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on Tools & Techniques

A listing in reverse chronological order of articles by:



  • Dennis Craggs — Big Data Analytics series

  • Perry Parendo — Experimental Design for NPD series

  • Dev Raheja — Innovative Thinking in Reliability and Durability series

  • Oleg Ivanov — Inside and Beyond HALT series

  • Carl Carlson — Inside FMEA series

  • Steven Wachs — Integral Concepts series

  • Shane Turcott — Learning from Failures series

  • Larry George — Progress in Field Reliability? series

  • Gabor Szabo — R for Engineering series

  • Matthew Reid — Reliability Engineering Using Python series

  • Kevin Stewart — Reliability Relfections series

  • Anne Meixner — Testing 1 2 3 series

  • Ray Harkins — The Manufacturing Academy series

by Larry George Leave a Comment

Ergodicity, Toilet Paper, and Field Reliability

Ergodicity, Toilet Paper, and Field Reliability

Ergodicity means that cross-section probabilities equal longitudinal lifetime probabilities. (“Ergos” is Greek for “work.” Think of “ergonomics”.) Ergodicity means that we can estimate age-specific field reliability functions from cross-section data: ships (installed base) and returns (complaints, failures, service parts’ sales, etc.). Ships and returns provide information about lifetimes. Returns are the superpositions of failures of products or their parts started at different times. What does ergodicity have to do with toilet paper? [Read more…]

Filed Under: Articles, on Tools & Techniques, Progress in Field Reliability?

by Carl S. Carlson 1 Comment

Relationship between FMEA and Risk Management

“If no one ever took risks, Michelangelo would have painted the Sistine floor.” – Neil Simon

FMEA and Risk Management are two distinct bodies of knowledge. This article explores some of the interactions between these two important methods. It is not intended to be a complete analysis of the similarities, differences, and linkages between FMEA and risk management. Rather, it is a high-level overview.

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques Tagged With: FMEA, risk management

by Ray Harkins Leave a Comment

The Tragedy of the Commons

The Tragedy of the Commons

Imagine you were a rancher with a herd of cattle and a small field in which to graze them. One of your primary concerns include determining how many cattle the field could support. With too few cattle, you give up potential earnings that the field could readily sustain. But too many cattle consume the grass faster than the field could replenish it, resulting in malnourished cattle and degraded land quality.

Therefore, as a rancher with long-term prospects, inspecting and maintaining the field, planting new grass, and limiting the number of new cattle in the field all become a cornerstone of your business model. [Read more…]

Filed Under: Articles, on Tools & Techniques, The Manufacturing Academy

by Steven Wachs Leave a Comment

How is Formal Experimentation different from Simplistic Approaches? (Part II)

How is Formal Experimentation different from Simplistic Approaches? (Part II)

Statistically based DOE provides several advantages over more simplistic approaches such “one-factor-at-a-time” experimentation.  These advantages include:

  • The use of statistical methodology to determine which factors are actually (statistically) significant
  • Balanced experimental designs to allow stronger conclusions with respect to cause and effect relationships (as opposed to just finding correlations)
  • The ability to understand and estimate interactions between factors
  • The development of predictive models that are used to find optimal solutions for one or more responses

[Read more…]

Filed Under: Articles, Integral Concepts, on Tools & Techniques

by Larry George Leave a Comment

Gozinto Theory and Parts’ Installed Base

Gozinto Theory and Parts’ Installed Base

Andrew Vázsonyi led an interesting life. He collaborated with mathematician Paul Erdös, he was co-founder of The Institute of Management Sciences, and he wrote “Which Door has the Cadillac: Adventures of a Real-Life Mathematician”. Around 1970, Andrew Vázsonyi interviewed for a teaching job in Sauder School of Business, University of British Columbia. During the job interview, he taught us Gozinto Theory. [Read more…]

Filed Under: Articles, on Tools & Techniques, Progress in Field Reliability?

by Steven Wachs Leave a Comment

How do I Choose the Appropriate Type of Control Chart?

How do I Choose the Appropriate Type of Control Chart?

Proper control chart selection is critical to realizing the benefits of Statistical Process Control.  Many factors should be considered when choosing a control chart for a given application.  These include:

  • The type of data being charted (continuous or attribute)
  • The required sensitivity (size of the change to be detected) of the chart
  • Whether the chart includes data from multiple locations or not
  • The ease and cost of sampling
  • Production volumes

[Read more…]

Filed Under: Articles, Integral Concepts, on Tools & Techniques

by Ray Harkins Leave a Comment

Andragogy – How Adults Learn to Learn

Andragogy – How Adults Learn to Learn

This strange word andragogy was popularized in the early 1970’s by educational researcher, Malcolm Knowles. It is etymologically rooted in the Greek language from two words “aner”, which means “man” and “agogos”, which means “to lead”. Fused together, andragogy means “leading men”, or to paraphrase, leading or educating adults. Andragogy is often contrasted with pedagogy, typically referring to the education of children. [Read more…]

Filed Under: Articles, on Tools & Techniques, The Manufacturing Academy

by Oleg Ivanov Leave a Comment

The Dark Side of the HALT

The Dark Side of the HALT

Thems that die’ll be the lucky ones.
~ Robert Louis Stevenson

This post is a continuation of the series “Is the HALT a Life Test or not?”

Test two samples and demonstrate reliability R=0,99 over a lifetime with CL=0,99. This is real. But what payment will we pay, besides the duration of the test on triple lifetime, which can be significantly accelerated by the way? [Read more…]

Filed Under: Articles, Inside and Beyond HALT, on Tools & Techniques

by Steven Wachs Leave a Comment

How is Formal Experimentation different from Simplistic Approaches (Part I)

How is Formal Experimentation different from Simplistic Approaches (Part I)

Statistically based DOE provides several advantages over more simplistic approaches such “one-factor-at-a-time” experimentation.  These advantages include:

  • The use of statistical methodology to determine which factors are actually (statistically) significant
  • Balanced experimental designs to allow stronger conclusions with respect to cause and effect relationships (as opposed to just finding correlations)
  • The ability to understand and estimate interactions between factors
  • The development of predictive models that are used to find optimal solutions for one or more responses

This article will explore the first two advantages in a bit more detail.  The second two advantages will be discussed in the next article post.  [Read more…]

Filed Under: Articles, Integral Concepts, on Tools & Techniques

by Larry George 1 Comment

How Can You Estimate Reliability Without Life Data?

How Can You Estimate Reliability Without Life Data?

Myron Tribus’ UCLA Statistical Thermodynamics class introduced me to entropy, -Sp(t)ln(p(t)). (p(t) is the probability of state t of a system.) Professor Tribus later advocated maximum-entropy reliability estimation, because that “…best represents the current state of knowledge about a system…” [Principle of maximum entropy – Wikipedia] Caution! This article contain statistical neurohazards.

Claude Shannon wrote that entropy (log base 2) represents information bits, “…an absolute mathematical limit on how well data from the source can be losslessly compressed onto a perfectly noiseless channel.”  [Beirlant et al.]

Maximum likelihood estimation is one way to estimate reliability from data. It maximizes the probability density function of observed data, Pp(t), e.g., for observed failures at ages t. It is equivalent to maximize -Sln(p(t). Maximum entropy reliability estimation maximizes entropy -Sp(t)ln(p(t). That’s same as maximizing the expected value, -Sp(t)ln(p(t), of the log likelihood -ln(p(t). Fine, if you have life data, ages at failures t censored or not. [Read more…]

Filed Under: Articles, on Tools & Techniques, Progress in Field Reliability?

by Steven Wachs Leave a Comment

10 Keys for Maximizing the Benefits of your SPC Program

10 Keys for Maximizing the Benefits of your SPC Program

Statistical Process Control charts have been called the Voice of the Process.  Progressive manufacturers utilize control charts to “listen” to their processes so that potentially harmful changes will be quickly detected and rectified.  However, not all SPC programs deliver to their highest capability as there are many elements to get right to achieve maximum utility.  Highly effective SPC programs combine technical competencies, such as using an appropriate chart and sample size for the application, with effective management techniques such as enabling operator buy-in and involvement.  This article identifies ten keys that unleash the power of SPC.    [Read more…]

Filed Under: Articles, Integral Concepts, on Tools & Techniques

by Larry George Leave a Comment

Here’s the Data

Here’s the Data

Ralph Evans was editor of the IEEE Transactions on Reliability from 1969 until 2004. He was a very good editor for my 1977 article, and he used me as a reviewer, because I was critical of BS and academic exercises. Ralph moved to University Retirement Community, Davis, CA. He died in 2013, https://ieeexplore.ieee.org/stamp/stamp.jsp?tp=&arnumber=6587564. I wish I’d known he lived nearby so I could have visited and argued with him.

Ralph’s editorials [1 and 2] pled, “Data, Data, Oh Where Art Thou Data?” He wrote, “Field-data are largely garbage. I believe they deserve all the negative thinking possible.” “True field-data are wonderful-much better than fancy equations. Unfortunately, they are very difficult to get. Thus data from the field are largely garbage because they do not represent what really happened.” [Read more…]

Filed Under: Articles, on Tools & Techniques, Progress in Field Reliability?

by Ray Harkins Leave a Comment

Measuring Quality Control Effectiveness

Measuring Quality Control Effectiveness

Aside from meeting specific requirements within quality standards such as ISO 9001 and ISO 13485, well-designed quality system metrics can also serve as meaningful indicators of the strengths and weaknesses of your organization’s processes. As a quality manager, I often consider how precisely our quality system objectives and other metrics describe the effectiveness of our quality processes. Certain metrics such as customer-reported DPPM and customer survey results usually serve to indicate your customers’ satisfaction related to quality. As metrics such as these are tracked over time, managers get a general sense of improvement or decline. Composite measures such as these, however, do not discriminate between quality assurance (preventive) and quality control activities. [Read more…]

Filed Under: Articles, on Tools & Techniques, The Manufacturing Academy

by Steven Wachs Leave a Comment

What is the Relationship between Process Stability and Process Capability?

What is the Relationship between Process Stability and Process Capability?

Process Stability and Process Capability are both extremely important aspects of any manufacturing process.  Often the concepts behind process stability and process capability and the relationship between them are misunderstood.  This article attempts to clarify both ideas and the relationship between them.   [Read more…]

Filed Under: Articles, Integral Concepts, on Tools & Techniques

by Carl S. Carlson Leave a Comment

Why FMEA Needs to be Team-Based

Why FMEA Needs to be Team-Based

“Many ideas grow better when transplanted into another mind than the one where they sprang up.”
Oliver Wendell Holmes

In the international FMEA community, one of the hot topics is how much of an FMEA can be automated versus how much needs to be team-based. Some experts say the future of FMEA requires an automated approach, as systems are getting more and more complex. Others say FMEA must always be grounded in a team of subject matter experts, narrowly focused on the highest priority issues.

In this article, I will share my thoughts on why FMEA needs to be team-based, and what elements can be prepopulated or automated.

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques

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