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 Carl S. Carlson Leave a Comment

Gathering Information

[Author note: This article is being published mid-month, and is part of the FMEA Preparation series. It was earlier written, but inadvertently omitted from publication, as part of this series.]

Gathering Information for FMEA Preparation

One of the most important steps in FMEA preparation is gathering all of the relevant documents and information. If this step is missed or done inadequately the FMEA meetings will be burdened with extra tasks related to missing information, the time of the subject-matter experts will be wasted, and the FMEA results potentially compromised.

“True genius resides in the capacity for evaluation of uncertain, hazardous, and conflicting information.” – Winston Churchill

[Read more…]

by Perry Parendo Leave a Comment

Seven Simple Tools of Problem Solving

Problem solving can often be accomplished using Seven Simple Tools. Scope, data collection and data display need to be addressed, and these tools cover the needs in a manner with limited complexity. [Read more…]

by Ray Harkins Leave a Comment

What is Process Capability Analysis? Really.

I recently read the results of a AAA survey where Americans were asked to rate their own driving abilities. 73% of those surveyed considered themselves “better-than-average” drivers. Obviously only 50% of the drivers can actually be better than average. So it follows that at least 23% of those surveyed are mis-estimating their own skills.

This over-confidence in one’s abilities seems to find its way into all sorts of areas … including process capability analysis. Everyone who’s been around manufacturing for any length of time has certainly heard of Cp and Cpk. Most of them know that “higher is better” when it comes to these indices. And many will nod their heads and smile when you suggest that Cpk and Ppk account for centeredness, whereas Cp and Pp do not. But only a small percentage of manufacturing professionals can cogently answer the question, “What is Process Capability analysis?” [Read more…]

by Perry Parendo Leave a Comment

Countering Belief Bias

It has been said that beliefs come first, and we then find supporting facts for them second. Can we reduce this belief bias? Can we improve our decision making? [Read more…]

by Perry Parendo Leave a Comment

Bias Toward Outside Inputs

Resolving a company challenge can get complicated. Could an outside resource accelerate the process? Or is it a distraction? Are there behavioral reasons we need to consider to provide a balance perspective to make the decision? This is discussed in this video. [Read more…]

by Carl S. Carlson Leave a Comment

Using Process FMEAs to Improve Process Control Plans

“Science is the process that takes us from confusion to understanding…” – Brian Greene

Properly done, Process FMEAs should improve manufacturing and assembly processes and corresponding process controls. This article describes how PFMEAs can be used to improve process controls, which are embodied in the Process Control Plan (PCP).

[Read more…]

by Perry Parendo Leave a Comment

Bias for Achieving Success

We all have biases impacting our ability to achieve success. We need to acknowledge them. By making personal choices, we can improve our odds. There are also team structure and ground rules to consider for providing an advantage. [Read more…]

by Perry Parendo Leave a Comment

Process Capability

Process capability is a key technique for confirming design and process requirements. This video discusses common elements of the approach. [Read more…]

by Perry Parendo Leave a Comment

Why the Tie

As casual dress has taken over many work environments, we still wear a tie to events and while working with clients. Why do we continue to do this? Listen to hear the background of this choice. [Read more…]

by Perry Parendo Leave a Comment

Corrective Action and Preventative Action – CAPA

A critical operation within many organizations is CAPA processes. The tool set to address issues is extensive. This video addresses the topic at a high level to help direct your approach. [Read more…]

by Carl S. Carlson Leave a Comment

Using Design FMEAs to improve Design Verification Plans

“I didn’t fail the test, I just found 100 ways to do it wrong.” Benjamin Franklin

Properly done, Design FMEAs should improve product designs and test plans. This article describes how DFMEAs can be used to improve testing and analysis, which are embodied in the Design Verification Plan (DVP).

[Read more…]

by Dev Raheja Leave a Comment

Warranty Costs are Lot More than the Accounts Tell You

In November 2019, General Motors recalled over 640,000 pickup trucks worldwide because hot gas from a high-tech seat belt can set the carpeting on fire [1]. The recall covers 2019 and 2020Chevrolet Silverado and GMC Sierra 1500 trucks. Also included are some 2020 Silverado and Sierra 2500 and 3500 heavy-duty pickups. All have carpet as a floor covering, GM says it uses a small explosion to move a piston that tightens the belts before a crash. The explosion can release hot gas through an opening in a bracket, possibly setting the carpet on fire. The company reports two fires but no injuries. [Read more…]

by Perry Parendo Leave a Comment

Do Not Just Make Data

Focusing on data only is a limiting view compared to wanting to make decisions. The decisions should come first, and the data to support that comes second. This video covers this conversation. [Read more…]

by Perry Parendo Leave a Comment

Trust with Your Information

Your R&D work is full of sensitive information. How do you know you can trust Perry’s Solutions with your process? This video covers this topic. [Read more…]

by Perry Parendo Leave a Comment

False Hustle

A coaching friend talked to me once about “False Hustle” – things that players do to look like they are working hard. In fact, it is a lazy habit and avoidable by doing things right. The same things happens in corporate situations with product development. This video gives examples for each environment. [Read more…]