Introduction to Reliability and Maintenance Management

Introduction to R & M Management

Fred SchenkelbergFMS Reliability

Reliability Engineering and Management Consultant

Carl S. CarlsonReliaSoft Corporation

Senior Reliability Consultant

2014 RAMS – Tutorial 2A - Schenkelberg

Reliability Engineering & Management Consultant

Fred SchenkelbergReliability Engineering

& Management Consultant

FMS Reliability

(408) 710-8248

[email protected]

Carl S. CarlsonSenior Reliability Consultant

ReliaSoft Corporation

[email protected]@effectivefmeas.com

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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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2014 RAMS – Tutorial 2A - Schenkelberg 4

First Challenge as Reliability Engineer

New heating cable design

How long will it last?


What did I need to know?

Timeline

Budget

Samples

What else?

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How long should it last?Is this a 1 or 5 year problem?

What is the goal?

How does your organization state reliability goals?


First Assignment as Reliability Engineer

Put together a reliability plan for new vehicle programLesson learned: select the vital few tasks


Outline of topics

Requirements Tasks Risk Reduction Tasks Assurance Tasks Organizational Tasks Primary Steps to Achieving High Reliability


Requirements TasksSet Reliability Targets

Function

Environment

Duration

Probability

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Balance with other objectivesFeatures or functions of the product

Cost of the product

Time to market

Reliability


Cable part of a larger system• Cable, sensor, power supply,

controller, and connectors

• Materials, processes, assembly, design, transportation, and installation


Story of 50% field failure rate

All elements met reliability goal.

Field data agreed


Apportion the goal

Sys

Sub 1 Sub 2 Sub 3 Sub 4 Sub 5


Apportion the goal

Sys

Sub 1 Sub 2 Sub 3 Sub 4 Sub 5

With series system, product of sub system reliabilityis system reliability.


Apportion complete goal

Function

Environment

Duration

Probability

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Story of “you need to improve reliability”No goal

No field data

No Pareto of issues

Just make it better, as warranty expenses too high


Communication of Reliability Goals

Where should they reside?

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Requirements TasksIdentify 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.


Two basic questions

What will fail?

When will it fail?

Information to permit appropriate product development decisions

2014 RAMS – Tutorial 2A - SchenkelbergTesting to Pass

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Outline of topics



Risk Reduction TasksDesign-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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• Understand stress• Understand strength• Separate stress from strength


Henry Petroski Design Paradigms

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Discovery


Discovery ToolsDiscovery Tools


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.


Risk Reduction TasksAchieve 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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Extra tasks for critical suppliersDue care tasks for all other suppliers

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Risk Reduction TasksImplement 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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Outline of topics



Assurance TasksVerify 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.


When will it fail?

Everything Fails at some point.


Typical early life failures

Product does not meet design specifications

Material or component characterization

Process characterization

Assembly characterization


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


Prediction of overstress

Not commonly possibly

Design errors

Environment

Unexpected use

When significant adverse consequence may occur explore mitigation or fail safe approaches


Wear out and related

Everything fails – eventually

Understand failure mechanisms and environment

The race to cause a failure

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Prediction of wear out

Guesses

Estimates

Predictions

Previous products

Models

Testing

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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


Is it good enough?

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Is it good enough?

How do we know?

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Is it good enough?

How do we know?

We understand thefailure mechanisms& business objectives

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Assurance TasksContinuously 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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FRACAS

A method to keep it all together

Triage

Prioritization

Closure

Grey area of when to stop fixing and ship


Assurance TasksMaintain 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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Maintenance Considerations


Value


Outline of topics



Organizational TasksEstablish organizational resources

Organizational resources include personnel, training, procedures, and business processes.

Will help move the organization to higher stages in the Maturity Matrix


Organizational TasksInstitutionalize 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.


Achieving reliability objectivesis an organization-wide endeavor.

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Organizational TasksAdvance 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


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


Step 1: Develop

Reliability Strategic Vision

Step 2: Perform

Reliability Gap Assessment

Step 3: Develop

Reliability Program Plan

Step A: Set reliability

targets

Step B: Identify

reliability data needs

Step C: Design-in Reliability

Step D: Achieve supplier reliability

Step E: Implement

reliable manufacturing

Step F: Verify

reliability reqmts met

Step G: Continuously

improve reliability

Step H: Maintain

high reliability

thru-out life

Step I: Establish

organizational resources

Step J: Institutionalize

reliability tasks

Primary Steps to Achieving High Reliability(High Level)

Step 4: Execute

Reliability Program Plan

Step 5: Assess Prgm

Lessons Learned

Step K: Advance Up

Maturity Matrix

Requirements Tasks Risk Reduction Tasks

Assurance Tasks Organizational Tasks


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.


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.


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


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


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


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.

Introduction to Reliability and Maintenance Management

Technology

Transcript of Introduction to Reliability and Maintenance Management