The document discusses traits found in effective reliability programs. It summarizes that effective reliability programs 1) clearly state goals and how reliability will be measured, 2) allow for tradeoffs to be made between reliability and other factors, and 3) securely find failures through techniques like FMEA, HALT, and field trials to get to the root cause of issues. The document is from a consultant discussing their experience with reliability programs across different industries.

1. Traits Found in Effective
Reliability Programs
Fred Schenkelberg
Consultant
fms@fmsreliability.com
www.fmsreliability.com
(408) 710-8248

2. A couple of days…
• Upstairs – calm,
orderly, effective
• Downstairs – urgent,
interruptions,
frustrating
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3. Background
• The 10x program in HP in the 80’s
• Revitalized program at HP in 2000
• Consulting experience across industries
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4. Maturity
Measurement Categories Maturity Stage
• Mgmt Understanding and 1. Uncertainty
attitude 2. Awakening
• Quality Organization 3. Enlightenment
Status 4. Wisdom
• Problem Handling
5. Certainty
• Cost of Quality
• Quality Improvement
Actions
Crosby, 1979
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5. State Clear Goals
Reliability 4 Elements
• Function
• Duration
• Probability
• Environment
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6. MTBF
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7. Make the Estimate
Reliability Value
Parts Count Vendor ALT’s Demonstration Actual
Concept 1st Proto 2nd Proto Mfg Field
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8. Secure Failures
• Find failures
– FMEA
– HALT
– ALT
– RDT
– Field Trials
• Get to root cause
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9. Every failure counts
• Lets say out of 100 prototypes, 5 exhibited
unique failures.
• If the goal is 95%, good right?
• A 90% lower confidence bound is 63%.
• Consider variation and sample risks
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10. Summary
1. State Clear Goals & Measure
2. Enable Tradeoffs
3. Secure Failures
What are your questions?
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