Your Reliability Engineering Professional Development Site
A listing in reverse chronological order of articles by:
One of the primary questions we answer as reliability engineers is:
How long will it last?
Reliability prediction is the forecast or prognostication attempting to quantify either the time till failure, or expected future failure rate or warranty claims, or required spare parts.
We need to know as we make decisions today about the design or purchase.
Over the past week or two, I’ve received requests and comments that have given me pause. Why is it that I have time to answer questions and share information? Why do I spend the time to do so in the first place?
I have found that responding to questions or requests for assistance is rewarding.
Today I received a request for help in a job search. Last week it was an employer looking for a perfect candidate. I’ve received questions about graduate school in the US from a Chinese undergraduate. A question on accelerated life testing approaches. Another on maintenance practices and data analysis.
For each, I try to provide an answer or direct to find an answer.
When a product or asset works as it’s expected for as long or longer than expected, we often consider it reliable.
Consumers around the world look for reliable products and services. Some will pay a premium with the desire to obtain failure free value from the purchase. When designing a product or service we often want to create the most reliable item within the constraints of time, resources, and cost. Designers and engineers may add margin or safety factors into calculations and decisions to avoid failures.
Many of us have heard that fixing a design is orders of magnitude less expensive early the product lifecycle. Product recalled or major failures can damage profits and brand image.
Here are three ways you can invest in improving product reliability. [Read more…]
Some believe leaders are born and become natural leaders. Others believe leadership can be taught and anyone can become a leader. I believe leadership is situational and when intentional can be very powerful.
I learned leadership theory and enjoyed plenty of practice attending the US Military Academy. I certainly practiced leadership during my tour in the Army.
And, I’m not an expert on leadership.
One of the first things taught in a data analysis class, or in first-grade math, is the plot. A graphical representation of the data. Bar charts, pie charts, histograms, box plots, and the x-y scatter plot. These and others simply help us to understand the nature of the data.
The ‘nature’? The data is only a record of an observation. Counts, colors, numbers, or something similar. The ‘nature’ is, to me, the behavior, maybe pattern, or story the data may reveal.
The forums, chats, tweets (#bluelightofdeath), blogs, and mainstream media (CNN & Vancouver Sun) are looking closely at the launch of Sony’s Playstation. There are reports of dead on arrival and ‘blue light of death’ failures. One business blog discusses the need to understand and match customer expectations as a way to avoid bad press.
I find the expectation is pretty simple.
It should be simple
A brand new device, in this case, an expensive new game console, the entire experience of the purchase, transport, unpacking, hookup and first turn on should be a joy. The anticipation for those picking up the device on the first day comes crashing down to despair when the device fails to work. Products are expected to provide value, and you expect the device in front of you to work as expected. It’s simple.
I once explained to my son that not all units from production will work (he was in junior high school). He said he understood and that it is fine if the game console he buys just works. Ship the ones that don’t work to someone else. [Read more…]
Boeing representatives explained the Dreamliner would need an additional 6 months of work to bring the aircraft’s reliability on par with the existing 777 model.
They made the announcement at the start of the Dubai air show. Not a good start to a week of showing off the features of the aircraft. How does a companay respond to early reliability problems in the news?
Generally, even the most general reliability goal of a new product is to be as good or better than the last model. Sure, the Dreamliner has many new features, materials, and upgrades. Yet, it did as much or more design evaluation and testing as any model previously. [Read more…]
Recently I asked for recommendations for books for maintenance reliability engineers. The following list, in no order, are the recommendations. Thanks to all who participated. [Read more…]
At the start of class on reliability and maintenance engineering, one of the students asked,
“What is reliability engineering? What do you do?”
This made me think. What is it we do? How to you explain to someone our role?
I like to say, “We break things” with a big wink and a smile. And to some extent, as we explore what fails and how it fails. We most likely have to test our theories and break something. Or, when working with new product designs we employ tools to discover what will break. So, I suppose part of what we do is break things. Yet, that is not a complete answer. [Read more…]
The reasonable man adapts himself to the world; the unreasonable one persists in trying to adapt the world to himself. Therefore all progress depends on the unreasonable man. In Maxims for Revolutionists (1903) by George Bernard Shaw It is those that see the world as it should be that prompts change. I believe it is those resisting change to be unreasonable; I suppose it depends on your point of view. The idea or invention may be an inspiration or take diligent work, yet the real work is in changing the reasonable to a new way of viewing the world. Understanding everyone is not as unreasonable as yourself helps you prepare others for change. Challenging the resistance may label you as unreasonable. Be prepared and drive on, you are in good company. Fred Schenkelberg Reliability Quote of the Day, ISSN 2329-0099 http://www.fmsreliability.com/publishing/category/quotes/ where you can sign up for a daily quote sent to you via email —
I received a request from Quality Progress magazine to provide a quote and 100 words about the selection. The above is my submission. [Read more…]
Value for any business activity is a guiding principle to stay in business.
While not always about money, it is about value. We invest in product design and distribution, plant design and operation, to realize a benefit or return on the investment which makes the investment worth the effort and time. Same with our individual work- we endeavor to make a difference and realize not just a paycheck, (well some do). Increasing value is our responsibility as reliability professionals. [Read more…]
A common issue with solder, other than its ability to compliantly attach electronic packages to circuit boards, is its ability to fail with normal use.
Over time the normal thermal cycling causes the packages to move relative to the circuit board and the solder moves to accommodate. Each cycle the solder accumulates damage. Over time the number of cycles accumulates as does the damage. Eventually, the solder cracks and create an intermittent connection or disrupts the electron flow completely (open).
The reasonable man adapts himself to the world; the unreasonable one persists in trying to adapt the world to himself. Therefore all progress depends on the unreasonable man.
In Maxims for Revolutionists (1903) by George Bernard Shaw
It is those that see the world as it should be that prompts change. I believe it is those resisting change to be unreasonable; I suppose it depends on your point of view. The idea or invention may be an inspiration or take diligent work, yet the real work is in changing the reasonable to a new way of viewing the world.
During a normal day, we unconsciously tie our shoes, brush our teeth and drive to work, mostly by routine and without too much conscious thinking about the tasks. Occasionally we answer the phone and have to think a little about the conversation. Or we design an experiment for the next project, thinking we can save time by using the same test as last time. Then we slip comfortably into a routine. Do we not think anymore?
Reliability engineering is thinking.
… Or, reliable learning. One of the best things about reliability engineering is the never ending opportunity to learn. We work with materials, assembly processes, and people creating and maintaining products, machines, and systems. Other engineering disciplines tend to focus on one aspect of a design or process – mechanical engineers make allowances for the circuit board location and heat transfer requirements, yet do not word on the circuits themselves. Electrical engineers just the opposite, they focus on electronics and power and attempt to fit within the constants imposed by industrial designers. Maybe architects are close to the breadth of reliability engineering as they contribute the aesthetic and functional elements of a design, and consider the maintenance and longevity of the building. Yet, they are not involved with the actual aging and maintenance. [Read more…]