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You are here: Home / Archives for Articles / on Tools & Techniques

on Tools & Techniques

A listing in reverse chronological order of articles by:



  • Dennis Craggs — Big Data Analytics series

  • Perry Parendo — Experimental Design for NPD series

  • Dev Raheja — Innovative Thinking in Reliability and Durability series

  • Oleg Ivanov — Inside and Beyond HALT series

  • Carl Carlson — Inside FMEA series

  • Steven Wachs — Integral Concepts series

  • Shane Turcott — Learning from Failures series

  • Larry George — Progress in Field Reliability? series

  • Gabor Szabo — R for Engineering series

  • Matthew Reid — Reliability Engineering Using Python series

  • Kevin Stewart — Reliability Reflections series

  • Anne Meixner — Testing 1 2 3 series

  • Ray Harkins — The Manufacturing Academy series

by Ray Harkins 2 Comments

Understanding Job Satisfaction with Maslow’s Hierarchy of Needs

Understanding Job Satisfaction with Maslow’s Hierarchy of Needs

In a season 2 episode of AMC’s acclaimed TV show “Better Call Saul”, its lead character Jimmy McGill asks his assistant Omar to “take a letter” as he dictates a handful of disjointed phrases to tender his resignation from his lucrative position at the Davis & Main law firm1. During a pause between Jimmy’s thoughts, Omar blankly states, “I just didn’t realize how unhappy you were here.” Jimmy’s response, while puzzling and a bit comical, describes a concept key to understanding the nature of job satisfaction. He replies to Omar, “Not unhappy, per se. More like not happy.”

[Read more…]

Filed Under: Articles, on Tools & Techniques, The Manufacturing Academy

by Larry George 1 Comment

Uncertainty in Population Estimates?

Uncertainty in Population Estimates?

Dick Mensing said, “Larry, you can’t give an estimate without some measure of its uncertainty!” For seismic risk analysis of nuclear power plants, we had plenty of multivariate earthquake stress data but paltry strength-at-failure data on safety-system components. So we surveyed “experts” for their opinions on strengths-at-failures distribution parameters and for the correlations between pairs of components’ strengths at failures. 

If you make estimates from population field reliability data, do the estimates have uncertainty? If all the data were population lifetimes or ages-at-failures, estimates would have no sample uncertainty, perhaps measurement error. Estimates from population field reliability data have uncertainty because typically some population members haven’t failed. If field reliability data are from renewal or replacement processes, some replacements haven’t failed and earlier renewal or replacement counts may be unknown. Regardless, estimates from population data are better than estimates from a sample, even if the population data is ships and returns counts!

[Read more…]

Filed Under: Articles, on Tools & Techniques, Progress in Field Reliability?

by Ray Harkins 1 Comment

The Window and the Mirror; A Framework for Building Credibility

The vast majority of professionals will never rise to the heights of leading a major corporation. But because of the public nature of executives and the companies they oversee, business leaders and their management methods often form effective case studies for those who manage smaller projects and organizations.

Over time, professionals who make a habit of reading trade journals and analyzing business reports can begin spotting both the useful and the futile patterns among these executives’ leadership styles. One such pattern, coined by the bestselling author of “Good to Great” Jim Collins, is called “The Window and the Mirror”.1

[Read more…]

Filed Under: Articles, on Tools & Techniques, The Manufacturing Academy

by Carl S. Carlson 7 Comments

Reviewing AIAG / VDA FMEA Handbook

Reviewing AIAG / VDA FMEA Handbook

I am often asked for my opinion about the FMEA Handbook that was jointly published by AIAG and VDA in 2019. Here is a summary of my candid views on this handbook, excerpted from a presentation I gave at the 2019 Guangbin Yang Reliability Symposium.

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques Tagged With: Failure Mode and Effects Analysis (FMEA)

by Larry George 1 Comment

Progress in LED Reliability Analysis?

Progress in LED Reliability Analysis?

ANSI-IES TM-21 standard method may predict negative L70 LED lives. (L70 is the age at which LED lumens output has deteriorated to less than 70% of initial lumens.) Philips-Lumileds deserves credit for publishing the data that inspired an alternative L70 reliability estimation method based on geometric Brownian motion of stock prices in the Black-Scholes-Merton options price model. This gives the inverse Gauss distribution of L70 for LEDs. 

[Read more…]

Filed Under: Articles, on Tools & Techniques, Progress in Field Reliability?

by Ray Harkins Leave a Comment

To Change is to Change Twice

To Change is to Change Twice

As a teenager in the 1980s, I was an avid reader of Omni, a now defunct magazine dedicated to the future—a far-off world filled with super humans, artificial biospheres and frequent encounters with extraterrestrial beings. Omni catered to armchair futurists like me with science and science fiction stories by A-level writers like Bernard Dixon and William Burroughs.

Future-oriented mass media such as Omni and “Star Wars” gives its consumers a plausible vision of everyday life for future generations. What these sources don’t typically deliver, though, is the path of change to get there. 

[Read more…]

Filed Under: Articles, on Tools & Techniques, The Manufacturing Academy

by Ray Harkins Leave a Comment

The Cost of Opportunity

The Cost of Opportunity

Everyone working in a decision-making role has at least an intuitive understanding of the concept of opportunity costs-the value of the thing you didn’t choose. Simply stated, when you say ‘Yes’ to one thing, you simultaneously say ‘No’ to everything else you could have chosen instead. And those things to which you say ‘No’ have a value that you’re relinquishing. When I was a teenager, I heard an older gentleman quip, “When I said ‘I do’ to my wife, I was also saying ‘I don’t’ to all the other girls out there”. That man understood opportunity cost.

[Read more…]

Filed Under: Articles, on Tools & Techniques, The Manufacturing Academy

by Carl S. Carlson 4 Comments

Evaluating Facilitator Skills

How to Evaluate the Skills of a Facilitator?

Leading is about learning to be a facilitator – Ashif Shaikh

Ask yourself, when teams work very well together, what are the positive characteristics of the team leader? When teams are dysfunctional, and have poor outcomes, what skills of the leader need to be improved?

Let’s talk about facilitators

Giving proper feedback is a great way to help a colleague improve FMEA facilitation skills. Carefully listening to feedback from a colleague is an important way to improve one’s own FMEA facilitation skills. Both are aided by understanding and using facilitation quality objectives. [Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques Tagged With: Facilitation

by Larry George 1 Comment

What’s Wrong Now? Intermittent Failures?

What’s Wrong Now? Intermittent Failures?

“Aircraft LRUs test NFF (No-Failure-Found) approximately 50% of the time” {Anderson] Wabash Magnetics claimed returned crankshaft position sensors had 89-90% NTF (No-Trouble-Found), Uniphase had 20%, Apple computer had 50% [George].

[Read more…]

Filed Under: Articles, on Tools & Techniques, Progress in Field Reliability?

by Ray Harkins Leave a Comment

Expanding your Opportunities

Expanding your Opportunities

As the quality manger for a tier two automotive supplier, I recently had the opportunity to hire a quality supervisor following the retirement of a long-time member of our team. Our company’s human resource manager and I worked together through the entire selection process. Given the status of our region’s economy and the recent closure of several large factories, I wasn’t surprised when our mailbox started filling up with resumes in response to ads on the popular Internet job sites. The typical respondent was a mid-career professional with over 15 years of experience in manufacturing that had either been recently laid-off due or who wanted to move up in their career.

[Read more…]

Filed Under: Articles, on Tools & Techniques, The Manufacturing Academy

by Larry George Leave a Comment

What’s Wrong Now? Multiple Failures?

What’s Wrong Now? Multiple Failures?

How is failure testing done on the Space Station? Could FTA (Fault Tree Analysis) be used in reverse to detect multiple failures given symptoms? That’s what NASA was programming in the 1990s. I proposed that the ratios P[part failure]/(part test time) be used to optimally sequence tests. Those ratios work if there are multiple failures, as long as failure rates are constant and failure times are statistically independent. 

[Read more…]

Filed Under: Articles, on Tools & Techniques, Progress in Field Reliability?

by Ray Harkins Leave a Comment

Sharpening the Axe – Developing a Process Inspection Plan

Sharpening the Axe – Developing a Process Inspection Plan

Abraham Lincoln taught the value of adequate preparation when he said, “Give me six hours to chop down a tree and I will spend the first four sharpening the axe.” By training, quality professionals are often focused on verifying the correctness of a product. A traditional inspector at the Lincoln Timber Company might have dutifully marked in her audit log the date and time, the type and size of tree, followed by the comment, “Cut down.”

But Honest Abe would have advised her to take a closer look at the tools and process used to complete the job.

[Read more…]

Filed Under: Articles, on Tools & Techniques, The Manufacturing Academy

by Larry George Leave a Comment

What’s Wrong Now? Shotgun Repair

What’s Wrong Now? Shotgun Repair

Shotgun repair is trying to fix a system problem by replacing parts until the problem goes away. It is often done without regard to parts’ age-specific reliability information. Should you test before replacement? Which test(s) should you do? In which order? How long? Which part should you replace next if the test gave no indication of what’s wrong? What if test indication is imperfect or the fault is intermittent? What if there are more than one part failure?

[Read more…]

Filed Under: Articles, on Tools & Techniques, Progress in Field Reliability?

by Carl S. Carlson Leave a Comment

Getting to Consensus

Getting to Consensus

Getting to Consensus with the FMEA Team

“A genuine leader is not a searcher for consensus but a molder of consensus.”
Martin Luther King

One of the challenges for any team leader is bringing the team together and agreeing on decisions and actions going forward.

Consensus building is the best practice for all of the FMEA team decisions. This means the FMEA team takes the time to understand all sides of an issue and finds a solution or determines a course of action that is supported by all team members. Facilitating is a consensual activity.

[Read more…]

Filed Under: Articles, Inside FMEA, on Tools & Techniques Tagged With: Facilitation

by Ray Harkins Leave a Comment

What is Design Thinking?

What is Design Thinking?

With all the buzz these days about design thinking, some of you may be wondering what it’s all about. How does it relate to design? And what can non-designers gain from it?

Design thinking is far more than simply designing products and services—it’s an approach to problem-solving that can be applied to an incredibly wide range of applications.

[Read more…]

Filed Under: Articles, on Tools & Techniques, The Manufacturing Academy

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