on Product Reliability

The reasonable man adapts himself to the world; the unreasonable one persists in trying to adapt the world to himself. Therefore all progress depends on the unreasonable man.

In Maxims for Revolutionists (1903) by George Bernard Shaw

It is those that see the world as it should be that prompts change. I believe it is those resisting change to be unreasonable; I suppose it depends on your point of view. The idea or invention may be an inspiration or take diligent work, yet the real work is in changing the reasonable to a new way of viewing the world.

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as reliability professionals anymore?

During a normal day, we unconsciously tie our shoes, brush our teeth and drive to work, mostly by routine and without too much conscious thinking about the tasks. Occasionally we answer the phone and have to think a little about the conversation. Or we design an experiment for the next project, thinking we can save time by using the same test as last time. Then we slip comfortably into a routine. Do we not think anymore?

Reliability engineering is thinking.

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All Reliability Tasks

Having been invited to evaluate reliability practices within a company, I conducted a series of interviews with various staff members. When asked any question on the reliability techniques used, members of the engineering, procurement, operations, and quality departments all responded with nearly the same comment: “Oh, the reliability guy does that.” It appeared that the organization had one reliability engineer who did everything related to reliability. His interview was scheduled last that day. I was looking forward to meeting him. [Read more…]

Imagine you are requested to assist a design team in determining how to best improve the reliability of a product. You learn that the organization produces a range of point of sale (POS) devices and they have invited you to a meeting with their staff to discuss the product and ways to improve the field reliability.

To help understand the situation, you may have already started to think of a set of questions whose answers would lead to suitable recommendations: [Read more…]

An essential element of a successful reliability program is the notion that all reliability activity relates to decisions. If you are performing a HALT because it is listed in the product development guidelines, or because it was carried over from the last program’s plan, and the HALT results are not part of the design improvement decision-making process, then you probably should not be doing so. If the HALT results yield little or no information (e.g., it is just being checked off the list as accomplished) then the HALT itself provides little or no value. [Read more…]

This will be the last of the series, considering the different positions in an organization that deals with product reliability. We’ve moved away from the positions where the focus on reliability is central, but there are important considerations in relation to product reliability for each of these roles still. In this concluding post the subjects are the manufacturing team, and field service and call center staffs. [Read more…]