Design for Serviceability/Maintainability Workshop

This three-day, practical, hands-on workshop covers the principles of design for serviceability and maintainability illustrating these principles with numerous examples of good and bad application. The workshop includes exercises to reinforce understanding of principles. The final exercise uses one or more of your company’s products and service procedures to analyze serviceability and identify changes to improve the serviceability of the design. The workshop is intended for design and service personnel who need to collaborate during development to develop a serviceable or maintainable design along with technical and program management.

This workshop is conducted onsite for individual clients and customized to the nature of the client’s products and service processes with client examples to illustrate the various principles.

1. INTRODUCTION TO DESIGN FOR SERVICEABILITY/MAINTAINABILITY

  • Introductions, Agenda, and Capturing Issues for Discussion
  • Design for Serviceability (DFS)/Design for Maintainability Overview
  • The Five Service Process Drivers as a Framework for Analysis
  • Cost Relationships – Reliability/Durability, Diagnosability and Service Cost
  • Address DFS Fallacies
  • Design for Serviceability/Maintainability Objectives
    • Reduce Service Requirements and Frequency
    • Facilitate Diagnosis
    • Minimize the Time and Effort to Disassemble, Repair/ Replace, and Reassemble the Product as Part of the Service Process
    • Reduce Costs of Service Parts

2. DESIGN FOR SERVICEABILITY/MAINTAINABILITY PLANNING

  • Customer Needs Related to Reliability, Availability and Serviceability/Maintainability – A Basis for Planning
  • Develop a Service Strategy
  • Consider Levels of Repair Strategies
  • Consider Spare Parts Strategies
  • Service Strategy Paradigm Shifts
  • Derive Product Requirements Related to Serviceability/Maintainability

3. DESIGN FOR RELIABILITY AND DURABILITY TO MINIMIZE SERVICE REQUIREMENTS

  • Design for Reliability
  • Use Voice of the Customer to Understand the Range of Operating Environments
  • Tools to Analyze and Improve Reliability During Development and Operation
    • Reliability Prediction
    • Failure Modes and Effects Analysis (FMEA)
    • Failure Reporting and Corrective Action System (FRACAS)
  • Design Strategies and Techniques to Improve Reliability
  • Design for Durability
  • Design Strategies and Techniques to Improve Durability

4. DESIGN FOR DIAGNOSABILITY

  • Testing and Diagnosis
  • Types of Faults
  • Visibility to Isolate Failures and Faults
  • Guidelines for External Test
  • Guidelines for Internal Test and Monitoring
  • Built-In Self-Test
    • Capture Operating Parameters with Sensors
    • Establishing and Monitoring Set-Points for Alarms
    • Capture Equipment History and Trends to Provide Context for Diagnosis
    • Local vs. Remote Monitoring
  • Fault Tree Analysis to Develop Trouble-Shooting Guides
  • Using Diagnostic Data to Troubleshoot and Determine the Problem
  • Presenting Diagnostic Information – Human Factors with Indicators, Displays and Messages

5. DESIGN FOR SERVICEABILITY/MAINTAINABILITY OVER-ARCHING PRINCIPLES

  • Three Over-Arching Principles – Simplification, Standardization and Mistake-Proofing
  • Simplify Product Architecture
    • Modular vs. Integrative Architecture Trade-offs
    • Use Multi-Function Modules and Take Advantage of Module Structure
    • Simplify Interconnections
  • Simplify Assembly Design; Minimize Parts to Reduce Service Procedure Steps
  • Criteria for Minimum Parts
  • Minimize Parts Exercise
  • Standardization – Minimize Part Variety
  • Standardization Approach and Method
  • Mistake-Proof Assembly (Poke Yoke)
  • The Six Mistake-Proofing Principles
    • Elimination
    • Replacement
    • Prevention
    • Facilitation
    • Detection
    • Mitigation
    • Examples of the Six Mistake-Proofing Principles
  • Mistake-Proofing Process
  • Mistake-Proofing Exercise – Identify Mistake-Proofing Opportunities

6. DESIGN FOR SERVICEABILITY/MAINTAINABILITY PROCESS AND PRINCIPLES

  • Starting Point: What are the Serviceable Items and Required Procedures
  • Design for ServiceabilityMaintainability Process
  • Principles Organized by the Service Process Step
  • Diagnosability – Principles, Approaches and Human Factors Considerations
  • Consideration of Service Preparation Steps – Instructions, Marking and Labeling, Hand Tools, & Other Factors
  • Factors to Consider in Designing for Safe Service and Maintenance
  • Accessibility and Ergonomics
  • Minimize Disassembly Steps to Access Replaceable/Repairable Items
  • Disassembly Considerations
    • Unfastening: Fastening and Attachment Methods and Considerations
    • Threaded Fastener Considerations & Guidelines
    • Integral Attachment Guidelines and Examples
    • Interconnections: Disconnection and Removal
    • Minimize Weight and Handling
    • Minimize Disassembly and Assembly Motions
    • Design for Minimum and Common Service Tools
    • Part Robustness and Handling
    • Design for Ease of Disassembly and Removal
  • Repair and Replacement Considerations
    • Replacement Standards
    • Service Parts Considerations
    • Cleaning and Refurbishment
  • Reassembly Considerations
    • Design for Ease of Reassembly
    • Part or Module Handling and Orientation
    • Part or Module Insertion and Location
    • Self-Locating and Self-Fastening Features
    • Reconnection Considerations
    • Avoid Calibration and Adjustments
  • Case Studies and Benefits
  • Design for Service/Maintenance Exercise

7. DFS AND THE DEVELOPMENT PROCESS

  • Recommended DFS Process Steps by Development Phase
  • Early Service Involvement
  • Like Product and Process Review
  • Developing and Using Serviceability/Maintainability Design Guidelines and Checklists
  • Structured DFS Evaluation – Conducting Virtual Service Procedures with CAD Assembly Models and Prototype Products
  • Structured DFS Evaluation – Conducting Virtual Service Procedures with Prototype Products
  • Address DFS in Design Reviews
  • Track and Address Failures
  • Collect Data and Enhance Diagnosability and Serviceability
  • Develop a Business Case to Justify DFS Features and Capabilities
  • DFS Performance Measurement & Metrics

8. SUMMARY

  • 10 Steps to Improve DFS
  • Key Success Factors
  • Questions and Discussion

9. DFS ANALYSIS OF COMPANY ITEM(S)

  • Exercise Objectives
  • Analysis Methodology
  • DFS Team Analysis Exercise
  • Review of Team Findings
  • Final Questions and Discussion