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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: * 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.

Reliability Culture: How Leaders Build Organizations that Create Reliable Products

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