Reliability Culture
How leaders build organizations that create reliable products
Published on 4. March 2021
Book
Hardback
304 pages
978-1-119-61243-8 (ISBN)
Description
Most technology companies understand the importance of reliability when it comes to product development. The testing tools, analysis methods, etc. The problem with the implementation of reliability often doesn't come from the engineers; it often comes from the organizational leaders. The leaders don't translate all the factors of the program, time to market, cost point, features, and reliability to the teams in the same manner that the company holds these goals. The result is released products that don't match the carefully crafted product specifications when in the customer's hands. This book shows senior leadership how to build a culture that is both centered around reliability and can generate impressive profits. They don't have to compromise. Leadership will see how their actions affect product development in a new light. They will be introduced to new methods that will immediately enable them to have those crafted product specifications translate 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, clearly summarized, and methods for advancing their passionate struggle. New methods that they can incorporate and promote in their organizations will be clearly explained so they can begin this process.
More details
Other editions
Additional editions
E-Book
02/2021
1st Edition
Wiley
€100.99
Available for download
E-Book
01/2021
1st Edition
Wiley
€100.99
Available for download
Content
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
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