SIC Developing a Reliability Centre Culture (Reliability Program) Dr. Julio Pulido Director Global Reliability and Test Engineering

(1)

SIC 2008

Dr. Julio Pulido

Director Global Reliability and Test Engineering

Developing a Reliability Centre

Culture

(Reliability Program)

(2)

Acknowledgements

To the Global Reliability and Test

Engineering Team at Ingersoll Rand.

Without them…. there will not be any

success.

(3)

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Climate Control

Stationary

Refrigeration

Transport

Refrigeration

Service &

Aftermarket

Solutions

#1 Worldwide

in

refrigerated

trailers

#1 in remote

display cases –

N.A.

#1 N.A. service

provider

(4)

•

Systems are designed based on product Utilization profiles.

•

Refrigeration systems for applications on Trailer, Truck, Marine and

Air Transport.

(5)

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Agenda

z

Understanding the business

z

Reliability Planning

z

Testing Planning

z

How to built the program?

Elements of the program

Processes in the program

Training of the people

z

First 90 days

(6)

What is obvious?

z

Defining Customers requirements

z

Driving customer requirements in to the

product, service or solution.

z

Validation and Verification of customers

requirements

z

Measuring success

z

Having a learning organization

z

Ability to bring technologies and reliable

products to market faster than our competitors

z

Defining Customers requirements

z

Driving customer requirements in to the

product, service or solution.

z

Validation and Verification of customers

requirements

z

Measuring success

z

Having a learning organization

z

Ability to bring technologies and reliable

products to market faster than our competitors

We want a process that can be translated into customer loyalty

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Corporate Strategies

Must not be a Panacea

z

Concurrent Engineering

z

Six Sigma

z

Design for Six Sigma

z

Total Quality Management

z

Panacea Cycle

Idea relating to obvious

Cult (Gurus and

Followers).

o

Popular Acclaim

o

Disenchantment

o

Repudiation

(8)

Creating the process culture

Let’s define our strategy and culture

z

Are our products Reliable?

z

Do we use the right technology?

z

Do our products have the right

functionalities?

z

Can we deliver reliable products to the

market at the “right” speed?

How do we know?

Do our customers care?

How do we improved it ?

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How do we execute /implement

the program

z

We should nurture a learning process

z

The organization must be structure to support the

process

What are the roles of the different

organizations in the design process?

What are the expectations from the different

organizations?

Product Development is not an solely engineering activity…..

It is an organizational responsibility!

(10)

Let

’

s define Success

z

….develop and establish a disciplined approach in product design…..

allowing time to market… that is driven by the voice of the

customer…..improve product quality/reliability by reducing cost of

ownership….resulting into an increase market share

z

….develop and establish a disciplined approach in product design…..

allowing time to market… that is driven by the voice of the

customer…..improve product quality/reliability by reducing cost of

ownership….resulting into an increase market share

Three elements

a) Capture customer wants in a methodic way

b) The organization can translate wants to specifications

by validation and verification of specifications

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Impact of Reliability to IR

-

CC

(12)

Impact of Reliability to

our customers

(13)

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Business Environment

Influence of Globalization

z

Regarding Suppliers

We are moving from compliance to effectiveness.

Objective is not to audit conformance and compliance, but to

assess capability.

Keeping the product from becoming a commodity.

z

Regarding Product vs. Solutions Strategy

The entire development process must be considered

o

Is it a managed process?

o

Is process design incorporated or integrated with product

design?

o

What approaches to both process and product verification and

(14)

Supplier Engagement Program

Suppliers fully integrated into the development process

allows for faster learning process

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Barriers to Reliability Programs

z Internal and external to the organization Resistance to change

Lack of knowledge in Reliability Inadequate training

Management does not support the process Capital resources aren’t there

No adequate staff to work on issues Goals not well defined

No adequate time to address the issue Time to Market

Product development cost Competitors do not do it! No local test facilities

No local experts; Corporation is devoid true leadership A consisted culture is not ingrained in the organization Processes are not object-oriented but completion-oriented. Lack of focus on excellence

Pursuit of the latest panacea

(16)

In the future, as the organization matures,

Minimum Reliability Metrics

z

1) Warranty as % of sales

Good starting point

Correlates cost of quality to revenue Affected by currency fluctuations Affected by Operational Actions

z

2) % of Claims per unit manufacture

The organization has a better knowledge of product reliability Relates directly to customer perception

Correlates to cost of quality

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Results _ Achieved with the

program

_{Values are modified}

Metrics help to define the Strategy

(18)

Forecasting of Future Warranty

z

Makes sense for the following reasons

Cost avoidance of field issues

Prediction of required warranty reserves

Spare Part management

z

Models Used

Nature of product

o

Reparable Vs Non Reparable

Warranty coverage

o

Full vs Limited

Replacement Policy

o

Full vs limited

Replacement Policy

o Pro-rata vs free

Warranty Dimension

(19)

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Processes and analysis need to

be value added

(20)

Reliability Program Strategic

Objectives

z

Reduce the development cycle

Developing product operational profiles Defining product operational environments

Identification of opportunities in product Warranty Component accelerated life testing

Potential failure mode identification and control Analysis and testing capabilities worldwide

z

Reduce Life Cycle Cost

Reduce product failure during Warranty period

Reduce customer operational cost (life cycle cost minimization)

o

Maximize expected component life

o

Minimize repair time

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People Capabilities

We should treat every action as an opportunity for learning – about

what to do but also, more important, about how to think

(22)

Reliability Engineering Vision

Statement

To provide a product failure-free

experience to the end costumer

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Reliability Engineering Mission

Statement

The Reliability Engineering team derives,

verifies and validates Ingersoll-Rand

Climate Control product life

requirements through reliability

analysis, prototyping and testing.

(24)

Reliability Engineering Strategy

(25)

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System Reliability Strategy

(26)

Development Process _ Best

Practices Benchmarks (TOOLS)

Phase 1 Business Opportunity Phase 2 Concept Feasibility Phase 3 Design & Planning Phase 4 Product Test Process Design Phase 5 Implementation, Verification Phase 6 Launch & Production Voice of the Customer Kano Analysis Klein Analysis QFD Factor Analysis Customer Research Competitor Benchmarking Lessons Learned Requirements Analysis QFD Functionality Map DFMEA Screening DOE TRIZ RBD Pugh Concept Selection PFMEA Modeling, Simulation FEA CFD Statistical Analysis Design Scorecard Design for X Robust Design DFMEA, Maintainability Reliability Modeling (FTA, RBD, Markov) DOE Measurement System Evaluation Design Scorecard HALT, HASS, ESS, SST, ALT Robust Optimization Mfg. Process Map Design Scorecard Numerical Evaluation of Methods Customer Satisfaction (VOC) Control Plan Lessons

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Creating a a

“

Signature Process

”

Process Established

Deployment

Process

Functionality

alignment

Learning

BEGINNIN

G

(28)

Reliability Centered Culture

z

DFSS methodology is

oriented to avoid problems

by eliminating issues that

can occur.

Primary goal is to eliminate manufacturing defects

z

Design for Reliability (DFR)

process oriented to

generate product with long

term specific reliability

levels.

Oriented to reduce issues due to customer’s product

utilization levels.

z

Reliability Centered Culture

(RCC) drives the

organization through

solutions leadership to

warrant solutions with high

availability to customers.

Use reliability concepts to help select innovations that will drive higher product availability

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The concept

The Strategic Approach

z

Design for Reliability

Starts with the Idea phase of the

product development cycle.

Uses physics-of-failure

techniques to design out

potential problems

z

Reliability Verification

Test ensures meeting customer’s

reliability objectives\

o

Process Reliability

o

Design Maturity Testing

z

Analytical Physics

Collects knowledge about

product physics of failure

o

Understanding how customer

use affects product performance

o

Understanding environmental

(30)

Design Assessment

z

The goal is to identify any potential

failure modes that are inherent in a

design early in the design process.

Analytical Tools

Involvement of the entire team in

evaluation and planning (DFMEA,

Hazard Analysis, HALT, ESS).

z

Performed at system or subsystem

level to component level.

Stress levels must simulate

environmental application and

stress level of usage.

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Development Phase

z

Demonstrate

level of product

Reliability

z

Provide

statistical

significant Test

Plans (Balance

Reliability with

add-on cost)

z

Provide plan to

guide Test

Engineers

(32)

Product

Reliability Cycle

We can reduce our exposure during product launch using Reliability

Techniques.

Improve customer’s product availability by using Reliability Centered Maintenance

Techniques and designing Maintainability into the product

We can accelerate our development process (internal and suppliers) by creating technically sound validation

processes (ALT) and Robust Design Techniques

Reliability Techniques can be used to develop EXPERT/ SMART

Systems. Defining critical design variables, we

can help manufacturing in controlling Quality.

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The Building Blocks

FRACAS Warranty Analysis (opportunities) (Projects / PIP) Audit Program Q &R Field Test support

Service Repair Metrics (MTTR, System Availability)

Periodic Customers Surveys (30, 90 and 180

days)

Maintainability and PM requirements Tracking of Field

Failure Modes (Database)

(34)

Reliability and Test Strategy

z

Testing of lower-level components and sub-assemblies is less

expensive and can be more effective in exploring the limitations

of the design than testing at the level of the complete system

z

Leverage regional test equipment and capabilities to support

global product development, productivity and sourcing initiatives

z

Develop component, sub-system and system test parameters for

accelerated life testing based on operational profiles

z

Develop product operational profiles to identify and control

potential failure modes

z

Reduce customer operational costs by maximizing component

expected life

(35)

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(36)

Product Development Process

(NPD)

z

Reliability process needs to be fully integrated.

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Project scope based on

Risk

(38)

Development Tasks

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TEST ENGINEERING STANDARD

OPERATING PROCEDURE (TESOP)

(40)

Knowledge based Product

Development

z

Knowledge Based product Development

Test First and then Design

Customer Interest in Engineering job not only

sales and Marketing

Capture the knowledge develop during the

process

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Reliability Analysis

(42)

Non destructive Evaluations

Non destructive testing

z

Equipment is high fidelity

Modal

Radiography

Ultrasonic

Etc…

z

History of applications

Health Monitoring

z

Integrated sensing

z

Equipment with less fidelity.

z

Less subjective

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Health Monitoring

z

Commercial

applications are

driving the need for

health monitoring

technology.

Reliability

Centered

Maintenance

(Condition-based

maintenance)

z

Monitoring is based

on customer product

utilization.

(44)

Design Based on Historical Data

(45)

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Analysis vs. Testing

z Analytical tools guide the testing optimization

process.

z Optimization analysis

improve the cost and speed of the development

process.

z Improve Testing effectiveness using

Accelerated life testing or Stress Step Testing, Highly Accelerated Stress

Screening

z Electronic DOE using Monte Carlo Simulation

(46)

How to Start?... First 90 Days

z Promote Yourself

Make a mental break from your old job

z Accelerate Your learning

Markets, products, technologies, systems, structures

z Match Strategy to situation

Challenges and Opportunities

z Secure early wins

ID opportunities and Create Value

z Negotiate Success

Productive Working relationship

z Achieve Alignment

Organizational Architect

Your organization in alignment with peers organizations.

z Build your team

Right and Smart people

Smarter than you!!... Engagement and Empowerment.. It is ok to make mistakes

z Create coalitions

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Biographical Sketch

z

Julio Pulido, Ph.D., MSc, MBA

Director Global Reliability and Test Engineering

He is responsible for Reliability and Test activities at IR – CC (Thermo

King, Hussman, Krack and Koxka) engineering laboratories around the

Globe. The test capabilities are oriented to R&D Activities,

Development Testing, and Product Reliability validation.

Dr. Pulido is also responsible for implementing the Reliability

Engineering program at IR – Climate Control and insuring regulatory

and compliance requirements for Climate Control products.

(48)

Thank You