Elements of a Reliability Engineering Program

Transcription

1 2011 ARS, India: Bangalore Track 2, Begins at 1:35 PM, Thursday, October 13th Elements of a Reliability Engineering Program Dr. Julio E. Pulido Director DfR Strategy and Planning

2 The following presentation was delivered at the: PRESENTATION SLIDES International Applied Reliability Symposium, India October 12-14, 2011: Bangalore, India The International Applied Reliability Symposium (ARS) is intended to be a forum for reliability and maintainability practitioners within industry and government to discuss their success stories and lessons learned regarding the application of reliability techniques to meet real world challenges. Each year, the ARS issues an open "Call for Presentations" at and the presentations delivered at the Symposium are selected on the basis of the presentation proposals received. Although the ARS may edit the presentation materials as needed to make them ready to print, the content of the presentation is solely the responsibility of the author. Publication of these presentation materials in the ARS Proceedings does not imply that the information and methods described in the presentation have been verified or endorsed by the ARS and/or its organizers. The publication of these materials in the ARS presentation format is Copyright 2011 by the ARS, All Rights Reserved.

3 Agenda Reliability vs. Quality Quality Vs Reliability What is Reliability Engineering? How it helps the bottom line? How to drive Knowledge? How to implement? From Strategy to Tactics Closing Thoughts Slide Number: 2 Quality is the ability of a product to meet a specification. Reliability is the ability of a product to meet a specification over time. Slide Number: 3 Slide Number: 4 Slide Number: 5

4 What is Reliability Engineering? Reliability is one of the most important quality characteristics of components, products and systems. Slide Number: 6 It is an engineering discipline for applying scientific know-how to a component, product, plant, or process in order to assure that it performs its intended function, without failure, for the required time duration in a specified environment. Reliability is the combination of Physics, Statistics and Engineering into one discipline! Statistics Physics Engineering Slide Number: 7 Questions That Can Be Answered Conflicting Directions? What s the expected life of the product? How many returns/failures are we expecting in the next period of time? How much is it going to cost us to: Deal with failures and/or returns? Develop and support this product? Maintain this product? Get spare parts? Can we make it more cost-effective? This information is then used to assess the financial impact of the reliability of the products, and to improve the overall product reliability and consequently the financial strength of the organization. Slide Number: 8 Which way should I go? Slide Number: 9

5 Fast and Reliable Way Life Cycle Cost Speed Reliability Drive by Knowledge we will get me there faster, and with target reliability By aligning reliability expectations with customers expectations in the early program development stage, we can develop a new product faster, and make it more reliable. Only achievable by having the right capability development program. Slide Number: 10 Customers look at product availability and Life cycle cost. In the other side.. Availability is achieved by product target Reliability and solutions optimized Maintainability Slide Number: 11 Knowledge KNOWLEDGE BASE RELIABILITY PROGRAM A mixture of experience, values, contextual information, and insight that provides a framework for evaluating and incorporating new experience and information and making decisions. Relationships Principles Trade-Off Patterns Slide Number: 12 Selection Extraction Environment Slide Number: 13

6 Risk Analysis Three questions Risk Assessment What can go wrong? How likely is it? What are the consequences? Lessons Learned DFMEA Risk Communication Nature of the risk Nature of the benefits Uncertainty Options considered. DFR Risk Assessment Reliability Commitment Risk Management Which risks are significant to deal with? Strategies to avert, control or minimize risks. Assess effectiveness of strategies Slide Number: 14 Once you know the critical customer interest Do you know your critical knowledge gaps at deliverables commitment? Do you typically close the knowledge gaps later in design loopbacks? How do you develop the required knowledge in the organization time over time? Slide Number: 15 Engineering issue today ROADMAP TO IMPLEMENTATION Long time to innovate or introduce new designs. We achieve required reliability Reliability of components is verified at integration time vs. development time. Are your communicating with your suppliers? We do not achieve required reliability. Why? Do not have a program Do not have specific competency or Do not have the capability to achieve the required reliability Component performance verified in system during development via testing System modeling will drive numerical verification of solution. Slide Number: 16 The journey starts with the first step Slide Number: 17

7 Road Map Elements A Vision You need one! Strategic Vision Assessment Create a Plan Set Targets Design Reliability Supplier Reliability Reliability Assurance Reliability Growth Organizational Resources Institutionalize Reliability Make it the responsibility of engineering to achieve reliability objectives Integrate reliability methods into ongoing engineering procedures and tasks Slide Number: 18 Slide Number: 19 System Reliability Strategy Maturity of a Design Program Products Service Solutions Slide Number: 20 The best indicator that organizational learning is taking place is that predictions improve. Slide Number: 21

8 Test Strategy Field Data Acquisition It is critical!! Testing of lower-level components and sub-assemblies is less expensive and can be more effective in exploring the limitations of the design and testing at the level of the complete system Leverage regional test equipment and capabilities to support global product development, productivity, and sourcing initiatives Develop component, sub-system and system test parameters for accelerated life testing based on operational profiles. Develop product operational profiles to identify and control potential failure modes Reduce customer operational costs by maximizing component expected life Slide Number: 22 Prototype system operating in the field Real time operational information. Understanding of actual utilization levels Slide Number: 23 FROM STRATEGY TO TACTICS The Process How can I implement? Slide Number: 24 Integrated process allowing for transfer and knowledge sharing across the organization Suppliers integrated in the technology and development process Design specifications travel across the Design cycle process. Limit curves and DOE allow the organization to understand technology limitations. Slide Number: 25

9 The Process. Design Strategies Continuous integrated Enterprise Process (Engineering + Supplier Management + Marketing) Slide Number: 26 Slide Number: 27 Closing the Knowledge Gap Slide Number: 28 Slide Number: 29

10 Technology Deliverable CLOSING THOUGHTS Technology FMEA Identification of critical variables defining failure condition. Limit curves can be used to define limits of operations. R(t) for a set of applications. Why should I implement the program? Limit Curve Expected life at each condition is understood!! Slide Number: 30 Slide Number: 31 Reliability is Money! Reliability is an Enterprise Activity Even though reliability science and methods can be esoteric, proper execution, analysis and actions have a direct impact on the financial performance of the company! Slide Number: 32 Reliability is directly related to financial performance. Assure that it is viewed in that perspective within your organization. Integrate your suppliers by having clear reliability targets. Increase program visibility. Market and publicize program successes. Communicate findings, information and analysis to the rest of the corporation. Assure that it is viewed as a value added program. You Design Reliability and You Manufacture Quality To optimize Life Cycle Costs for your Customer Slide Number: 33

11 Author Dr. Julio Pulido Julio Pulido is a Director of Design for Reliability Engineering at ReliaSoft Corporation. His responsibility is to drive the capability development of Design for Reliability for consulting clients. He holds BS from the Federal University of Bahia, Brazil, MS from the Federal University of Rio Grande do Sul, Brazil, PhD from Federal University of Rio de Janeiro, Brazil, PhD Research at Duke University and MBA from Xavier University. His specialty is in the area of Structural Analysis, Design for vibration and Structural Reliability, and accelerated testing techniques. He has published over 40 works at different international Symposiums. julio.pulido@reliasoft.com Direct Line: Slide Number: 34 Thank You! Slide Number: 35