Abstract

Carl and Fred discussing the reasons for performing a Reliability Gap Assessment, and how it fits into the Reliability Plan.

Key Points

Join Carl and Fred as they discuss the important role of Reliability Gap Assessment in creating effective reliability plans.

Topics include:

• Why gap assessment is essential before creating a reliability plan
• What happens when you write a reliability plan before doing a gap assessment
• Learning how to manage reliability programs is a life long process
• Each reliability tools have unique selection criteria
• Gap assessment is necessary to select the right tools based on the capability of the organization

Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques, to field data analysis approaches.

SOR 343 Why Perform a Reliability Gap AnalysisCarl S. Carlson

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Show Notes

Here is a high-level description of the 5-step process to achieving high reliability that Fred and Carl refer to in this podcast. Chapter references are for the draft book tentatively titled Reliability Engineering Management.

Step 1: Develop Reliability Strategic Vision

It is important to begin any new activity with a clear understanding of the goals and objectives. Reliability strategic vision is the envisioned future from a reliability viewpoint. It includes necessary infrastructure, resources, skills, methods capability, and reliability of products and processes. It is developed with full management support, and understood by all employees. Reference chapter 6 in our new book for full description of reliability strategic vision including how it is developed and examples.

Step 2: Perform Reliability Gap Assessment

The reliability gap assessment begins with understanding the reliability vision. It is an assessment done by observations and direct communication with key stakeholders in the company. It analyzes shortcomings (gaps) to achieving the vision, identifies capability of current products and processes, and assesses effectiveness of current reliability methods. Gaps include both organizational capability and application of reliability methods.

The assessment document outlines the shortcomings or gaps between reliability vision and current reliability capability, from business and technical standpoint. It is input to development of effective reliability plan. Reference chapter 7 for complete information on how to perform a reliability gap assessment, including examples.

Step 3: Select the right reliability methods

Using the reliability strategic vision and the reliability gap assessment, select the vital few reliability methods  that are needed to close the gaps and achieve the reliability objectives. Be specific on the method description. Don't just say FMEA , say Design FMEA on Subsystem X. Don't just say DOE , say DOE on decal application process.

Step 4: Create and effective reliability plan

At this point we have identified the vital few tools that are needed to achieve the reliability objectives. We are ready to develop the specific tasks that close the gaps from the reliability gap assessment and achieve the vision for reliability. The needed tasks pull together all necessary resources, address high-risk areas, strengthen organizational shortfalls and perform  the selected tools. We transition from a list of reliability tools to specific tasks (what, who, when, where, how). The plan is organized, and approved by management.

Reference chapter 9 for complete information on how to create an effective reliability plan, including examples.

Step 5: Execute reliability plan tasks

If you have done the first 4 steps properly, the reliability plan will encompass a set of tasks that are necessary for project success, and have been bought into by management. The tasks will be described in sufficient detail to accomplish the objectives, and written in an executable manner. At this point the focus is on execution, and the key to execution is to leverage management support to ensure each task is completed. Ensure all gaps are closed in reliability objectives are achieved.

Reference chapter 10 for complete information on how to execute reliability plan tasks, including examples.