Speaking Of Reliability: Friends Discussing Reliability Engineering Topics | Warranty | Plant Maintenance
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What Counts as a Failure?
What Counts as a Failure?
Abstract
Kirk and Fred discuss the analysis of what can or should be considered a failure.
Key Points
Join Kirk and Fred as they discuss the criteria for what constitutes a failure during testing and in the customer’s use.
Topics include:
DFMEA and Assumptions
DFMEA and Assumptions
Abstract
Carl and Fred discuss a listener question about the assumptions that go into a Design FMEA, relating to manufacturing and assembly.
Key Points
Join Carl and Fred as they discuss assumptions that go into FMEAs, how they are determined and applied.
Topics include:
Question: if the product meets dimensions, do we assume it works as intended? Question: does the Design FMEA assume the product is manufactured to specifications? Does the Process FMEA assume the design is good? Are there exceptions to these assumptions? ...Listening and Reliability Engineering
Listening and Reliability Engineering
Abstract
Carl and Fred discuss why the skill of listening is essential to successful application of reliability engineering.
Key Points
Join Carl and Fred as they discuss the ability to influence others, and how this can be enhanced by listening. In order to achieve reliability objectives, it is necessary to influence other engineers and managers to incorporate reliability information and ideas.
Topics include:
Harvard Business Review article from Aug 2025, titled “Soft Skills Matter Now More Than Ever, According to Research” Reliability engineers need to b...Data Usage
Data Usage
Abstract
Enrico and Fred discuss the need for data analysis.
Key Points
Join Enrico and Fred as they discuss
Topics include:
Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques to field data analysis approaches.
Download Audio...Quality Management Systems
Quality Management Systems
Abstract
Dianna and Fred discuss the implementation and effectiveness of Quality Management Systems (QMS) and how they impact organizational performance.
Key Points
Join Dianna and Fred as they discuss the implementation and effectiveness of Quality Management Systems (QMS) and how they impact organizational performance.
Topics include:
Define an integrated system to drive organizational decisions about quality. Implement systems that empower decision making at every level of the company. Capture your current baseline processes to help guide future improvements. Avoid creating quality manuals that sit...Customer Service and AI
Customer Service and AI
Abstract
Dianna and Fred discuss customer service and AI: focusing on the impacts and challenges presented by the adoption of Artificial Intelligence (AI) for customer service.
Key Points
Join Dianna and Fred as they discuss the critical function of customer service, focusing on the impacts and challenges presented by the adoption of Artificial Intelligence (AI).
Topics include:
Frustrating experiences with poorly implemented AI customer service systems. Customer loyalty developed by providing excellent, personalized service. Changing performance metrics from tracking call duration to maximizing...Consumer Electronics and Cars
Consumer Electronics and Cars
Abstract
Mojan and Fred discuss consumer electronics and cars. Consumer and automotive electronics may share similar technologies, but their reliability challenges are worlds apart. Designing for the stresses of a living room is nothing like designing for the stresses inside a car.
Key Points
Join Mojan and Fred as they discuss:
Why testing approaches for consumer devices don't translate directly to automotive.
How heat, vibration, integration, and even everyday scenarios (like food spills) shape design.
The role of data...
Planned Obsolescence
Planned Obsolescence
Abstract
Mojan and Fred discuss Planned Obsolescence in product development. Planned obsolescence isn't just about making people buy the next model it's a complex mix of engineering, business, and sustainability decisions. How do we decide how long a product should really last?
Key Points
Join Mojan and Fred as they discuss:
The trade-offs between design life, warranty costs, and reparability.
How sustainability goals are reshaping lifespan expectations.
Stories of products that kept working decades after their intended design life.
...
Training Options
Training Options
Abstract
Kirk and Fred discuss the evolution of ways to learn reliability and failure analysis with so much information available on the internet.
Key Points
Join Kirk and Fred as they discuss the many different training options for understanding reliability issues
Topics include:
Internet searches can now provide access to many different sources of information, from books to videos on how to discover and repair many types of consumer products, but the best understanding comes from disassembling the failed system and seeing the real...Failure Mechanism Awareness
Failure Mechanism Awareness
Abstract
Kirk and Fred discuss the many different failure mechanisms and the need for understanding the failure mechanisms and causes of failures.
Key Points
Join Kirk and Fred as they discuss why it is necessary to have an understanding of material science and the physics of failure mechanisms to do a thorough failure analysis.
Topics include:
What's So Hard About Planning
What’s So Hard About Planning
Abstract
Carl and Fred discuss a subject that some people find difficult. How to plan for reliability.
Key Points
Join Carl and Fred as they discuss a key skill in reliability engineering and management: planning. How does one go about developing a good plan to accomplish the goals of a project?
Topics include:
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.
Key Points
Join Carl and Fred as they discuss student feedback from a course that Fred recently taught. During his office hours, many students were very interested in learning more about communications skills.
Topics include:
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.
Key Points
Join Kirk and Fred as they discuss the methods for testing the empirical thermal limits of a power supply or circuit board.
Topics include:
If possible, the thermal over-temperature protection (OTP) devices should be disabled, but it may not be possible, and we discuss the potential options for overcoming these limits. CPUs in PCs all have a thermal diode shutdown circuit built into t...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
Key Points
Join Kirk and Fred as they discuss the worth of performing HALT on a system after market release
Topics include:
Determining when to perform HALT during development is critical. The product must have a working prototype that meets the environmental specifications before any stress testing begins. Initial field failures are extremely valuable and de...The Trouble with Interfaces
The Trouble with Interfaces
Abstract
Carl and Dianna discuss the topic of interfaces, in reliability engineering and FMEA.
Key Points
Join Carl and Dianna as they discuss the different types of interfaces, and how they can be included in system reliability models and FMEAs.
Topics include:
Team Creativity Techniques
Team Creativity Techniques
Abstract
Dianna and Carl discuss team creativity techniques, especially relating to FMEA.
Key Points
Join Dianna and Carl as they discuss team creativity techniques.
Topics include:
Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability...
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 – 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, let’s run a hypothetical. You’re 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 you’re 26 knowledge in your domain has doubled. Let’s say, you’re 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 products’ 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
Topics include:
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 RE’s 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 ‘why’ 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 …
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 ‘reliability’ (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 ‘systemic’ or endemic root causes). So, how do bearings fail?
Topics include:
Simple answer – spalling. Spalling is a type of fat...Decisions and Metrics
Decisions and Metrics
Abstract
Greg and Fred discuss the importance of key metrics, whether KPI’s or OKR’s, to determine the quality of decision making.
Key Points
Join Greg and Fred as they discuss decision making, metrics, and objectives. What works? What doesn’t? And, how to develop better operational measures. Topics include:
How organizations track performance? What key metrics are used? What is the difference between KPI’s and OKR’s 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 doesn’t have the engineering knowledge, skills, and abilities to design things. Why? Companies don’t 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...
