Reliability Culture How Leaders Build Organizations that Create Reliable Products

By outlining how reliability engineering practices fit within a product development program, the reader will have a better understanding of how roles and goals align with the program and how this applies to their specific role.

Reliability Culture: How Leaders Build Organizations that Create Reliable Products, will help readers develop a deep understanding of reliability, including what it really means for organizations, how to implement it in daily operations, and, most importantly, how to build a culture that is centered around reliability and can generate impressive profits. When senior leaders work toward reliability, product details often get lost in translation. This book will enable organizations to overcome this problem by showing leaders how their actions truly affect product development. They will be introduced to new methods that will immediately enable them to have carefully crafted product specifications translated into matching, highly reliable products. This book will also be a breath of fresh air for reliability engineers and managers; they will see their daily struggle identified and will learn new methods for advancing their passionate struggle. These new methods will be clearly explained, so readers can begin the important process of incorporating and promoting reliability in their organizations. Benefits of this book include:

Adam P. Bahret, is Founder of Apex Ridge Reliability, a reliability engineering consulting firm. He has an MS in Mechanical Engineering from Northeastern University and is a Certified Reliability Engineer and a member of ASQ and IEEE. He has spoken at conferences such as RAMS, ASTR, and Reliability Days. Mr. Bahret is author of the second edition of How Reliable is Your Product: 50 Ways to Improve Product Reliability.

Series Editor’s Foreword [to follow]

Acknowledgments

Introduction

Chapter 1.   The Product Development Challenge              3

Key Players         3

Follow the Carrot or Get out of the Race.               6

I’m not That I’m Lazy, it’s that I just don’t care.   8

Product Specification Profiles     11

Product Drivers 14

Bounding Factors             15

Reliability Discipline        16

Chapter 2 Balancing Business Goals and Reliability             1

Return on Investment   1

Program Accounting       4

Rule of 10s          4

The Reliability Engineers Responsibility to Connect to the Business Case 10

Role of the Reliability Professional           13

Summary             16

Chapter 3. Directed Product Development Culture            1

The Past, Present, and Future of Reliability Engineering  3

Influences           4

The Invention of “Inventing”       6

Quality and Inventing are Behaviours      9

As Always, WWII Changed Everything     11

The Post War Influence Diminishes          13

Reliability Is No Longer a Luxury 16

Understand the Intent   19

Levels of Awareness       21

Summary             23

Chapter 4             2

Awakening, The Stages to Mature Product Development 2

Accountability   4

Ownership Chart              9

Communicating Clearly  14

Behind the Words at Work           16

When you want to improve         19

My personal case             20

When we can’t communicate at the organizational level 23

Summary             30

Chapter 5             2

Testing Intent    2

Transferring Ownership 6

What transferred ownership looks like   13

Guided by All The Goals All The Time       16

Summary             19

Chapter 6 New Roles      1

Role of Change Agents   2

Reliability Czar   5

The Czar is a link               6

Direct Input        7

Distilling Information     8

Who is the Czar?              9

How the Czar works with the Team and Leadership          12

Tips for the Czar                14

Role of Facilitators           15

Facilitation Technique    16

Creating a Narrative        19

Role of Reliability Professionals 21

Stop Asking for Resource              21

Connect Reliability to the Market              22

Summary             25

Chapter 7 Program Assessment: 1

Measurements 1

What to Measure            3

Using Reliability Testing as Program Guidance     6

The Primary Wear-out Failure Mode        9

The Random Fail Rate During Use Life     10

Reliability Maturity Assessments              11

Steps for an Assessment               12

The Team            14

The Topics           16

The Scoring         17

Analyze, The Reliability Maturity Matrix 19

Review with the Team and Summarize   21

Recommend Actions      22

Assess Particular Areas in More Detail     23

Golden Nuggets 24

Summary             24

Chapter 8   Reliability Culture Tools          1

Advancing Culture           1

Manipulative Managing 3

Transfer Why     5

Reliability Bounding        6

Strategy Bounding           7

Bounding ROI     11

Invest and Return Tables               14

Deciding by Bounding    19

Anchoring           20

Intent Anchor    22

Delivery Anchor 24

Focus Rotation  26

The  Focus Rotation Steps            27

Working in Freedom and with Ownership             29

Summary             32

Chapter 9   Guiding the Program in Motion           1

Guidance Bounding         1

Guide Bounding ROI        2

Program Risk Effects Analysis      7

Fully Access Risk               10

Program freezes don’t work.      11

The Chill Phase 12

PREA Tables and Calculations      14

Summary             24

Chapter 10 May Risk Analysis Guided Project Management          1

Failure Mode Effects Analysis Methodology         2

Design Failure Mode Effects Analysis       2

Reliability Design Risk Summary 6

Process Failure Mode Effects Analysis     10

Use Failure Mode Effects Analysis             11

Failure Reporting and Corrective Action System 12

Root Cause Analysis        13

Brainstorming    18

Summary             22

Chapter 11.  The Reliability Program        2

Reliability Program Plan 2

Common Reliability Program Plan Pitfalls.              4

The plan doesn’t account for a broad audience:  4

Not including Return on Investment (ROI):           5

Too Much:          5

Too Little:            6

Not Including Concise and Clear Goals:   7

Not Utilizing Testing Initiatives   9

Major Elements of a Reliability Program Pan        9

Purpose               10

Scope    10

Acronyms and Definitions            11

Product Description        13

Design for Reliability (DFR)           14

Reliability Goals 15

Use Case, Environment, Uptime 17

Recommended Tools by program Phase 19

Design Risk Analysis        20

Failure Modes Effects Analysis (FMEA)   20

Reliability Allocation Model         23

Testing 27

Accelerated Life testing (ALT)      34

System Level Testing      36

Summary             39

Chapter 12   Sustained Culture   1

Lasting Changes in Culture           1

Summary             4

Index

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