Cover image for World class reliability : using Multiple Environment Overstress Tests to make it happen
Title:
World class reliability : using Multiple Environment Overstress Tests to make it happen
Author:
Bhote, Keki R., 1925-2013.
Personal Author:
Publication Information:
American Management Association : New York, [2004]

©2004
Physical Description:
xix, 218 pages : illustrations; 24 cm
Language:
English
Added Author:
ISBN:
9780814407929
Format :
Book

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Summary

Summary

"Six Sigma has been a giant in the quality movement but has been a pygmy in improving field reliability, i.e., reducing failure rates for customers. Traditional reliability techniques are woefully inadequate and produce fictitious reliability numbers.

World Class Reliability , by contrast, presents a powerful technique to improve reliability by factors of 10:1 and even 100:1. It is Multiple Environment Overstress Tests (MEOST), used by NASA on its famous Lunar Module. Field failures that are found, traditionally, only after months of field exposure can now be ""smoked out"" in hours in the design laboratory and rapidly corrected; MEOST achieves this by combining several stresses and taking them beyond design stress very, very rapidly.

The result: fantastic reliability improvements; much reduced design cost, manpower, and cycle time; speed to market well ahead of competition; customer loyalty and dramatic profit enhancements for corporations."


Author Notes

Keki R. Bhote (Glencoe, IL) is president of Keki R. Bhote Associates, a consulting group specializing in quality and productivity improvement.

050


Table of Contents

List of Figuresp. xi
List of Tablesp. xiii
Prefacep. xv
Prologuep. 1
Part I The Challenge for Industry: Regaining Lost Profitsp. 9
1 Corporate Paradise Lost and Regained
The Ten Gold Nuggets for a Dramatic Profit Increasep. 11
The Alphabet Economyp. 11
Business Management--The Bete Noire, the Culpritp. 12
The Ten Gold Nuggets to Make Profits Soarp. 14
2 A Breakthrough in Reliability--The Need
Objectives, and Benefitsp. 27
The Compelling Need for Reliabilityp. 27
Causes for Poor Reliabilityp. 33
The Reach-Out Objectives of True Reliabilityp. 35
The Overwhelming, Tangible Benefits of True Reliabilityp. 36
The Future Direction for Reliabilityp. 37
An Organizational Infrastructure for World-Class Reliabilityp. 38
Part II What Not to Do: Current but Ineffective Reliability Methodologiesp. 43
3 Reliability Mathematics--Complex and Ineffectivep. 45
The Bathtub Curve Does Not Hold Water!p. 45
The Convoluted Logic of Military Testingp. 47
The Futility of Reliability Mathematicsp. 47
The Computer Approach to Reliabilityp. 52
Reliability Failure Distributionsp. 52
Graphical Solutions Using Weibull Plotsp. 54
Main Weaknesses of Mathematical Approaches to Reliabilityp. 57
4 Reliability Predictors--Cooking the Books with
Reliability Cookbooksp. 59
A Plethora of Reliability Cookbooksp. 59
Reasons for Inaccuracies Among the Handbooksp. 61
A Company's Own Field History--A Better Predictorp. 63
5 Reliability Estimators--A Cloudy Crystal Ballp. 65
Failure Mode and Effects Analysis (FMEA)p. 66
Fault Tree Analysis (FTA)p. 71
6 Reliability Demonstration--Throwing Money at the Problemp. 75
An Evolution in Reliability Demonstrationp. 75
Thermal Cycling: The Dawn of True Reliability Progressp. 78
Single Environment Sequential Tests: Another False Startp. 84
7 Highly Accelerated Life Tests--HALT and HASSp. 87
HALT Backgroundp. 87
HALT Methodologyp. 88
Highly Accelerated Stress Screening (HASS)p. 90
Other Environmental Stress Screening (ESS)p. 92
Highly Accelerated Stress Audit (HASA)p. 93
Part III The Climb to MEOST: The Mount Everest of Reliabilityp. 95
8 Base Camp 1--Design Reliability Infrastructure Design: The Bete Noire of a Company's Failuresp. 97
1. Organization of the Design Functionp. 98
2. Management Guidelinesp. 100
3. Techniques to Capture the Voice of the Customerp. 106
4. Quality, Cost, and Cycle Time in Designp. 116
5. Creativity Stimulation: Releasing the Engineer's Bottled-Up, Creative Geniep. 119
9 Base Camp 2--Essential Prerequisites for MEOSTp. 123
1. Derating: Oxygen for the Climb to MEOSTp. 123
2. Temperature: The Enemy of Reliabilityp. 130
3. Modular Designsp. 130
4. Design for Manufacturability (DFM)p. 131
5. Design for Mistake Proofing: Poka-Yokep. 132
6. Design for Minimum Variability (High C[subscript pk])p. 133
7. Design for Robustness: High S/N Ratiop. 134
8. Design for Maintainability and Availabilityp. 136
9. Design for Resale (Residual) Valuep. 137
10. Product Liability Analysis: Preventing Ambulance Chasingp. 138
11. Destructive Physical Analysis (DPA)p. 144
12. Field Escape Controlp. 146
13. Mini-MEOST Sampling in Productionp. 147
14. Dealer Feedback and Zero Time Failuresp. 148
15. Field Failure Reliabilityp. 149
10 The Climb to the Mount Everest of Reliability--MEOSTp. 155
The Salient Principles of MEOSTp. 155
MEOST History, Applications, Successesp. 159
Types of Stresses: Combined vs. Isolated Stressesp. 162
Preamble and Preparations for MEOSTp. 166
The Eight Stages of MEOSTp. 174
11 The Amazing Versatility of MEOST--New Applications and Challengesp. 191
The Economic Benefits of MEOSTp. 191
The Many Uses of MEOST--Its Commandeering of Many Disciplinesp. 194
Appendix Laboratory Equipment/Chambers for MEOSTp. 203
Referencesp. 209
Indexp. 211