WCM 2012 5 Ways to Reduce Warranty Costs
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A short tutorial that introduces five ways to reduce warranty costs. Design a better product leads the list with concrete means to do so. Plus advice directly for the warranty professional to make a difference.
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WCM 2012 5 Ways to Reduce Warranty Costs
- 1. 2012 ®
- 2. ® Five Ways to Reduce Warranty Costs Fred Schenkelberg Consultant FMS Reliability
- 4. Introduction ® • First a few questions • How do you talk about Reliability? • What is the cost of unreliability? • What is included? • Warranty? • Who is in charge of reducing warranty costs? • C-suite • Engineering • Operations
- 5. What really happens when products fail? ®
- 6. A few observations WHAT IS THE CURRENT SITUATION?
- 9. Direction
- 10. Just checking… DO YOU WANT TO REDUCE WARRANTY COSTS?
- 11. Approach How to approach creating a reliable product
- 12. Reliability Goal ® • Function • Duration • Probability • Environment
- 13. Reliability Goal ® • Function • How fails? • Duration • How long? • Probability • Survival Chance • Environment • Use and weather
- 14. Apportionment ® System Elements • With 5 major elements • 95% reliable over 2 years… • Each has to be at least • 99% reliable over 2 years…
- 15. Apportionment ® System Elements • With 5 major elements • 95% reliable over 2 years… • Each has to be at least • 99% reliable over 2 years…
- 17. Focus on Failure Mechanisms ® • Real or imagined • Discovered or measured • Modeled or measured • Eliminate or mitigate
- 18. Reliability Measured ® • Function • Duration • Probability • Environment
- 19. Supply Chain How to improve supplier or component reliability
- 20. The five standard responses ® • “Never seen that before….” • “You must be overstressing it…” • “ESD…” • “We know and have a fix in place…” • What have you heard?
- 21. Set reliability requirements ® • Apportioned goal • Expected Environment • Read the datasheet • Interpret • Ask more questions
- 22. What are you going to do with this? ®
- 23. What are you going to do with this? Peck’s Eqn ® Arrhenius Norris-Landzberg
- 24. What are the failure mechanisms ® • What is expected to fail? Why? • Given our environment… • Given our design… • Given variation…
- 25. Trust and Verify ® • Identify what is important • And, measure it • Let vendor know you are measuring it.
- 27. Environment/Use Techniques to improve understanding of customer’s use conditions
- 28. Weather ® • Varies • Not always at extremes • Also includes: • Power line • ESD/Lightening • Noise • Etc.
- 29. Phases ® • Shipping • Installation • Use • Takeoff • Level flight • landing
- 31. Measurement Methods ® • Studies • Surveys • Monitoring • Data loggers • On-board sensors • Indicators
- 32. Maturity Techniques to measure reliability proactively not reactively
- 34. Subtle differences ® Reactive Proactive • >25% fixing problems • < 5% • Individual “Hero” • Product performs • Lot’s of testing • Very selective testing • Surprises • Confirmation
- 35. Failures Guidelines to improve failure analysis
- 36. Friday afternoon ® • Panic • What if… • Focus blame…
- 37. Gather data and facts ® • Details • Environment • Exposure • Extent
- 38. Remain Calm
- 39. Guidelines ® • Use an FA lab, not vendor • Seek understanding • Fix processes
- 40. Golden Nuggets ® • Identify classic errors • Create and review short list • Start of program • Near program end • (read Petroski Design Paradigms)
- 41. Summary ® • Approach • Supply Chain • Environment/Use • Maturity • Failure