Speaking Of Reliability: Friends Discussing Reliability Engineering Topics | Warranty | Plant Maintenance
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Office Hours, Plus
Soft Skills Plus
Abstract
Carl and Fred discuss the wide range of soft skills that reliability engineers need to learn, in order to be fully successful in their jobs.
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Overcoming Product Protections for HALT
Overcoming Product Protections for HALT
Abstract
Kirk and Fred discuss turning off the built-in over-temperature production circuits to perform thermal HALT.
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HALT Late in the Program
HALT Late in the Program
Abstract
Kirk and Fred discuss using HALT for a product that has been in the field and has many documented reliability issues from the initial warranty returns
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The Trouble with Interfaces
The Trouble with Interfaces
Abstract
Carl and Dianna discuss the topic of interfaces, in reliability engineering and FMEA.
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Team Creativity Techniques
Team Creativity Techniques
Abstract
Dianna and Carl discuss team creativity techniques, especially relating to FMEA.
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How do We do 'Reliability Allocation'?
How Do we Set Reliability Requirements?
Abstract
Chris and Carl discuss a listener question on FMEA RPN and connection to reliability requirements.
Key Points
Join Chris and Carl as they discuss RPN is not a reliability metric and there are better ways to do allocation to set requirements.
Topics include:
How do We do 'Reliability Allocation'?
Pitfalls of Reliability Allocation
Abstract
Carl and Chris discuss the broad subject of reliability allocation. What is it, when is it used, and what are the primary pitfalls to success?
Key Points
Join Carl and Chris as they discuss setting and allocating reliability requirements. Topics include:
What are primary pitfalls to doing reliability allocation? What are the characteristics of good reliability requirements? Engineering reliability into products Wrong assumptions Consider adding a margin, in system reliability modeling, for errors or things not thought of Goals versus requirements Including reliability requirements...Special Characteristics
Special Characteristics
Abstract
Carl and Dianna discuss two of the least understood and potentially powerful FMEA data elements: Special Product Characteristics for Design FMEAs, and Special Process Characteristics for Process FMEAs.
Key Points
Join Carl and Dianna as they discuss the application of Special Characteristics in FMEAs. Topics include:
What are some other names for Special Characteristics? What is definition of characteristic, product characteristic, and process characteristic? How can special characteristic be used in FMEAs? Do special characteristics require extra controls in the Process Control Plan? Who defines special ch...How HA and FMEA Relate
How HA and FMEA Relate
Abstract
Dianna and Carl discuss the relationship between Hazard Analysis (HA) and Failure Mode and Effects Analysis (FMEA).
Key Points
Join Dianna and Carl as they discuss the how HA and FMEA relate and how they can work in synergy to create safer products.
Topics include:
Fundamental differences and similarities How HA can effectively quantify risk by calculating the probability of harm, a dimension often missing from FMEA Practical techniques for identification and collective ownership of ideas Early HA and FMEA in...How FMEA Worksheets can Help (and Hinder)
How FMEA Worksheets can Help (and Hinder)
Abstract
Chris and Carl discuss FMEA worksheets (we know ⌠boring) ⌠but can be incredibly helpful and useful. So what are they and how do they help us?
Key Points
Join Chris and Carl as they discuss FMEA worksheets, which are an important part of a Failure Mode and Effects Analysis (FMEA) that help us identify the potential issues with a product or process before they become issues â meaning we can (hopefully) help us design them out of existence when it is cheap and easy t...
Reliability Engineering and Artificial Intelligence
Reliability Engineering and Artificial Intelligence
Abstract
Carl and Chris discuss the changing opportunities and challenges with AI and reliability engineering. What are the positive interactions, and where should we be concerned?
Key Points
Join Carl and Chris as they discuss their views on the roles that AI can play in reliability programs. Topics include:
What are the limitations of AI in supporting reliability programs? One concern is if AI is being oversold, and replaces necessary human involvement. Another concern is the possibility of AI moving a company towards mediocrity. ...Show Me the Money
Show Me the Money
Abstract
Greg and Dianna discuss how quality and reliability engineers can become AI boomers NOT doomers. Engineers are being challenged with AI. What can and should we do to survive and even prosper in the age AI disruption.
Key Points
Join Greg and Dianna as they discuss AI opportunities. What can you do to become an AI boomer.
Topics include:
Stories of career disruption. What is the human in the loop or middle. Tips and tools to become an AI boomer.Enjoy an...
Quality and Reliability Disrupted
Quality and Reliability Disrupted
Abstract
Dianna and Greg discuss your employability in the AI age. So, letâs run a hypothetical. Youâre a 22 year old mechanical engineer. You do robotic quality and reliability with a knowledge half-life of 4 years.  That means by the time youâre 26 knowledge in your domain has doubled. Letâs say, youâre now 30. Knowledge in your domain has quadruped. Problem: you have not updated your knowledge skills and abilities. Are you still employable.
Key Points
Join Dianna and Greg as they discuss what we all face nowadays. ...
Risk or Safety Triggers
Risk or Safety Triggers
Abstract
Greg and Fred discuss how and when to escalate problems and risks.
Key Points
Join Greg and Fred as they discuss resolution and escalation of risk and nonconforming products.
Topics include:
What is the role of a professional code of ethics? What is the trigger for escalation. What are different types of safety triggers. How can you mitigate risks if you an internal employee or professional engineer?Enjoy an episode of Speaking of Reliability. Where you can join friends as they...
Keep it Simple
Keep it Simple
Abstract
Kirk and Fred discuss the challenge of using simple models for one finite element to extrapolate damage scalar metrics to very complex systems.
Key Points
Join Kirk and Fred as they discuss system models and how most fatigue damage models have many input variables, such as vibration and temperature, that can be very difficult to simultaneously measure across a system during operation
Topics include:
The vibration response of a test unit can be very different depending on how it is coupled or mounted...Connectors
Connectors
Abstract
Kirk and Fred discuss the reliability of electrical connectors
Key Points
Join Kirk and Fred as they discuss the many ways that electrical connectors can lead to system failures.
Topics include:
The connector manufacturer may design a connector that is slightly modified from a standard reference design, which worked for many applications, but they cannot know the details of how it may be affected by your productsâ end-use environments, such as higher thermal or vibration conditions in your system. Many connector issues are due to fretting cor...10 Gems Career Start Advice
Ten Career Gems for New Reliability Engineers
Abstract
Carl and Fred discuss our top advice for those starting a role as a reliability engineer for the first time.
Key Points
Join Carl and Fred as they discuss
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AI Future of FMEA
AI Future of FMEA
Abstract
Carl and Fred discuss the use of AI with FMEA, what works and what does not work.
Key Points
Join Carl and Fred as they discuss the broad subject of FMEA and AI. We look at early lessons learned, discuss opportunities, and focus on the most important concerns.
Topics include:
How FMEA can interact with Model-Based Engineering? FMEA pre-population, which fields can be pre-populated and which should not? What is role of human team in FMEA? What are primary ways to reduce...What do Reliability Engineers Do?
What do Reliability Engineers Do?
Abstract
Dianna and Fred discuss what do Reliability Engineers do?
Key Points
Join Dianna and Fred as they discuss what do Reliability Engineers do? An REâs role extends far beyond just crunching numbers and running tests.
Topics include:
How they act as crucial links between diverse teams Their ability to help teams shape decisions that profoundly affect product performance, customer satisfaction, and business outcomes. Bridging departmental silos, managing inherent conflicts, and advocating for the voice of the customerThey also ta...
Enough Data?
Enough Data?
Abstract
Dianna and Fred discuss a common reliability engineering dilemma: do we have enough data? Is data nirvana achievable?
Key Points
Join Dianna and Fred as they discuss a common reliability engineering dilemma: do we have enough data? Is data nirvana achievable?
Topics include:
Hidden challenges for RE, from too little to overwhelming amounts Departmental silos and data quality nightmares The art of purposeful collection Buy-in for better data and how explaining the âwhyâ behind its collection can transform resistance into collaborationEnjoy an epis...
Risk Monitoring Triggers
Risk Monitoring Triggers
Abstract
Greg and Fred discuss ways to detect and monitor changes in a system. So, what is the trigger to indicate an event, threat, or anomaly that can result in a risk. This becomes critical if you want to focus on the critical few NOT the insignificant many.
Key Points
Join Greg and Fred as they discuss what triggers risk and how to monitor it. Topics include:
What is a risk trigger? How to monitor significant events, threats, and anomalies. How to be proactive, preventive, predictive, and...Reliability Allocation
Reliability Allocation
Abstract
Enrico and Fred discuss various approaches to allocation.
Key Points
Join Enrico and Fred as they discuss the pros and cons of different approaches to reliability goal allocation for subsystems and components.
Topics include:
Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics...
Portable Device Feasibility
Portable Device Feasibility
Abstract
Chris and Fred discuss how we assess product feasibility ⌠at the concept stage! Great topic.
Key Points
Join Chris and Fred as they discuss product feasibility when it is nothing more than a concept. There is a lot to unpack here! This comes from a question raised by a Singaporean listener who is a student looking at the feasibility of a portable device that repels mosquitoes, utilizing cutting-edge technology, including the ability to detect the unique frequencies of flying mosquitoes.
Topics include:
Hand-held dev...Equations for Goal Setting
Equations for Goal Setting
Abstract
Chris and Fred discuss what equations (if any) exist for setting and optimizing reliability goals ⌠sometimes trading off against other goals. Wo âŚ
Key Points
Join Chris and Fred as they discuss equations that exist to help you come up with and optimize reliability goals and targets. This comes from a listener who points out that well-known reliability software contains equations based on Weibull distributions, optimization algorithms, and perhaps alchemy that can do all this for you. What do we think?
Topics include:
Reli...Customer Requirements
Customer Requirements
Abstract
Chris and Fred discuss customer requirements when it comes to reliability. How do we get this wrong?
Key Points
Join Chris and Fred as they discuss requirements ⌠not just yours ⌠when it comes to reliability. What can go wrong?
Topics include:
MTBF and other wrong metrics. People love the MTBF because it is simple, a single number, and it feels like it represents âreliabilityâ (but it does not). Sometimes we try hard to convince people not to use it, but they still want to. AND ⌠th...Bearing Failure and Analysis
Bearing Failure and Analysis
Abstract
Chris and Fred discuss how bearings fail. Bearings are among the most common components used in products and systems. So, how do they go wrong?
Key Points
Join Chris and Fred as they discuss how bearings fail, in response to a question from one of our listeners whose organization has experienced some bearing failures in wind turbines (all of which were caused by âsystemicâ or endemic root causes). So, how do bearings fail?
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Simple answer â spalling. Spalling is a type of fat...Decisions and Metrics
Decisions and Metrics
Abstract
Greg and Fred discuss the importance of key metrics, whether KPIâs or OKRâs, to determine the quality of decision making.
Key Points
Join Greg and Fred as they discuss decision making, metrics, and objectives. What works? What doesnât? And, how to develop better operational measures. Topics include:
How organizations track performance? What key metrics are used? What is the difference between KPIâs and OKRâs metrics? How to improve performance measuresEnjoy an episode of Speaking of Reliability. Where you can join frien...
Communicating Complex Topics
Communicating Complex Topics
Abstract
Enrico and Fred discuss a few approaches that may be effective when communication complex topics to others.
Key Points
Join Enrico and Fred as they discuss the need for many engineers to improve their ability to communicate effectively.
Topics include:
Enjoy an episode of Speaking of Reliability. Where you can join friends as they di...
Loss of Expertise
Loss of Expertise
Abstract
Greg and Fred discuss what happens when a company doesnât have the engineering knowledge, skills, and abilities to design things. Why? Companies donât make commodity stuff any more. They outsource these items. The challenge of outsourcing often means outsourcing engineering expertise. Big problem. So what are the solutions?
Key Points
Join Greg and Fred as they discuss what companies can do when engineering expertise is outsourced. Topics include:
What are the problems of outsourcing design and manufacturing? What are design and sourcing solutions? What are le...Research Options
Research Options
Abstract
Kirk and Fred discuss the new options for doing technical research, including Google Scholar and AI tools like ChatGPT
Key Points
Join Kirk and Fred as they discuss the validity and limitations of using the new tools for technical research.
Topics include:
ChatGPT sometimes creates fabricated information, but you can evaluate its relevance and accuracy by asking questions on a subject you already understand and see if you agree with the information it returns. Besides the online tools for searching, it is good to discuss...Vendors and Reliability
Vendors and Reliability
Abstract
Kirk and Fred discuss the value or risks of sending failed components to the vendor for failure analysis.
Key Points
Join Kirk and Fred as they discuss the best way to get accurate failure analysis (FA) of a failed component.
Topics include:
Component suppliers for high volume devices are typically not going to do a deep dive failure analysis for a small volume OEM, and the failure of their component may not be due to the component, but instead it could be...Mastering AI and Career
Mastering AI and Your Career
Abstract
Greg and Fred discuss how AI is changing work, careers, and jobs. Last week, Fiverr CEO warned staff: âAI is coming for your jobs, including mine!â So what does this really mean for reliability and quality professionals? And importantly, what can you do about it?
Key Points
Join Greg and Fred as they discuss how AI is changing engineering. Topics include:
Understand why âpaying duesâ and learning the craft of engineering is slowly disappearing. Know what quality âvibing is. Understand why asking the ârightâ questions is more i...Reliability Engineering Books
Reliability Engineering Books
Abstract
Chris and Fred discuss talk about how to ârankâ reliability engineering books that are actually based on helpfulness (and perhaps not an algorithm).
Key Points
Join Chris and Fred as they discuss the different reliability engineering books and how they ârankâ regarding their usefulness for reliability engineering.
Topics include:
Whatâs âwrongâ with Google and Amazon rankings? A couple of things. First is that reliability engineering books donât sell hundreds of units a week (surprise!) So, a couple of sales here and there can change...Psychology and Reliability
Psychology and Reliability
Abstract
Chris and Fred discuss the psychology behind (bad) reliability decisions. Humans run (and ruin) everything!
Key Points
Join Chris and Fred as they discuss the different ways psychology can influence reliability engineering decisions. Reliability is often something where feedback is delayed. That is, failure will occur years after a shortcut was made during design. And that is where psychology steps in.
Topics include:
Letâs go nuclear. Australian politicians recently looked at creating a nuclear power generation industry where there previously was none. No...Better Risk Matrices
Better Risk Management
Abstract
Greg and Fred discuss risk management tools specifically the advantages and disadvantages of using color -coded risk matrices.
Key Points
Join Greg and Fred as they discuss how risk matrices can be used effectively and graphically to communicate the likelihood and severity of risks. Risk matrices are inherently not precise and accurate. However, they are a useful heuristic decision making tool
Topics include:
What are risk matrices. How and where should risk matrices be used for decision making. Why are risk matrices an impo...AI and Reliability Planning
AI and Reliability Planning
Abstract
Carl and Fred discuss a few ways to use AI during the reliability planning process.
Key Points
Join Carl and Fred as they discuss when and why using AI may be helpful.
Topics include:
Enjoy an episode of Speaking of Reliability. Where you can join friends as they di...
System FMEA
System FMEA
Abstract
Carl and Fred discuss a question from a listener about the scope and procedure for a System FMEA, and what is different from other FMEA types.
Key Points
Join Carl and Fred talk about the essential elements of applying FMEA to larger systems.
Topics include:
How early should you do a System FMEA? What part of system FMEA is âblack boxâ? Which âblack boxesâ need further development? What is the scope of the FMEA? What are the boundaries? What are limitations of doing a single m...Risk Planning
Risk Planning
Abstract
Greg and Fred discuss risk planning and why folks donât do it. And, then they wonder what and why something happened.
Key Points
Join Greg and Fred as they discuss the fact we live in a world of uncertainty and risk. Think fires. Think tariffs. Think AI. What do you do about it?
Topics include:
What is risk planning? Why plan is a 4 letter word for most folks? Why risk denial or risk aversion is the new normal? What you can do to become...Phantom Test Results
Phantom Test Results
Abstract
Dianna and Fred discuss phantom test results in reliability testing.
Key Points
Join Dianna and Fred as they discuss phantom test results and the challenges of reliability test methods.
Topics include:
The importance of root cause analysis for test failures. How test rigs and measurement systems themselves can give false positive or false negative results. Why understanding customer use cases is critical for effective testing.Hear stories about phantom test results, incorrect test criteria, and unexpected product failures driven by factors not...
Sample Size Considerations
Sample Size Considerations
Abstract
Dianna and Fred discuss sample size considerations for reliability testing.
Key Points
Join Dianna and Fred as they discuss sample size considerations, tackling the frequently asked question: âHow many samples do I need?â.
Topics include:
Understanding the trade-offs between desired reliability/confidence levels and the massive sample sizes often required. Balancing statistical significance with practical significance and defining acceptable criteria. How tools like FMEA can help justify your required confidence level. Overcoming real-world constraints like budget, sample availability, test method limitations, and measurement erro...
