Knotty Detection Abstract Carl and Fred discuss reader questions on FMEA detection, a subject which can be challenging and confusing. Detection is a key part of FMEA during product development as well as in operation. This podcast will discuss some of the “knottiest” challenges with understanding detection in FMEA. Key Points Join Carl and Fred as …

Learning Weibull Analysis Abstract Chris and Fred discuss Weibull Analysis and how it can help you can first take your ‘tentative’ steps to learn more about it. Key Points Join Chris and Fred as they discuss Weibull analysis. This is perhaps one of the most talked about forms of analysis reliability engineers talk about. And so for some people who …

Learning From Those Closest Abstract Kirk and Fred discuss the fact that many times those on the assembly and production lines are the ones that have the most information for assembly issues and causes of failures, yet the information they have is not heard by the engineers and management that could improve it. Key Points Join Kirk and Fred as they…

Getting Failure Feedback Abstract Kirk and Fred discuss the many required tests before market release and post market ongoing reliability testing and why testing is so necessary. Key Points Join Kirk and Fred as they discuss the reasons we have to do so many tests to get the feedback on failures sometimes long after the tests have no failures for l…

Data Analysis Assumptions Abstract Greg and Fred discuss the importance and context of assumptions in data analysis. Key Points Join Greg and Fred as they discuss assumptions making decisions using non parametric data. Topics include: What is non parametric data? Why, when, and how to use non parametric data? How to make good decisions using non pa…

AI Challenges and Opportunities Abstract Greg and Fred discuss AI – both the challenges and opportunities for quality and reliability professionals. Key Points Join Greg and Fred as they discuss how AI may have the same impact as the discovery of electricity or the steam engine. Both created economic disruption and personal change. So, hang on. Be …

Robustness Abstract Philip and Fred discuss the idea of a robust design for a product or system. Key Points Join Philip and Fred as they discuss Topics include: To improve the ability of a product to withstand unexpected stresses, improve the robustness. Design techniques to improve robustness. Various methods to improve reliability like stress-str…

Vintage Experience Abstract Philip and Fred discuss the value of the experience our co-workers may be able to share. Key Points Join Philip and Fred as they discuss Topics include: Accumulated experience over time Tips on helping others share their expertise in a valuable way Tip on effectively sharing your own experiences. Enjoy an episode of Spea…

Shorter Lifespan of Newer Appliances Abstract Carl and Fred discuss an article from the Wall Street Journal describing how newer appliances tend to have more complexity and shorter lifespans, and what can be done to reverse the trend. Key Points Join Carl and Fred as they discuss the factors that influence reliability in large, complex appliances, …

Value of Design FMEA Abstract Carl and Fred discuss an interesting question from a listener about modeling the money value of Design FMEAs. Key Points Join Carl and Fred as they discuss whether it is possible to predict the cost savings due to design changes driven by Design FMEA. Topics include: The challenge of predicting warranty costs from FMEA…

Forecasting Returns Abstract Chris and Fred discuss how you go about forecasting returns … and understanding things like warranty reliability for products that are ‘shipped all over the place? … at different times? Sound familiar? Key Points Join Chris and Fred as they respond to a question from one of our listeners where he was struggling to under…

Atlanta Airport Outage Abstract Chris and Fred discuss what happened during the ‘2017 Atlanta Airport Blackout’ where power was lost for 11 hours, hundreds of flights had to be diverted, passengers needed to be housed in hotels, and lots of other costly things. Surely this was due to some sort of unforeseeable event bordering on the ‘supernatural?’…

Customer Support Abstract Dianna and Fred discuss the challenges as a customer when calling for customer support. Key Points Join Dianna and Fred as they discuss customer support. Topics include: why current contact methods make it seem that customers are not a priority. the missing link: the problem the customer is facing. how changing the managem…

Getting Questions Answered Abstract Dianna and Fred discuss the challenges in asking others reliability questions and getting questions answered. Key Points Join Dianna and Fred as they discuss getting questions answered about reliability. Topics include: places to ask questions being able to say “failure” ways to look at asking questions to help y…

Moose Lodge Syndrome Abstract Greg and Fred discuss how institutions can and should adapt, but often don’t. The result is that even most Fortune 500 companies have a 10 year half life. Key Points Join Greg and Fred as they discuss the inability of organizations to change and pivot. ‘Moose Lodge Syndrome’ is a metaphor for organizational resistance …

Check Your (Decision Making) Bias Abstract Greg and Fred discuss how bias is a part of all of us. Our challenge is that bias impacts our decision making from simple rules of thumb to complex decisions. Key Points Join Greg and Fred as they discuss heuristic and complex decision making. Topics include: What are decision making or problem solving bia…

Failure and Hazard Rate Abstract Chris and Fred discuss the similarities and differences between two terms that many people think mean the same thing. Key Points Join Chris and Fred as they discuss the idea that a failure rate and hazard rate are the same, or are they? Topics include: What is the ‘hazard rate’? The rate at which functional products…

Field and Operational Time Abstract Chris and Fred discuss a listener’s question about dealing with different ‘duration’ metrics for their field data … so how do we find things like ‘operating time’ and other age-related metrics that aren’t calendar time that simply aren’t there? Key Points Join Chris and Fred as they discuss how to work with a pro…

Risk vs Reliability Abstract Carl and Fred discuss whether the reliability community should focus on the body of knowledge associated with risk or reliability. Key Points Join Carl and Fred as they discuss risk versus reliability, and how they interact in bringing about safe and economical products. Topics include: Risk as uncertainty Is everything…

When I Know it’s Not Right Abstract Carl and Fred discuss a question brought up at recent conference: what do you do when you are supposed to do something that you know is not the right thing to do? The context was reliability engineering and management. Key Points Join Carl and Fred as they discuss how to react when your customer or your managemen…

When to Consider Reliability Abstract Kirk and Fred discuss at what point in the product development process should we consider applying reliability engineering to the concept and actual prototypes. Key Points Join Kirk and Fred as they discuss the reliability process and reliability tools and methods and when to apply them. Topics include: Reliabi…

Predicting the Unknowns Abstract Kirk and Fred discuss the world of reliability predictions and the issue of predictions when many, if not most of the causes of unreliability, are surprises. Key Points Join Kirk and Fred as they discuss use of good design rules and building in some margins of safety, but yet when the systems fail it’s usually a sur…

Be Helpful Abstract Chris and Fred discuss the importance of being helpful when it comes to reliability engineering. After all, it is much easier to have people want to come to you as opposed to forcing them to do something they don’t want to. To be influential is to be helpful. Key Points Join Chris and Fred as they discuss how important it is to …

Interpreting formulae and not just generating numbers … Abstract Chris and Fred discuss how formulae (or formulas!) can be very important … but it is way more important to understand what formulae represent, and how they work. Listen to this podcast if you want to learn more! Key Points Join Chris and Fred as they discuss how important it is to und…

Change Management Success Abstract Greg and Fred discuss organizational change management and behavior change. Greg’s change management is sell the sizzle. Fred’s is give them the steak. Discover why? Key Points Join Greg and Fred as they share change management stories including tips and tools for success. Topics include: What is change management…

Contingency and Risk Planning Abstract Greg and Fred discuss various situations where contingency and risk planning may be required. Key Points Join Greg and Fred as they discuss contingency and risk ‘what if’ planning. Topics include: When should a contingency and risk plan be developed. How to develop a contingency plan. What are the critical ele…

FTA vs RBD Abstract Chris and Fred discuss the differences, pros and cons of FTA (fault tree analysis) and RBD (reliability block diagrams). Need to learn more about how to model system reliability? Do you struggle to spell FTA or RBDs? Listen to this podcast! Key Points Join Chris and Fred as they discuss the differences between these things we ca…

K out of N Systems Abstract Chris and Fred discuss about this thing called a ‘k out of n’ system … and how most people don’t really know about how they contribute to system reliability. Do you know what the reliability curve of a ‘k out of n’ system looks like when compared to series or parallel systems? Don’t know what these systems are? Listen to…

FMEA Detection – Useful? Abstract Carl and Fred discuss a reader question about assessing risk related to detection, as part of FMEA procedure, specifically its usefulness and application. Key Points Join Carl and Fred as they discuss FMEA detection in FMEA. Topics include: What is FMEA detection? How is FMEA detection assessed in FMEA? What is the…

Reliability Goals and Requirements Abstract Carl and Fred discuss the importance of well-written reliability requirements and whether they should be goals or actual requirements. Key Points Join Carl and Fred as they discuss reliability goals and requirements. Topics include: Project goals or metrics are not sufficient What to do if reliability is …

Redundancy Risk Balance Abstract Greg and Fred discuss what is redundancy and why it’s a critical business tool. Key Points Join Greg and Fred as they discuss process and product redundancy in a world that wants to reduce friction and be lean. Topics include: What is redundancy? Why redundancy is important in a lean world? When and how should redun…

Risk and Reliability Lenses Abstract Greg and Fred discuss risk and reliability lenses for solving today’s dynamic problems. Key Points Join Greg and Fred as they discuss the intersection of risk and reliability lenses under uncertainty. Fred says: “Reliability is the critical lens to understanding and addressing today’s engineering problems”. Greg…

Reliability from WWII Abstract Chris and Fred discuss some of the things we have learned in the world of reliability directly due to World War II. Not many people know that around one third of today’s medical vaccines were developed out of necessity from World War II … and something similar happened when it came to making things reliable. Key Point…

Just Assuming Abstract Chris and Fred discuss what it means to ‘assume’ something. We assume things all the time in our daily lives. We would never get anything done if we didn’t rely on quick ‘guesses’ about the world around us. But then there are those ‘assumptions’ that get us in trouble. So what’s the difference? Key Points Join Chris and Fred …

Regulation Reducing Safety Abstract Greg and Fred discuss conformity assessment and what should and can you do to comply with a regulatory requirement. Key Points Join Greg and Fred as they discuss safety regulations and compliance to standards. Topics include: What is conformity assessment? Why is conformity assessment important? How can you demon…

Improving Information Abstract Greg and Fred discuss how to improve your ability to get the right information to solve the right problems. Key Points Join Fred and Greg as they discuss how to focus on the right information if you’re doing an analysis, surveillance, or audit. Topics include: Do you ask the right questions to solve the right problem?…

When to do Monte Carlo Simulation (… and what is it)? Abstract Chris and Fred discuss when you should do this thing called Monte Carlo simulation? … in fact … what is it? Key Points Join Chris and Fred as they discuss when and how Monte Carlo simulation can help you with reliability modeling and analysis. What is it anyway? Topics include: What is …

Many Ways to Estimate Reliability Abstract Chris and Fred discuss how we can go about estimating reliability … especially when you don’t have a lot of data, experience or other things that textbooks say you need to have to estimate reliability? Key Points Join Chris and Fred as they discuss how you go about estimating reliability, especially if you…

Lifespan of an FMEA Abstract Carl and Fred discuss a reader question about what is called a “living FMEA.” Is this a good idea? How is it done? Key Points Join Carl and Fred as they discuss whether to update FMEAs with test and field information on an ongoing basis. Topics include: An updated FMEA needs to begin with a good quality FMEA, as baselin…

RCM and FMEAs Abstract Carl and Fred discuss a reader question on FMEAs that involve maintenance. Specifically, can a Design FMEA have causes that are maintenance related? Key Points Join Carl and Fred as they discuss Reliability Centered Maintenance, and the role that FMEA plays in doing RCM projects. Topics include: RCM includes an FMEA front end…

Details and Plans Abstract Greg and Fred discuss why and how the triple constraints of a project: schedule, cost, and scope variances result in risks that can result in project failure. Key Points Join Greg and Fred as they discuss schedule risk, cost risk, and scope risk. Topics include: What are schedule, cost, and scope risks? How do you measure…

Plug and Pray Abstract Greg and Fred discuss why engineers plug numbers into a formula not really knowing why or what they are doing. At best, this is called ‘plug and play.’ At worst, this is called ‘plug and pray’ the formula works. Key Points Join Greg and Fred as they discuss the challenges of why professionals see a formula and pray it gives t…

Bad History Challenge Abstract Kirk and Fred discuss how to deal with those who have said that they tried using the HALT methodology with a past project but did not find any benefit from it. Key Points Join Kirk and Fred as they discuss the situation where a we are trying to introduce a new methodology for reliability and a key player on the team t…

Cycles or Time Abstract Kirk and Fred discuss whether we should use time or number of cycles or total time a product has been available for use. Key Points Join Kirk and Fred as they discuss a question from a listener on whether it’s better to use time or cycles as a reliability metric. Topics include: As with most of our discussions, the decision …

Creating Reliability Awareness Abstract Chris and Fred discuss how to help me, you and the people around us more aware of reliability (and reliability engineering)? Good question! Key Points Join Chris and Fred as they discuss how we go about creating reliability awareness in an organization. The answer isn’t always a webinar. And the answer has to…

Required to Use MIL-HDBK 217? Abstract Chris and Fred discuss Military Handbook 217 Version F for the ‘Reliability Prediction of Electronic Equipment’ or MIL-HDBK 217F … and why being forced to use it is borderline evil. Key Points Join Chris and Fred as they discuss MIL-HDBK 217F contains lots of estimates of failure rates of different types of el…

Using DFR Tools Abstract Kirk and Fred discuss using Design for Reliability (DFR) for reliability development of a new product. Key Points Join Kirk and Fred as they discuss the use of DFx, being design for tests, design for manufacturing and design for reliability and the basics of good designs. Topics include: There are many CAD tools that have e…

Using Outside Labs Abstract Kirk and Fred discuss the use and tradeoffs of using external environmental testing and failure analysis labs versus having in-house equipment Key Points Join Kirk and Fred as they discuss the advantages and drawbacks of a independent test and or failure analysis lab, versus stetting up an internal lab. Topics include: C…

Dealing with Data Abstract Philip and Fred discuss the first basic steps when confronted with a pile of data. Key Points Join Philip and Fred as they discuss Topics include: Consider the source and collection method Consider what we are trying to learn and need to know Plot the data – dot plots, histograms, etc. Enjoy an episode of Speaking of Reli…

Consumable Product Reliability Abstract Chris and Fred discuss how to approach reliability objectives and testing for consumable elements of a product or system. Key Points Join Chris and Fred as they discuss how to deal with consumable product reliability … that is the bits of your system that aren’t ‘components’ or ‘subsystems’ and are like fuel …