Reliability Culture
Description
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:
* For the organizational leader, this book provides tools for aligning reliability objectives and methods with the company s business and brand goals
* For the reliability engineer, this book identifies and proposes solutions for integrating their discipline within the larger program objective and activities
* Engineers and leaders alike will benefit from detailed discussions of product negotiation, program assessment, culture change methods, and more
* All readers will understand the progression of product design methods over the previous decades, including how market acceptance is changing
Reliability Culture: How Leaders Build Organizations that Create Reliable Products is intended for a broad audience that includes organizational leaders, engineers of all disciplines, project managers, and business development partners. The book is aimed at outlining how reliability engineering practices fit with all program activities, so any team members will benefit.
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Person
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.
Content
Series Editor's Foreword by Dr. Andre Kleyner xi
Acknowledgements xiii
Introduction xv
1 The Product Development Challenge 1
Key Players 1
Follow the Carrot or Get Out of the Race 3
It's Not That I'm Lazy, It's That I Just Don't Care 5
Product-specification Profiles 8
Product Drivers 9
Bounding Factors 10
Reliability Discipline 11
References 15
2 Balancing Business Goals and Reliability 17
Return on Investment 17
Program Accounting 18
Rule of 10s 20
Design for Reliability 21
Reliability Engineer's Responsibility to Connect to the Business Case 23
Role of the Reliability Professional 26
Summary 28
References 29
3 Directed Product Development Culture 31
The Past, Present, and Future of Reliability Engineering 32
Influences 32
The Invention of "Inventing" 33
Quality and Inventing Are Behaviors 34
As Always, WWII Changed Everything 35
The Postwar Influence Diminishes 36
The Emergence of Japan 37
Reliability Is No Longer a Luxury 38
Understand the Intent 39
Levels of Awareness 40
Summary 41
References 42
4 Awakening 43
Stage 1 43
Stage 2 43
Stage 3 44
Stage 4 44
The Ownership Chart 44
Comparing Charts 45
Benefits of the Ownership Chart 45
Communicating Clearly 50
Behind the Words at Work 51
When You Want to Improve 53
My Personal Case 53
Getting the Message Across 54
The Importance of Time 54
When We Can't Communicate at the Organizational Level 55
When Scheduling Trumps Testing 57
Summary 58
5 Goals and Intentions 61
Testing Intent 61
Testing to Improve 61
Quick Question 61
Ownership 62
Fear-driven Testing 62
Transferring Ownership 63
Leadership and Transference 64
Objectives and Transference 65
What Transferred Ownership Looks Like 67
The Benefits of Successful Transference 67
A Racing Bike Analogy 68
Guided by All the Goals All the Time 69
The Roadmap Conundrum 69
Why We Embrace Tunnel Vision 69
When No One Has a Plan 69
Summary 70
References 70
6 New Roles 71
Role of Change Agents 71
Reliability Czar 72
The Czar is a Link 73
Direct Input 74
Distilling Information 74
Who is the Czar? 74
How the Czar Works with the Team and Leadership 76
Tips for the Czar 77
Role of Facilitators 78
Facilitation Technique 78
Creating a Narrative 80
Role of Reliability Professionals 80
Stop Asking for Resources 81
Connect Reliability to the Market 81
Summary 83
7 Program Assessment 85
Measurements 85
What to Measure 86
Using Reliability Testing as Program Guidance 86
The Primary Wear-out Failure Mode 88
The Random Fail Rate During Use Life 90
Reliability Maturity Assessments 90
Steps for an Assessment 91
The Team 92
The Topics 93
The Scoring 94
Analyze: The Reliability Maturity Matrix 94
Review with the Team and Summarize 95
Recommend Actions 98
Assess Particular Areas in More Detail 98
Golden Nuggets 98
Summary 99
References 99
8 Reliability Culture Tools 101
Advancing Culture 101
Manipulative Managing 101
Manipulative Management in Action 102
An Alternative to Manipulation 102
Transfer Why 103
Reliability Bounding 103
Fire and Forget 103
Reliability Feedback 104
Strategy Bounding 104
Strategy Bounding Toolkit 104
Midprogram Feedback 105
The Bounding Number 105
Bounding ROI 106
Invest and Return Tables 107
Deciding by Bounding 110
Anchoring 110
Closed Loop Control 112
Open Loop Control 112
Intent Anchor 113
Delivery Anchor 114
The Value of Anchoring 115
Focus Rotation 115
The Focus Rotation Steps 115
Working in Freedom and with Ownership 116
The Gore Example 117
Why Don't All Companies Do This? 118
Summary 118
9 Guiding the Program in Motion 119
Guidance Bounding 119
Guidance Bounding ROI 120
The Plan 120
The Issue 120
Technology Cascade 120
Timing is Everything 121
Our Choice 121
Using Bounding 121
The Results 122
Program Risk Effects Analysis 122
What Now? 123
Just Let It Go 123
Fully Access Risk 124
Program Freezes Don't Work 124
The Chill Phase 125
PREA Tables and Calculations 126
Summary 130
10 Risk Analysis Guided Project Management 131
Failure Mode Effects Analysis Methodology 131
Design Failure Mode Effects Analysis 132
Have an Experienced Facilitator Who Is Only Facilitating 132
The Facilitator Should Not Be the Scribe or "Spreadsheet Master" 132
Don't Let Conversations Go So Deep that 90% of the Room Is Just Listening Without Being Able to Contribute 133
Make a Scoring System that Is Meaningful, Not Standardized 133
The Scoring Is Comparative, Not Absolute 133
Reliability Design Risk Summary 134
The Objective of RDRS 134
Three Ranking Factors 135
Scoring and Evaluation 135
The Benefits of RDRS 136
Process Failure Mode Effects Analysis 136
Use Failure Mode Effects Analysis 136
Failure Reporting and Corrective Action System 137
Root Cause Analysis 138
Reaching a Wrong Conclusion 138
Reaching the Right Conclusion 138
The Stages of RCA 139
Brainstorming 140
Fundamentals of Brainstorming 140
Preparing for a Session 141
Select Participants 141
Draft a Background Memo 141
Create a List of Lead Questions 141
Three Simple Brainstorming Warm-ups 141
Setting Session Rules 142
Variations on Classic Brainstorming 142
Summary 143
References 144
11 The Reliability Program 145
Reliability Program Plan 145
Common Reliability Program Plan Pitfalls 146
The Plan Doesn't Account for a Broad Audience 146
Not Including Return on Investment (ROI) 146
Too Much 147
Too Little 147
Major Elements of a Reliability Program Plan 149
Purpose 149
Scope 150
Acronyms and Definitions 150
Product Description 151
Design for Reliability (DfR) 151
Reliability Goals 152
Use Case, Environment, Uptime 153
Recommended Tools by Program Phase 154
Design Risk Analysis 155
Failure Mode Effects Analysis (FMEA) 155
Reliability Allocation Model 157
Testing 159
Summary 166
12 Sustained Culture 167
Lasting Change 167
The Seven-stage Process 167
Summary 168
Index 171
