Reliability Process Management A Methodological Approach Torino March 13, 2011

Transcription

1 Reliability Process Management A Methodological Approach Torino March 13, 2011 rpm Reliability Process Management

2 ITI Business Overview New Product Development Product Data Interoperability Cincinnati HQ (Milford, OH) Europe Cambridge UK Munich, Germany Paris, France Italia Torino, Italy Shanghai, China Beijing, China Tokyo, Japan Osaka, Japan Focus on Concept Development to achieve Breakthrough Improvements in Time To Market, Cost, Reliability & Quality

3 Major Clients

4 Reliability Process Management Reliability is a major driver of Customer Perceived Value CUSTOMER PERCEIVED VALUE SERVICE PERFORMANCE PRODUCT PERFORMANCE RELIABILITY COST OF OWNERSHIP INTANGIBLE DRIVERS 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

5 RPM Overall Objectives 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

6 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

7 CCM LWB CVT Without Credits With Credits Failures per 100 Hours Plan Target Final Target = = Actual New Content RPM Processes, Methods & Tools RPM Processes are customized for clients at different maturity levels Pre-Planning Perceived Analyze Quality Warranty Data Analysis Customer Requirements Usage Profiling Analysis Initial Activities Carry-Over Failure Mode Analysis Develop Life Cycle Model Reliability Planning Set LC Growth Targets Capability Analysis Analyze Product New Content Planning Develop & Evaluate Alternative LCG Plans Select & Optimize Recommended RG Plan Conduct ROI of LCG Plans Specific Tools are implemented and made available for different maturity levels Plan Detailed Activities Tracking Execute Activities Track & Manage Effort Adjust LCG Plan as required Final Evaluation of Effort LCG Testing Dynamically Plan Detailed LCG Activities Execute LCG Test Program Track and Manage LCG Status vs. Plan Adjust LCG Plan as required Reliability Target Achieving Infant Mortality LCG Problem Solving LC Tracking LC Measuring LC Monitoring SE/ALD TM ITI has deployed a Reliability Process Maturity Model - RPMM which allows to properly assess current Client capabilities and define a specific improvement plan RPMM Level 4-5 NC = Failures = 38 Final MTBF = 377 Highly Advanced Tools 20 NC = 19.2 Failures= 35 Final MTBF = New ContentSummary Starting New Content : 21.3 Target New Content : 11.9 Planned New Content : 20.1 Current New Content : 19.7 NC = 15.4 Failures = 30 Final MTBF = 466 NC = 12.1 Failures= 25 Final MTBF = Target = 11.9 Target = 11.9 Planning 10 10/11/ /28/2004 3/15/2005 6/1/2005 8/17/ /3/2005 1/19/2006 Date Analyze Reliability Warranty Capability Data Analysis Set Reliability Growth Target Analyze Product New Content Develop & Evaluate Alternative RG Plans Plan Detailed RG Activities Select & Optimize Approve RG Recommended Plan RG Plan Execute RG Test Program Track and Manage RG Status vs, Plan Adjust RG Plan as required Production Launch RG Testing NEW CONTENT SUMMARY Total New Content Phase 1 Unique New Content Phase 2 Unique New Content Phase 3 Unique New Content B D A C E N M RELIABILITY GROWTH CHART Sample Reliability Growth Results - Automobile Phase 2 G F H O J I K L RPMM Reliability Process Maturity Model RPMM Level 1 Total Test Hours Basic Tools

8 Reliability Process Maturity Model 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 Simulation Driven The fewer prototypes are necessary to achieve reliability targets LCRM (1) The more accurate the Reliability Predictions RPMM Reliability Process Maturity Model Ad Hoc Conventional RG Managed RG Initial RPM Mature RPM Client s Corporate Objective : LCRM=Life Cycle Reliability Management

9 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

10 Sources of Technical Risk for New Product Elements Changes (from the current design) to any of the following items will cause an increase in the technical risk Specification Environment Function Temperature Performance Humidity System (Peripheral Parts) Vibration Structure Power Source Shape Noise Circuit Electric Wave Software Light Parts Sound Material Water Processing Aggressive Atmosfera Assembly Facility

11 Reliability: from Failure Elimination to Failure Avoidance Technical Capability Corrective Actions Failure Elimination New Content (1) 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) Activities: measurable actions which improve the intrinsic reliability of the product design before physical representative units are built

12 Overall Process for Reliability Process Maturity Level 4-5 Pre-Planning Reliability Planning Planning 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 LCG Testing Plan, Execute and Track Failure Avoidance Actions: Activities Tracking Failure Elimination: Finalize and Execute Physical Reliability Growth Testing Reliability Target Achieving Failure Elimination, Lyfe Cycle Monitoring and Tracking LC Monitoring

13 Overall Process for Reliability Process Maturity Level 4-5 Reliability Planning Pre-Planning Perceived Quality Analysis Analyze Warranty Data Initial Activities Carry-Over Failure Mode Analysis Capability Analysis Set LC Growth Targets Analyze Product New Content Planning Develop & Evaluate Alternative LCG Plans Customer Usage Profiling Requirements Analysis Develop Life Cycle Model Select & Optimize Recommended RG Plan Conduct ROI of LCG Plans Execute Activities LCG Testing Execute LCG Test Program Problem Solving Plan Detailed Activities Track & Manage Effort Final Evaluation of Effort Dynamically Plan Detailed LCG Activities Track and Manage LCG Status vs. Plan Infant Mortality LCG LC Tracking Tracking Adjust LCG Plan as required Adjust LCG Plan as required Reliability Target Achieving LC Measuring LC Monitoring

14 Reliability From Physical to Virtual Reliability Growth New Content New Content Failures per 100 Hours Frequency Failure Failures per 100 Hours 22 Risk Assessment, Reliability Planninig and Definition New Content Chart for CT15 C Cab (EC460, EC360, EC330, EC290, EC240) NC = 21.3 Failures = 38 Final MTBF = RELIABILITY GROWTH CHART Sample Reliability Growth Results - Automobile Phase 1 Plan Actual NC = 19.1 Failures = 35 Final MTBF = 404 Planning Target = Final Target = RELIABILITY GROWTH CHART Sample Reliability Growth Results - Automobile Phase NC = 14.9 Failures = 29 Final MTBF = 476 Planned New Content Current New Content Target Plan Total Test Hours Actual NC = 11.9 Failures = 25 Final MTBF = 549 Target Final Target = = Target = 11.9 Target = New Content Chart for CT15 C Cab (EC460, EC360, EC330, EC290, EC240) (3/22/2005) 10 10/11/ /28/2004 3/15/2005 6/1/2005 8/17/ /3/2005 1/19/2006 NC = 21.3 Failures = 38 Final MTBF = 377 Date NC = 19.2 Failures = 35 Final MTBF = 403 Execution & Tracking Total Test Hours Reliability Growth Testing New Content Summary Starting New Content: 21.3 Target New Content: 11.9 Planned New Content: 20.1 Current New Content: 19.7 Target = 11.9 NC = 15.4 Failures = 30 Final MTBF = 466 NC = 12.1 Failures = 25 Final MTBF = 543 Target = /11/ /28/2004 3/15/2005 6/1/2005 8/17/ /3/2005 1/19/2006 Date Planned New Content Current New Content Target Reliability Growth and Tracking during Concept Engineering & Development Starting Point Improvement Demonstration Testing - RG Test Time Reduced Test Time

15 Reliability Tracking Progress of Activities is traced during Development New Content Tracking

16 Reliability Tracking 3 - Projected New Content at Start of RG 4 - Predicted Final Failure Rate Achieved with Current RG Plan 1 - New Content GAP at check point Estimated Final Failure Rate = 0, Estimation of Projected New Content 3 - Projected New Content GAP at Start of RG

17 Failures per Kilometers Failures per Kilometers NEW CONTENT SUMMARY Without With Eu05 Credits Credits Total New Content 46,0 29,1 Phase 1 Unique New Content 44,1 28,0 Phase 2 Unique New Content 1,9 1,1 Phase 3 Unique New Content 0,0 0,0 NEW CONTENT SUMMARY Without With Project X Credits Credits Total New Content 31,7 22,6 Phase 1 Unique New Content 23,3 17,4 Phase 2 Unique New Content 8,3 5,2 Phase 3 Unique New Content 0,0 0,0 Phase 4 Unique New Content 0,0 0,0 NEW CONTENT SUMMARY Without With Project X Credits Credits Total New Content 67,0 55,0 Phase 1 Unique New Content 67,0 55,0 Phase 2 Unique New Content 0,0 0,0 Phase 3 Unique New Content 0,0 0,0 Phase 4 Unique New Content 0,0 0,0 New Co ntent New Co ntent New Content Chart for CT15 C Cab (EC460, EC360, EC330, EC290, EC240) NC = Failur es = 38 Final M TBF = 377 New Content Chart for CT15 C Cab (EC460, EC360, EC330, EC290, EC240) NC = Failur es = 38 Final M TBF = 377 Tar get = Tar get = NC = Failur es = 35 Final M TBF = 404 NC = Failur es = 35 Final M TBF = 404 NC = Failur es = 29 Final M TBF = 476 NC = Failur es = 25 Final M TBF = 549 Tar get = / 11/ / 28/ / 15/ / 1/ / 17/ / 3/ / 19/ 2006 Da te NC = Failur es = 29 Final M TBF = 476 NC = Failur es = 25 Final M TBF = 549 Tar get = / 11/ / 28/ / 15/ / 1/ / 17/ / 3/ / 19/ 2006 Da te Planned New Content Cur r ent New Content Tar get Planned New Content Cur r ent New Content Tar get MTBF (Hours) MTBF (Hours) MTBF in Hours Phase Hours 3 Test Units Final Target = Phase Hours 4 Test Units Hours 5 Test Units 8/1/ /15/2006 2/15/2007-6/8/2007 Phase Hours 6 Test Units Test Time 7/23/ /1/ Impact of Missed Activities RELIABILITY GROWTH PLAN Test Case RG Program Planning - ITI Product Phase Kilometers 4 Test Units 21/01/ /08/ ,00 7,72 6,60 1,64 1,00 Final Target = 0,9 Phase Kilometers 4 Test Units 20/12/ /06/2008 5,66 1,76 Phase Kilometers 8 Test Units 16/07/ /01/2009 0,90 Phase Kilometers 4 Test Units 21/01/ /08/ ,00 8,79 RELIABILITY GROWTH PLAN Test Case RG Program Planning - ITI Product 7,39 Phase Kilometers 4 Test Units 20/12/ /06/2008 6,33 Phase Kilometers 8 Test Units 16/07/ /01/2009 Total Test Time: Kilometers Statistical Confidence: 75,0% Baseline Plan 1,96 2,08 0,10 Test Time 1,00 Final Target = 0,9 1,12 Total Test Time: Kilometers Statistical Confidence: 75,0% Baseline Plan 0,10 Test Time Product X RELIABILITY GROWTH PLAN System X at July Target not Achieved Within Budget Reliability Risk Concept A Total Test Time: Hours Statistical Confidence: 75.0% Reliability Risk Concept B XReliability Risk Concept C Too Risky Risk Analysis Risk Mitigation Reliability Plan 1000 Phase New Content 1307 Hours 3 Test Units Final Target = Phase New Content 2456 Hours 4 Test Units 8/1/2006-1/15/ Final Target = RELIABILITY GROWTH PLAN System X AT July without PR Phase 2 0 New Content Phase 3 0 New Content 2504 Hours 5 Test Units Test Time 297 RELIABILITY GROWTH PLAN System X AT July with PR Phase 2 0 New Content 2432 Hours 5 Test Units 3/15/2007-6/8/ Total Test Time: 4888 Hours Statistical Confidence: 70.0% Test Time Total Test Time: 6195 Hours Statistical Confidence: 70.0% Reliability Growth Plan Target Achieved with High Cost 297 Target Achieved with Lower Cost

18 Failures per 100 Hours Useful Life Reliability Growth Monitoring RELIABILITY GROWTH CHART Sample Reliability Growth Plan - Phase Target = Current Status: Total Test Time: 8954 Hours Final Target = Failures per 100 Hours: Statistical Confidence: 75% Actual Unresolved Failures: Planned Unresolved Failures: Total Test Time (Hours) Total Failures Reported: 122 Total Failures Resolved: 63 With effective problem solving and Reliability Growth management, the growth phase target is achieved as planned.

19 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 Activities Understand reliability risk areas and how to apply proactive activities to mitigate

20 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

21 Thank You