The slides that Carl and Fred present at the 2014 RAMS conference (www.rams.org).
An overview of tasks, approaches, and structure to creating a proactive and effective reliability program in your organization.
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Introduction to Reliability and Maintenance Management
1. Introduction to
R & M Management
Fred Schenkelberg
FMS Reliability
Reliability Engineering and Management Consultant
Carl S. Carlson
ReliaSoft Corporation
Senior Reliability Consultant
3. Tutorial Objectives
To introduce an outline to
guide management of an
effective reliability
program.
To make you think about
how to integrate reliability
engineering within an
organization.
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4. First Challenge as Reliability Engineer
New heating cable design
How long will it last?
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5. What did I need to know?
Timeline
Budget
Samples
What else?
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6. How long1 or 5 year
Is this a should it last?
problem?
What is the goal?
How does your organization
state
reliability goals?
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7. First Assignment as Reliability Engineer
Put together a reliability plan for new vehicle program
Lesson learned: select the vital few tasks
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11. Balance with other objectives
Features or functions of
the product
Cost of the product
Time to market
Reliability
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12. Cable, sensor, power supply,
Cable part of a larger system
controller, and connectors
•
•
Materials, processes, assembly,
design, transportation, and
installation
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13. Story of 50% field failure rate
All elements met
reliability goal.
Field data agreed
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15. Apportion the goal
Sys
Sub 1
Sub 2
Sub 3
Sub 4
Sub 5
With series system,
product of sub system reliability
is system reliability.
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17. NoStory of “you need to improve reliability”
goal
No field data
No Pareto of issues
Just make it better,
2014 RAMS Tutorial
as warranty expenses too –high2A - Schenkelberg
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19. Requirements Tasks
Identify Reliability Data Needs
Reliability data supports measuring and assuring
reliability requirements are attained.
Data can take the form of test failures, field
failures, degradation measurements, test or
analysis successes, and other forms.
Focus on data integrity and correct measurements.
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20. Two basic questions
What will fail?
When will it fail?
Information to permit appropriate
product development decisions
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23. Risk Reduction Tasks
Design-in reliability
This step involves selecting the “Design for
Reliability” tools that can be executed in the design
and manufacturing stages of product development
process
Such as Failure Mode & Effects Analysis, Derating,
Design Margin Analysis, Highly Accelerated Life
Testing, etc.
The focus of the DFR tools should be on high risk
areas, such as new technology and new applications
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24. • Understand stress
• Understand strength
• Separate stress from strength
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28. Prediction of early life failures
Not commonly possibly for unknown variation
Design in some margin
Derating
Safety factor
Determine margin
If variation is known, determine probability of
failures – still difficult to know when though.
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29. Risk Reduction Tasks
Achieve supplier reliability
Incorporate reliability specifications and tasks into
supplier bid packages
Select suppliers who are capable of achieving
reliability objectives
Identify critical supplier parts
Review and approve supplier tasks for critical parts
before shipment
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30. Extra tasks for critical suppliers
Due care tasks for all other suppliers
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31. Risk Reduction Tasks
Implement reliable manufacturing
Manufacturing Reliability is essential to ensuring the
manufacturing and assembly operations do not reduce
the inherent design reliability of products.
Steps must be taken to control manufacturing
processes so they are both stable and capable.
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33. Assurance Tasks
Verify Reliability Requirements Met
Develop and use reliability tests that use physical
testing methods, as well as analytical modeling
techniques.
Focus needs to be on proper analysis and
accelerated life testing.
Supplier reliability requirements for critical parts
must be verified before shipment.
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34. When will it fail?
Everything Fails at some point.
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35. Typical early life failures
Product does not meet
design specifications
Material or component
characterization
Process characterization
Assembly characterization
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36. Hit by a big hammer
Some stress is too large to accommodate
Lightening
Vehicle accident
Meteor strike
Hurricane
Possibly foreseen or expected, and not
economical to design the ability to withstand
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37. Prediction of overstress
Not commonly possibly
Design errors
Environment
Unexpected use
When significant adverse consequence may occur
explore mitigation or fail safe approaches
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38. Wear out and related
Everything fails –
eventually
Understand failure
mechanisms and
environment
The race to cause a failure
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39. Prediction of wear out
Guesses
Estimates
Predictions
Previous products
Models
Testing
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40. Life testing
Standards
Set levels
Environmental extremes
Single stress and model for acceleration factor
Determine the model and acceleration factor
Physics of failure modeling/testing
Pick one that fits risk, resources, and time
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41. Is it good enough?
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42. Is it good enough?
How do we know?
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43. Is it good enough?
How do we know?
We understand the
failure mechanisms
& business objectives
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44. Assurance Tasks
Continuously Improve Reliability
The value of physical testing should be enhanced
through use of appropriate Reliability Growth
Models and Life Data Analysis.
A Failure Review system (FRACAS) should be
instituted.
Reliability improvement methods throughout
product life cycle must be maintained.
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45. FRACAS
A method to keep it all together
Triage
Prioritization
Closure
Grey area of when to stop fixing and ship
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46. Assurance Tasks
Maintain High Reliability Throughout Life
Establishing and implementing proper service and
maintenance procedures will extend product life
and help ensure safe and trouble-free usage.
Understanding and addressing customer issues
during field usage is important.
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50. Organizational Tasks
Establish organizational resources
Organizational resources include personnel,
training, procedures, and business processes.
Will help move the organization to higher stages
in the Maturity Matrix
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51. Organizational Tasks
Institutionalize Reliability Tasks
It is the responsibility of engineering to achieve
reliability objectives.
Reliability methods must be integrated into
ongoing engineering procedures and tasks,
including design reviews, supplier selection, work
instructions, design procedures, etc.
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53. Organizational Tasks
Advance up the Maturity Matrix
Maturity Matrix represents stages of “maturity” of
a company with respect to
Product Requirements
Engineering
Feedback Process
Management
There are 5 stages of maturity that represent
increasing levels of organizational and
engineering capability
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54. Primary Steps to Achieving High
Reliability
Step 1: Develop Reliability Strategic Vision
Step 2: Perform Reliability Gap Assessment
Step 3: Develop Reliability Program Plan
Step 4: Execute Reliability Program Plan
Step 5: Assess Program Lessons Learned
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55. Primary Steps to Achieving High Reliability
(High Level)
Step 1:
Develop
Reliability
Strategic
Vision
Step 2:
Perform
Reliability Gap
Assessment
Step 3:
Develop
Reliability
Program Plan
Requirements Tasks
Step A:
Set reliability
targets
Step B:
Identify
reliability data
needs
Assurance Tasks
Step F:
Verify
reliability
reqmts met
Step G:
Continuously
improve
reliability
Step 4:
Execute
Reliability
Program Plan
Step 5:
Assess Prgm
Lessons
Learned
Risk Reduction Tasks
Step C:
Design-in
Reliability
Step D:
Achieve
supplier
reliability
Step E:
Implement
reliable
manufacturing
Organizational Tasks
Step I:
Step H:
Establish
Maintain
organizational
high
resources
reliability
2014 RAMS –
thru-out life Tutorial 2A - Schenkelberg
Step J:
Institutionalize
reliability
tasks
Step K:
Advance Up
Maturity
Matrix
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56. Step 1: Develop Reliability Strategic
Vision
In the words of American educator Steven Covey,
“begin with the end in mind.”
The Reliability Strategic Vision outlines the
overall vision for Reliability for the organization
or program.
It should be developed with full management
support, understood by all employees, and
integrated into work activities.
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57. Step 2: Perform Reliability Gap Assessment
A Reliability “Gap” Assessment is:
A comprehensive analysis of the specific “gaps” between a
company’s vision for reliability and current reliability capability
It begins with developing or understanding the company’s
reliability vision, and then analyzes the specific shortcomings to
achieving that vision.
The “gaps” are those issues or shortcomings that if closed or
resolved would move the company in the direction of achieving
its reliability vision. It is input to the Reliability Program Plan.
“Gaps” include both organizational capability and application of
reliability methods.
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58. Step 3: Develop Reliability Program Plan
A Reliability Program Plan (RPP) is a document that
defines the entire set of tasks that need to be
accomplished on a project or program, including
responsibility for execution, timing and resources, in
order to achieve the program reliability objectives.
The objective is to design and manufacture a highly
reliable product, on time, and in a cost effective manner.
Includes Steps A thru K
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59. Step 4: Execute Reliability Program Plan
Reliability Program Plan execution requires
management buy-in and support
Reliability plan tasks should be integrated into
company project planning and execution mechanisms
Provide a Work Break-Down Structure and schedule
for the RPP (who, what, when, where, etc.)
Empower reliability to raise the red flag when needed
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60. Step 5: Assess Program Lessons Learned
No reliability program is flawless
Maintain record of issues with development and
execution of reliability plan
Move the organization up the maturity matrix
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61. Conclusions
Developing and executing an effective Reliability
Program Plan is essential to achieving high reliability
for products and processes
By following the information in this
tutorial, companies can develop effective Reliability
Program Plans that achieve reliability
objectives, while staying within budget and timing
constraints.
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Notas del editor
Describe problem, scope and timeline. What I knew and didn’t know. Just part of a larger development project.
When decision needs to be madeHow important is the decisionTesting resources (chambers, measurement systems)Model and failure mechanismsWhat models and testing would be acceptable (believed)?
20 year product with very few or none dropping in power output by 20% or more. Buried in concrete tied to rebar in mountain road bridges, activated during and for 4 hours after snowfall.
Carl’s story about his first assignment as reliability engineer for the Caprice program. He had to develop a Reliability Plan and present to management. The plan was an exceedingly LONG list of reliability tasks.
First three are nearly possible to measure every day – R is not and at best only estimated. How to balance and make the appropriate decisions.Slightly different for maintained units – function, cost to maintain, time to repair, and availability
The cable is part of a larger system
Story of 50% field failure rate
Include key suppliers or vendors by providing them full reliability goals appropriate to their element of the product
Include key suppliers or vendors by providing them full reliability goals appropriate to their element of the product
Carl’s story about when GM used to communicate reliability goals by memo, and never made them actual requirements.
Carl’s story when he was manager of Fisher Body door system test lab, and all doors passed “tests”, in spite of highly unreliable doors in the field.
Carl’s story about chief engineer of the Brooklyn Bridge using design margins for the bridge cable. This story fits best after Fred’s bridge story after slide 26.
Maricopa & Phoenix Railroad Bridge Collapse – 1902 in Tempe AZ – flood water weaken – collapsed in following dry season
Petroski – designers design away from failureIf it is unknown what will fail, how can the design avoid it?Current standing bridge built in 1912
Literature, previous field returns, root cause analysis of any failure, engineering judgment, modeling and simulations, experimentationImage is a colored wood engraving, called Universum and is from The Flammarion engraving is a wood engraving by an unknown artist, so named because its first documented appearance is in Camille Flammarion's 1888 book L'atmosphère: météorologie populaire ("The Atmosphere: Popular Meteorology")
Old diesel train buffer’s between cars
Carl’s story about Cadillac CTS program, the first to use full scale reliability requirements and verification with suppliers of critical parts.
Supply Chain and Manufacturing VariationOverstress conditionsWear out and related
Rolling stones t shirt – new employee and separating circuit boards by hand
Story of one organization with 31 failure mechanisms and model used for decision making
Cable reliability testing and models
Story of study by intern on what was found and what caused field failures
Story of using reliability to achieve availability
Carl’s story about a missile program where the reliability engineer was assigned the task to achieve project reliability goals, without any support from the rest of engineering.