Speaking Of Reliability: Friends Discussing Reliability Engineering Topics | Warranty | Plant Maintenance
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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?
Topics include:
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...Fault Tree Analysis
Fault Tree Analysis
Abstract
Chris and Fred discuss the basics and uses of fault tree analysis. Chances are that if you have been taught about fault trees, it was for only one of the many ways you could use them.
Key Points
Join Chris and Fred as they discuss a couple of uses along with the basics of conducting fault tree analysis, or FTA.
Topics include:
What is a fault tree? It is a logical diagram that represents (for example) which combinations of components need to fail...Dismissing Failures
Dismissing Failures
Abstract
Chris and Fred discuss a common problem of dismissing or ignoring failures, especially when they donât fit your âprofile.â
Key Points
Join Chris and Fred as they discuss the problems and hazards that arise when a failure occurs and is ignored. This can be tricky, as it can sometimes be hard to spot them.
Topics include:
Prototype failures dismissed as âitâs a prototype and a one-off.â Then why even make prototypes? Most decisions are based on âconfidence.â And we can go to all sorts of dif...Test to Pass or Fail
Test to Pass or Fail
Abstract
Enrico and Fred discuss two of the most common reliability testing approaches.
Key Points
Join Enrico and Fred as they discuss the pros, cons, and pitfalls of designing and running a test that has no failures, or does.
Topics include:
Failures provide information A no-failure test design relies on trusted information and test conditions Remember to check your measurement system(s) and minimize measurement errorEnjoy an episode of Speaking of Reliability. Where you can join friends as they discuss...
Traditional Reliability Methods
Traditional Reliability Methods
Abstract
Kirk and Fred discuss a question from a listener about why traditional reliability methods don't work for modern electronics.
Key Points
Join Kirk and Fred as they discuss why traditional methods, such as those based on prediction using classical references like Military Handbook 217F don't work with today's electronics..
Topics include:
Adhesives
Adhesives
Abstract
Kirk and Fred discuss the reliability issues around using adhesives to attach mechanical assemblies.
Key Points
Join Kirk and Fred as they discuss the use of adhesives and testing the long-term reliability of adhesive bonds.
Topics include:
Mismatched coefficients of thermal expansion (CTE) pose a significant challenge for attaching glass, metals, and polymers. Epoxies that are used to encapsulate ICs in Plastic Encapsulated Microcircuits (PEM) are closely guarded formulas that match the TCE of the wire frame and leads. Many other factors can weaken the...Excessive Starts and Stops Modeling
Excessive Starts and Stops Modeling
Abstract
Chris and Fred respond to a question asked by one of our listeners ⌠who is wondering about the number of âstartsâ and âstopsâ on electrical and mechanical systems when it comes to characterizing reliability.
Key Points
Join Chris and Fred as they discuss how one goes about modeling the effects of âexcessiveâ âstarts and stops,â âpower up/power down,â âwind up/shut down,â and so on.
Topics include:
Starts and stops create different stresses and failure mechanisms. You wonât experience these when you are testing o...EV Battery Life
EV Battery Life
Abstract
Chris and Fred discuss the long-term life of electric vehicles (EVs) and other rechargeable batteries, which tend to be longer than predicted. Why?
Key Points
Join Chris and Fred as they discuss why some rechargeable batteries, like those on electric vehicle (EV) batteries, appear to last longer than what the manufacturers tell us they will. Why is that?
Topics include:
Laboratory testing often understates real-world use stresses. This often happens when people donât want their âbabyâ the wonderful new product they have design...Use and Environmental Data
How to use data from connected devices for derivation of mission profiles
Abstract
Enrico and Fred discuss the value of using real-world usage data to define mission profiles, advocating for a shift from deterministic to stochastic approaches. They touch on the impact of environmental conditions, the risk of selection bias in data analysis, and weigh the cost-benefit of using connected devices to improve design and reliability decisions.
Key Points
Topics include:
Importance of Evaluating Real Usage for Mission Profiles
Emphasized the need to base mission profiles on...Intermittent Failure During a Test
Intermittent Failure During a Test
Abstract
Chris and Fred discuss how you analyze the failure data from a test ⌠where failure is sometimes intermittent?
Key Points
Join Chris and Fred as they discuss intermittent failures during the test. What do you do? For example, letâs say something is being tested to see if it works every âcycleâ of operation. The idea is that it needs to last a certain number of cycles to work. What happens if the item passes the test ⌠but there were a couple of cycles during the...
Is a PhD Worth It?
Is a PhD Worth It?
Abstract
Chris and Fred discuss the importance (or lack thereof) of having a PhD in reliability engineering. Is it worth it?
Key Points
Join Chris and Fred as they discuss whether having a PhD in reliability engineering is worth getting. Thereâs a lot to unpack here âŚ
Topics include:
Simple answer ⌠no. But it depends on what you are trying to achieve. Many reliability engineers are self-taught or have accumulated knowledge from lots of âlittleâ courses. And many reliability engineers with a PhD ⌠are...Long-form Reading
Long-form Reading
Abstract
Dianna and Fred discuss long-form reading. Is it in decline?
Key Points
Join Dianna and Fred as they discuss long-form reading.
Topics include:
Gain valuable insights into improving reading habits and the benefits of...
Using FTA Effectively
Using RBD Effectively
Abstract
Dianna and Fred discuss using RBD Effectively.
Key Points
Join Dianna and Fred as they discuss using RBD Effectively.
Topics include:
Hear a compelling story about how a basic RBD approach led a team to exceed their reliability goals.
Enjoy an episode...
A Good Reliability Engineer
A Good Reliability Engineer
Abstract
Kirk and Fred discuss a simple question of what being a practical and sound reliability engineer means.
Key Points
Join Kirk and Fred as they discuss the different aspects of reliability engineering and what they need to be a good reliability engineer
Topics include:
Confidence Reliability
Confidence Reliability
Abstract
Kirk and Fred discuss the term confidence and its use in reliability engineering
Key Points
Join Kirk and Fred as they discuss confidence in predicted failure distributions and the use of reliability engineering.
Topics include:
Reliability and Safety
Reliability and Safety
Abstract
Carl and Fred discuss the difference between the body of knowledge of reliability and safety, and how they work together.
Key Points
Join Carl and Fred as they discuss the different roles and responsibilities of reliability and safety activities.
Topics include:
A Curse of Reliability Engineers
A Curse of Reliability Engineers
Abstract
Carl and Fred discuss the importance of reliability engineering and customer service working together to increase reliability and safety from the customer point of view. It is very important to understand how customers actually use your product, and customer service staff are uniquely positioned to provide that insight.
Key Points
Join Carl and Fred as they discuss how reliability engineers can improve customer service, and how customer service can provide critical reliability information.
Topics include:
The Testing Strategy
The Testing Strategy
Abstract
Enrico and Fred discuss a couple of ways to approach planning reliability testing.
Key Points
Join Enrico and Fred as they discuss a question about testing everything or not.
Topics include:
Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us...
Why Set a Reliability Goal
Why Set a Reliability Goal
Abstract
Chris and Fred discuss the importance of (trying to) set a reliability goal. Simple ⌠right?
Key Points
Join Chris and Fred as they discuss reliability goal setting. How do we do them? What makes good ones? How do we not set bad ones?
Topics include:
Intents and catchphrases are not goals. âWe have a five-year warranty!â Great ⌠what is the five-year reliability goal to support this warranty period? âIt should last 20 years!â Cool ⌠not all will, so how many can fail over twenty ye...Review of RAMS 2025
Review of RAMS 2025
Abstract
Chris and Fred discuss the success or otherwise of the Reliability and Maintainability Symposium (RAMS) 2025 ⌠with a focus on AI. What are your thoughts?
Key Points
Join Chris and Fred as they discuss the success of RAMS 2025 and its focus on AI. This year, RAMS 2025 was held in Florida.
Topics include:
How did its focus on AI go? RAMS historically has âthemesâ that rarely reflect what it is all about. This yearâs theme was about âAI.â While there was a fair bit of AI conten...Building a Reliability Team
Building a Reliability Team
Abstract
Dianna and Fred discuss building a reliability team.
Key Points
Join Dianna and Fred as they discuss building a reliability team.
Topics include:
Plus, find out how a reliability engineer saved a company...
Complex AI Reliability
Complex AI Reliability
Abstract
Dianna and Fred discuss complex AI reliability.
Key Points
Join Dianna and Fred as they discuss complex AI reliability: using AI for complex systems.
Topics include:
Enjoy an episode of Speaking of Reliability. Where you can join friends as...
Reliability Engineer or No
Reliability Engineer or No
Abstract
Enrico and Fred discuss about the role of the reliability engineer in modern organizations.
Key Points
Join Fred and Enrico in an engaging conversation about the evolving role of the reliability engineer in organizations and the broader question: Should reliability engineering be a dedicated function, or should it be integrated across teams?
This episode covers:
Centralized vs. Distributed Reliability Expertise Discussing the pros and cons of having a dedicated reliability engineer versus embedding reliability knowledge across teams. Insights into how organizations with...Value of Failures
Value of Failures
Abstract
Kirk and Fred discuss how many companies discard or never get back failed parts or subsystems even though they are high-value gold in the quest to make a more reliable product.
Key Points
Join Kirk and Fred as they discuss why so few companies realize the value of field failure returns, testing to limits, and the distribution of stress limits in testing several samples of a new product during development.
Topics include:
Semantics and the terms reliability engineers use are critical in selling...
