TY - BOOK AU - Bahret,Adam P. TI - Reliability culture: how leaders can create organizations that create reliable products T2 - Quality and reliability engineering series SN - 9781119612438 AV - TS156 U1 - 620/.00452 23 PY - 2021/// CY - Hoboken, NJ, USA PB - Wiley KW - Quality control KW - Reliability (Engineering) KW - Corporate culture KW - Leadership KW - Electronic books N1 - Includes bibliographical references and index; Table of Contents 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 N2 - "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"-- UR - https://onlinelibrary.wiley.com/doi/book/10.1002/9781119612483 ER -