ASQ Reliability Division

Who we are

&

How we can help

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The Pitch

• Is your organization involved in design, production, or quality? If so, then reliability is probably important to you. But you may not know much about reliability or how to go about achieving reliability.

We can help.

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A little about me• My name is Dan Burrows, I am the Reliability Engineering &

Test Director for a private company. I am an ASQ CRE, CSSBB, and CMQ/OE.

• Learned reliability at LTV Aerospace under Dr. Jerrell Stracener where I had the opportunity to work on special projects that covered the entire product lifecycle.

• Experienced in aerospace, electronics, automated assembly, heavy equipment, and production systems - product and process reliability.

• I don’t know everything about reliability, but I can reach out to other Reliability Professionals in the ASQ Reliability Division for assistance.

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ASQ Reliability Division

• Have you heard of us?

• The ASQ Reliability Division is the largest group in the world that promotes reliability training and education. asqrd.org

• The Reliability Body of Knowledge is our foundation. Reliability Body of Knowledge

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ASQ Reliability Division - Involvement• Collaboration / Networking /Communication

– LinkedIn ASQ Reliability Division | LinkedIn

– Quarterly Newsletter ASQ RD Newsletters

• Certification– ASQ CRE (Certified Reliability Engineer) How To Get CRE Certified

• How can you join us?– ASQ members, add Reliability Division membership (for $10, or if you

are a Senior Member you get two divisions included)

– If not an ASQ member, consider joining ASQ and the ASQ-Reliability Division

– Join the asqrd.org website (free for ASQ-Reliability Division members, $20 annual fee for nonmembers) and get all of the same benefits/discounts offered from the ASQ Reliability Division

• Volunteer Leadership Opportunities

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ASQ Reliability Division - Offerings• Training courses

– Onsite at conferences or as stand-alone (often partner with ASQ sections)

– ASQrd.org• Monthly live webinar training Upcoming Webinars

• A library of over 100 past webinars Past Webinars and 9,400+ hours of instruction archived

• All with the ability to earn certificates for “proof of training” (and ASQ Recertification Units)

• Conferences

– Sponsor for RAMS (www.rams.org) Reliability and Maintainability Symposium – the world’s largest reliability conference

– Sponsor for ASTR (www.ieee-astr.org) Accelerated Stress Testing & Reliability – focused accelerated testing

• Regional Councilors like me, are a part of our front line engagement with ASQ sections and other professional and public organizations.

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What is Reliability?

• What do you think reliability is?

• Textbook Definition:

Reliability is the probability that an item will perform its intended function for a specified interval under stated conditions following prescribed procedures.

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What does that really mean?

• You must know the customer’s need.

• You must know the application and usage.

• You must know the expected usage life.

• You must know how to maintain reliability.

It means, “Quality over time.”

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What does reliability look like?This light bulb at a Fire Station in Livermore, California has been working since 1901!Livermore's Centennial Light Bulb

We help Quality

• Structured Processes– Failure Mode and Effects Analysis (FMEA)

– Fault Tree Analysis (FTA)

– Failure Reporting and Corrective Action (FRACAS)

• Data and Statistics– Factory Data, Test Data, Field Data

– Discrete and Continuous Probability Distributions (especially Weibull) – probability of failure

– Predictions (failure rates, warranties, etc.)

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The Quality - Reliability Flow

• Reliability (and Quality) starts from the requirements and flows to design, testing, and production

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Product

Specification

• Control Drawing

Design FMEA

• Process FMEA

Qualification Testing

• Reliability Testing

Control Plan

• Inspection Instructions

We help Engineering

• “Designing for X”– Environment and Use

– Stress–Strength

– Design Margin and Derating

– Design FMEA

– Design of Experiments (DOE)

• Testing– Stress Testing – the earlier and harsher, the better

– Life Testing – accelerated life testing / degradation analysis

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• Understand environment and use based on customer requirements and feeding back field information.

• FMEA – Proactively design out potential failure modes that have high risk so that they don’t become realized in the customer’s hands

• Design for Reliability and Understanding Level of Risk

From this To this

How we help - Design

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Oh, you liked the curves

You Could Reduce Variation

Stress Strength

Stress Strength

You Could

Screen

Out

Weakness

Stress Strength

You Could

Add

Protective

Feature

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Panduit Reliability Training

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Failure Mode and Effects Analysis (FMEA)

What are

the Functions,

Item, or

Process?

What can

go wrong?

What are

the

Effect(s)?

How

bad

is it?

What are

the

Cause(s) and

Prevention?

How

often

does it

happen?

How is it

Detected?

How good

is this at

detecting?

What

is

the

Risk?

Does something

need to be changed?

- Design

- Process

- Control

- Procedure

Did the

action taken

lower the

risk?

How we help - Testing

• Stress TestingThe earlier we force

identifying failure

modes, the better the

design

• Accelerated Life TestingEyring Model: The combined acceleration factor of multiple stresses applied simultaneously multiplying together.

AccelerationTotal = AccelerationTemperature x AccelerationHumidity x AccelerationVibration

Example: A product with a temperature acceleration of 9.66, a humidity acceleration of 5.15, and a vibration acceleration of 11.39 will have a total acceleration of 566.64 if all stresses are applied simultaneously. That’s 25 years of life in 16 days of testing!

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We help Operations

• Processes

– Process FMEA

• Maintenance

– PM (Planned, Preventive, and Predictive)

• Optimization and Lean

– Process optimization - Design of Experiments (DOE)

– Total Productive Maintenance (TPM) and Overall Equipment Effectiveness (OEE)

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How we help – Preventive Maintenance

• Reliability trends inform maintenance strategy (TPM)

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Predictive Maintenance

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A couple of tips• If you didn’t learn anything about reliability, here are a couple

of tips…

• When offered an extended warranty when you purchase electronics don’t waste your money since most electronics will fail due to latent manufacturing defects that usually occur within the standard warranty period. Unless you drop your laptop or smart phone a lot.

• When offered an extended warranty when buying a car, have the sales person throw the extended warranty in at no charge. They usually will and cars are subject to wear out and the extended warranty gives you more wear out protection.

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Conclusion

• How can I help you?

• What follow up would you like?

• Get involved!

– Join the ASQ Reliability Division

– Join the asqrd.org web site

– Get involved with the ASQ Reliability Division leadership opportunities (or other opportunities within ASQ or your preferred division or group)

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