a career that enables such wonderful exploration and learning as part of my day-to-day work. [Read more…]

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Emerging Technology Reliability Considerations

As we continue to find and improve ways to master our environment, accomplish tasks, communicate, move, heal, etc. we continue to discover new materials, processes, and products. Emerging technologies often promise

lower costs
new functions
lighter weight
easier to use

They also may last longer.

As a minimum, they should last long as current solutions or longer or provide another compelling reason to use the new technology. [Read more…]