A Methodological Approach - Settore...

Reliability Process Management

A Methodological Approach

Torino March 13, 2011

rpmReliability Process Management

ITI Business Overview

Europe

Tokyo, Japan

Osaka, Japan

Cambridge UK

(Milford, OH)

Cincinnati HQ

Shanghai, China

Beijing, China

Product Data InteroperabilityNew Product Development

Focus on Concept Development to achieve Breakthrough Improvements in

Time To Market, Cost, Reliability & Quality

Torino, Italy

Paris, France

Italia

Munich, Germany

Major Clients

Reliability Process Management

Reliability Process Management (RPM) is a structured reliability approach which

encompasses all the key activities needed, from concept development through

production, to deliver high value & successful products to customers

RPM allows to manage reliability in all life cycle phases, with a systemic approach

and throughout the Extended Enterprise

CUSTOMER PERCEIVED VALUE

SERVICE PERFORMANCE

COST OF OWNERSHIP

PRODUCT PERFORMANCE

INTANGIBLE DRIVERS

RELIABILITY

Reliability is a major driver of Customer Perceived Value

Significantly improve Reliability during Development– Improvement of the starting reliability level of the first available representative

Products

Assure Reliability Growth and Technical Risk Mitigation during all development Phases

by proper management and tracking of proactive and virtual activities before prototype

builds

Achieve the expected reliability levels at Start Of Production

(SOP)– Achieve the reliability targets on production Products

Useful Life & Infant Mortality

– Obtain a significant reduction in warranty cost for the first 24 months of product

life and the overall “customer complaints”

RPM Overall Objectives

Successful RPM Applications

1. Automobiles (Vehicles & Major Subsystems)

2. Diesel Marine Engines (Commercial & Leisure)

3. Diesel Industrial Engines (Gen Sets, Stationary Applications, Industrial

Vehicles)

4. Trucks (Vehicles, Diesel Truck Engines, Major Subsystems, Articulated

Haulers)

5. Agricultural Equipment (Tractors, Combines, Harvesters, Hay Tools,

Planters, Accessory Equipment, etc.)

6. Construction Equipment (Loader Backhoes, Wheel Loaders, Skid Steers,

Crawlers, Drills, Excavators, Components, etc.)

7. Mining Equipment (Trucks and Drills)

8. Locomotives (Vehicle & Major Subsystems)

9. Fork Trucks (Electric, Internal Combustion Engines)

10. Injection Molding Machines

11. High Speed Laser Printers

C:/Documents and Settings/Enrico Bergamasco/Impostazioni locali/Temporary Internet Files/Impostazioni locali/Temporary Internet Files/OLK70/Case_Studies/Off-Highway_SEALD_Loader_Asia/Case_Study.ppt

http://img.turbo.fr/02452024-photo-salon-tokyo-2009-honda-crz-concept-2009.jpg

http://agriculture.newholland.com/italy/it/Products/Tractors/Pages/products_selector.aspx

CCM LWB CVT Without Proactive Credits With Proactive Credits

Total New Content 32.5 18.7

Phase 1 Unique New Content 27.4 14.2



NEW CONTENT SUMMARY

Target = 11.9

NC = 12.1Failures= 25Final MTBF = 543




Target = 11.9

10

12

14

16

18

20

22

10/11/2004 12/28/2004 3/15/2005 6/1/2005 8/17/2005 11/3/2005 1/19/2006

Date

Ne

w C

on

ten

t

New ContentSummary

Starting New Content : 21.3

Target New Content : 11.9

Planned New Content : 20.1

Current New Content : 19.7

Target = 11.9





Target = 11.9

10

12

14

16

18

20

22

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Date

Ne

w C

on

ten

t

New ContentSummary





Target = 11.9





Target = 11.9

10

12

14

16

18

20

22

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Date

Ne

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on

ten

t

New ContentSummary





Target = 11.9





Target = 11.9

10

12

14

16

18

20

22

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Date

Ne

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on

ten

t

New ContentSummary





Target = 11.9





Target = 11.9

10

12

14

16

18

20

22

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Date

Ne

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on

ten

t

New ContentSummary





Target = 11.9





Target = 11.9

10

12

14

16

18

20

22

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Date

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on

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t

New ContentSummary





Target = 11.9





Target = 11.9

10

12

14

16

18

20

22

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Date

Ne

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on

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New ContentSummary





Target = 11.9





Target = 11.9

10

12

14

16

18

20

22

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Date

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on

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t

New ContentSummary





New ContentSummary





Target = 11.9





Target = 11.9

10

12

14

16

18

20

22

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Date

Ne

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on

ten

t

New ContentSummary





Target = 11.9





Target = 11.9

10

12

14

16

18

20

22

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Date

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New ContentSummary





New ContentSummary





RPM Processes, Methods & Tools

RPM Processes are customized for clients

at different maturity levels

Specific Tools are implemented and made

available for different maturity levels

ITI has deployed a Reliability Process

Maturity Model - RPMM which allows to

properly assess current Client capabilities

and define a specific improvement plan

Set

Reliability

Growth

Target

Analyze

Product New

Content

Analyze

Warranty

Data

Develop &

Evaluate

Alternative

RG Plans

Select &

Optimize

Recommended

RG Plan

Approve RG

Plan

Execute RG

Test

Program

Track and

Manage RG

Status vs,

Plan

Adjust RG

Plan as

required

Production

Launch

Planning

Proactive RG Testing

Plan

Detailed RG

Activities

Reliability

Capability

Analysis

Set

Reliability

Growth

Target

Analyze

Product New

Content

Analyze

Warranty

Data

Develop &

Evaluate

Alternative

RG Plans

Select &

Optimize

Recommended

RG Plan

Approve RG

Plan

Execute RG

Test

Program

Track and

Manage RG

Status vs,

Plan

Adjust RG

Plan as

required

Production

Launch

Planning

Proactive RG Testing

Plan

Detailed RG

Activities

Reliability

Capability

Analysis

RPMM Level 1

RPMM Level 4-5

SE/ALDTM

Basic Tools

Highly Advanced Tools

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

RELIABILITY GROWTH CHART

Sample Reliability Growth Results - Automobile Phase 2

Target = 0.3107Final Target = 0.3107

0.1000

1.0000

10.0000

100 1000 10000 100000

Total Test Hours

Fa

ilure

s p

er 1

00

Ho

urs

Plan

Actual

RPMMReliability Process Maturity Model

Set LC Growth

Targets

Analyze

Product New

Content

Develop &

Evaluate

Alternative

LCG Plans

Select & Optimize

Recommended RG

Plan

Execute LCG

Test Program

Track and

Manage LCG

Status vs. Plan

Adjust LCG

Plan as required

Infant Mortality

LCG

Dynamically

Plan Detailed

LCG Activities

Execute

Proactive

Activities

Track &

Manage

Proactive Effort

Plan Detailed

Proactive

Activities

Adjust LCG

Plan as required

Final

Evaluation of

Proactive Effort

Analyze

Warranty Data

Capability

Analysis

Carry-Over

Failure Mode

Analysis

Develop Life Cycle Model

Initial Proactive

Activities

LC Tracking

Problem

Solving

LC Measuring

Conduct ROI of LCG Plans

Requirements

Analysis

Perceived

Quality

Analysis

Customer

Usage Profiling

Reliability Target Achieving

Reliability Planning

PlanningPre-Planning

Proactive Tracking

LCG Testing

LC Monitoring

http://www.reliasoft.com/BlockSim/figs/fig_blocksim7_mdi.htm

http://www.reliasoft.com/BlockSim/index.html

http://www.reliasoft.com/doe/

• ITI has deployed a Reliability Process Maturity Model which allows to properly

assess current state capabilities of the client and assist in the definition of a

specific improvement plan

– Each level represents a breakthrough in the effectiveness of the reliability process and the results

achieved

• The higher the RPMM level achieved:

– The lower the product development cost and time to market.

– The more upfront reliability planning and activities are realized

– The fewer prototypes are necessary to achieve reliability targets

– The more accurate the Reliability Predictions

Reliability Process Maturity Model

Simulation Driven

ConventionalRG

1

ManagedRG

2 3

LCRM (1)

4

Ad Hoc

0 6

Mature RPM

5

1: LCRM=Life Cycle Reliability Management

RPMMReliability Process Maturity Model

InitialRPM

Client’s Corporate Objective

Sources of Technical Risk

Unknown

Innovation and related New Content level

Known

Existing Warranty Problems

Existing Service Problems

Existing Maintainability Procedures

Existing Internal Manufacturing and Assembling

Problems

Existing Supplier Problems

Innovation :

New Content

Management

Company and

Product

“Technical

Capability (*)”

(*) The Company and Product “Technical Capability” evaluates the actual current state of the art of the company in terms of

its efficiency and effectiveness in addressing the Current Product problems and issues, it represents the “genetic code” of the

existing product that will be inherently transmitted into the new Product by the existing New Product Development Process

Sources of Technical Risk for New Product

Elements

Specification

Function

Performance

System (Peripheral Parts)

Structure

Shape

Circuit

Software

Parts

Material

Processing

Assembly

Facility

Environment

Temperature

Humidity

Vibration

Power Source

Noise

Electric Wave

Light

Sound

Water

Aggressive Atmosfera

Changes (from the current design) to any of the following items

will cause an increase in the technical risk

Proactive Reliability: from Failure Elimination to

Failure Avoidance

Technical

Capability

Corrective

Actions

Failure

Elimination

New Content

(1)

Proactive

Activities

(2)

Failure

Avoidance

(1) The New Content parameter is evaluated as the change of the system to the

reference product weighted by the importance to the Warranty Failure rate

(2) Proactive Activities: measurable actions which improve the intrinsic reliability of

the product design before physical representative units are built

Overall Process for Reliability Process

Maturity Level 4-5


Reliability Planning PlanningPre-Planning

Proactive Tracking

LCG Testing

LC Monitoring

Analyze Current Product behaviour, Warranty Data, Product Usage,

Market Perception, Product Capability

Analyze New Product, Define Targets, Define Risk

Mitigation and Product Target Achievement Tests

Plan, Execute and Track Failure Avoidance Actions:

Proactive ActivitiesFailure Elimination: Finalize

and Execute Physical Reliability Growth Testing

Failure Elimination, Lyfe

Cycle Monitoring and

Tracking

Overall Process for Reliability Process Maturity

Level 4-5

Set LC Growth

Targets

Analyze

Product New

Content

Develop &

Evaluate

Alternative

LCG Plans

Select & Optimize

Recommended RG

Plan

Execute LCG

Test Program

Track and

Manage LCG

Status vs. Plan

Adjust LCG

Plan as required

Infant Mortality

LCG

Dynamically

Plan Detailed

LCG Activities

Execute

Proactive

Activities

Track &

Manage

Proactive Effort

Plan Detailed

Proactive

Activities

Adjust LCG

Plan as required

Final

Evaluation of

Proactive Effort

Analyze

Warranty Data

Capability

Analysis

Carry-Over

Failure Mode

Analysis

Develop Life

Cycle Model

Initial Proactive

Activities

LC Tracking

Problem

Solving

LC Measuring

Conduct ROI

of LCG Plans

Requirements

Analysis

Perceived

Quality

Analysis

Customer

Usage Profiling


Reliability PlanningPlanningPre-Planning

Proactive Tracking

LCG Testing

LC Monitoring

New Content Chart for CT15 C Cab (EC460, EC360, EC330,

EC290, EC240) (3/22/2005)

Target = 11.9

NC = 12.1

Failures = 25

Final MTBF = 543

NC = 15.4

Failures = 30

Final MTBF = 466

NC = 19.2

Failures = 35

Final MTBF = 403

NC = 21.3

Failures = 38

Final MTBF = 377

Target = 11.9

10

12

14

16

18

20

22

10/11/2004 12/28/2004 3/15/2005 6/1/2005 8/17/2005 11/3/2005 1/19/2006

Date

New

Con

ten

t

Planned New Content

Current New Content

Target

New Content Summary

Starting New Content: 21.3

Target New Content: 11.9

Planned New Content: 20.1

Current New Content: 19.7

Fre

qu

ency

Fail

ure

Test Time

Reduced Test

Time

Starting Point

Improvement

Reliability Growth Testing

Proactive Reliability Growth and Tracking

during Concept Engineering & Development


EC290, EC240)

Target = 11.9

NC = 11.9

Failures = 25

Final MTBF = 549

NC = 14.9

Failures = 29

Final MTBF = 476

NC = 19.1

Failures = 35

Final MTBF = 404

NC = 21.3

Failures = 38

Final MTBF = 377

Target = 11.9

10

12

14

16

18

20

22

10/11/2004 12/28/2004 3/15/2005 6/1/2005 8/17/2005 11/3/2005 1/19/2006

Date

New

Co

nte

nt

Planned New Content

Current New Content

Target

Risk Assessment,

Proactive Reliability

Planninig and Definition

Proactive ReliabilityFrom Physical to Virtual Reliability Growth

Planning

Demonstration Testing - RG

Proactive Execution &

Tracking



Target = 0.7419

Final Target = 0.3107

0.1000

1.0000

10.0000

100 1000 10000

Total Test Hours

Failure

s per

100 H

ours

Plan

Actual



Target = 0.3107Final Target = 0.3107

0.1000

1.0000

10.0000

100 1000 10000 100000

Total Test Hours

Failure

s per

100 H

ours

Plan

Actual

Proactive Reliability Tracking

Progress of Proactive Activities is traced during Development

New Content Tracking

Proactive Reliability Tracking

1 - New Content

GAP at check point

3 - Projected New

Content at Start of RG

Estimated Final Failure Rate = 0,285

4 - Predicted Final

Failure Rate

Achieved with

Current RG Plan

2 - Estimation of

Projected New Content

3 - Projected New

Content GAP at Start of

RG

Impact of Missed Proactive Activities

7,72

1,64

6,60

1,76

5,66

0,90Final Target = 0,9

Phase 1

500000 Kilometers

4 Test Units

21/01/2007 - 15/08/2007

Phase 2

400000 Kilometers

4 Test Units

20/12/2007 - 01/06/2008

Phase 3

1346875 Kilometers

8 Test Units

16/07/2008 - 28/01/2009

0,10

1,00

10,00

Fa

ilu

res

per

12

00

00

Kil

om

eter

s

Test Time

RELIABILITY GROWTH PLANTest Case RG Program Planning - ITI Product

Total Test Time: 2246875 KilometersStatistical Confidence: 75,0%

Baseline Plan

8,79

1,96

7,39

2,08

6,33

1,12

Final Target = 0,9

Phase 1

500000 Kilometers

4 Test Units

21/01/2007 - 15/08/2007

Phase 2

400000 Kilometers

4 Test Units

20/12/2007 - 01/06/2008

Phase 3

1346875 Kilometers

8 Test Units

16/07/2008 - 28/01/2009

0,10

1,00

10,00

Fa

ilu

res

per

12

00

00

Kil

om

eter

s

Test Time

RELIABILITY GROWTH PLANTest Case RG Program Planning - ITI Product

Total Test Time: 2246875 KilometersStatistical Confidence: 75,0%

Baseline Plan

RELIABILITY GROWTH PLANSystem X AT July 13 06 without PR

24

98

32

161

46

297Final Target = 297

Phase 124.3 New Content1307 Hours3 Test Units

8/1/2006 - 12/15/2006

Phase 20 New Content2384 Hours5 Test Units

2/15/2007 - 6/8/2007


7/23/2007 - 11/1/2007

1

10

100

1000

Test Time

MT

BF

(H

ou

rs)

Total Test Time: 6195 HoursStatistical Confidence: 70.0%

RELIABILITY GROWTH PLANSystem X AT July 13 06 with PR

30

177

47


Phase 114.7 New Content2456 Hours4 Test Units

8/1/2006 - 1/15/2007


3/15/2007 - 6/8/2007

1

10

100

1000

Test Time

MT

BF

(H

ou

rs)


Eu05

Without

Proactive

Credits

With Proactive

Credits

Total New Content 46,0 29,1

Phase 1 Unique New Content 44,1 28,0



NEW CONTENT SUMMARY

Product X

Reliability Risk

Concept A

Reliability Risk

Concept B

Project X

Without

Proactive

Credits

With Proactive

Credits






NEW CONTENT SUMMARY

Project X

Without

Proactive

Credits

With Proactive

Credits






NEW CONTENT SUMMARY

Reliability Risk

Concept C

24

130

24

137

31


Phase 1

3360 Hours

3 Test Units

Phase 2

8065 Hours

4 Test Units

Phase 3

8960 Hours

6 Test Units

1

10

100

1000

10000

MT

BF

in H

ours

Test Time

RELIABILITY GROWTH PLAN

System X at July 13 2006


XToo Risky


EC290, EC240)

Tar get = 11. 9

NC = 11. 9Failur es = 25Final M TBF = 549




Tar get = 11. 9

10

12

14

16

18

20

22

10/ 11/ 2004 12/ 28/ 2004 3/ 15/ 2005 6/ 1/ 2005 8/ 17/ 2005 11/ 3/ 2005 1/ 19/ 2006

Da te

New

Co

nte

nt

Planned New Content

Cur r ent New Content

Tar get

Risk Analysis Risk Mitigation Proactive

Reliability Plan

Reliability Growth Plan


EC290, EC240)

Tar get = 11. 9

NC = 11. 9Failur es = 25

Final M TBF = 549



Final M TBF = 404


Final M TBF = 377

Tar get = 11. 9

10

12

14

16

18

20

22

10/ 11/ 2004 12/ 28/ 2004 3/ 15/ 2005 6/ 1/ 2005 8/ 17/ 2005 11/ 3/ 2005 1/ 19/ 2006

Da te

New

Co

nte

nt

Planned New Content

Cur r ent New Content

Tar get

Target not Achieved

Within Budget

Target Achieved

with

High Cost

Target Achieved

with

Lower Cost

Useful Life Reliability Growth Monitoring

With effective problem

solving and Reliability

Growth management, the

growth phase target is

achieved as planned.

Target = 0.742

Final Target = 0.311

0.100

1.000

10.000

100 1000 10000

Fa

ilu

res

per

10

0 H

ou

rs

Total Test Time (Hours)


Sample Reliability Growth Plan - Phase 1

Current Status:

Total Test Time: 8954 Hours

Failures per 100 Hours: 0.726

Statistical Confidence: 75%

Total Failures Reported: 122

Total Failures Resolved: 63

Actual Unresolved Failures: 59

Planned Unresolved Failures: 59

Benefits of the RPM Methodology

• Quickly analyzes trade-offs and risks

• Provides objective, quantitative results to support decision

making.

• Ensures a high level of management priority and

organizational focus on Reliability

• Facilitates communication concerning Reliability plans and

status

• Implements RG techniques in concept development

Understand how many units and how long to test

Understand how much invest in Proactive Activities

Understand reliability risk areas and how to apply proactive activities to

mitigate

Conclusions

• Importance of a structured and rigorous process able to

evolve accordingly with the Company growth

• Applicability to different environments in global market

– To support localized development

– Allowing globalization of the results

• Implemented across the complete extension of the

Product Development Process: from Concept to

Production

• Effective for the Extended Enterprise from Customer to

Suppliers

Thank You

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