Reliability Engineering in New Product Development

This three-day, hands-on workshop is based the development & deployment of reliability programs in various industries such as semiconductor equipment and automotive. It is applicable for new product development as well as reliability improvement efforts in any industry. This workshop is a combination of learning through examples and then extensive practice by the students for deeper learning. It would be beneficial for participants to have some exposure/experience with basic statistics.

Day 1: Analysis

  • Review goals, objectives, and expectations for course
  • Data Sources that are publicly available; military, government, industry and private.
  • Learn how to scrutinize the data for accuracy, applicability and usefulness
  • Establish current performance levels
  • Reliability Modeling for identifying opportunities and create sub-system goals that support system goals
  • Move company from focusing on Mean Time Between Failure (MTBF) to using Probabilities
    • Definition and calculation of MTBF
    • Understanding limitations and misconceptions around using MTBF to measure reliability
  • Measuring & analyzing data, including Weibull Analysis
    • Special data requirements
    • Creating and interpreting a Weibull plot
    • Cumulative Probability and Conditional Probability
    • Meaning of Characteristic Life and Slope for understanding the underlying nature of a failure mode
    • PM Optimization and Warranty Strategies
    • Available resources and software
    • Goodness of fit & Confidence Levels

Day 2: Understanding Causes of Existing & Potential Failure Modes

  • Review material in Day 1
  • Common approaches for identifying causes of failures – Root Cause Analysis (RCA), Fault Tree Analysis (FTA), etc.
  • Limitations of these approaches
  • Common approaches for identifying potential failures – Failure Modes and Effects Analysis (FMEA), Failure Modes Effects and Criticality Analysis (FMECA), and Design Failure Modes and Effects Analysis (DFMEA)
  • Limitations of these approaches
  • Science-Based Causal Analysis
  • Understanding & solving problems, e.g., Six-Sigma, Design Thinking, Agile, and other ideation techniques

Day 3: Solutions and Demonstrating Reliability

  • Review material covered in Day 2
  • Solution Ideation
  • Solution Quality: bad, good, and elegant
  • Design contradictions
  • Resolving contradictions with TRIZ
  • Reliability Testing Methods for demonstrating that the design goals have been met
    • Reliability Qualification Tests
    • Life Testing
    • Accelerated Life Testing including Highly Accelerated Life Testing (HALT) & Highly Accelerated Stress Screening (HASS)
    • Weibull-Based Zero-Failure Tests
    • Common mis-use of statistics
  • Process for bringing it all together
  • Strategies for implementation
  • Resources and Next Steps for Learning

Available Customizations:

  • Work on your issues as much as possible, instead of our examples.
  • Work in pairs or small groups.
  • This class is also offered in a “coaching” format where it is completed over a 2-3-month period while gradually covering the same content and practice, without requiring entire days in training.