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

Transcription

1 SIC 2008 Developing a Reliability Centre Culture (Reliability Program) Dr. Julio Pulido Director Global Reliability and Test Engineering

2 Acknowledgements To the Global Reliability and Test Engineering Team at Ingersoll Rand. Without them. there will not be any success. 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 2 2

3 Climate Control #1 Worldwide in refrigerated trailers #1 in remote display cases N.A. #1 N.A. service provider Transport Refrigeration Stationary Refrigeration Service & Aftermarket Solutions 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 3 3

4 Systems are designed based on product Utilization profiles. Refrigeration systems for applications on Trailer, Truck, Marine and Air Transport. Refrigeration control up to 0.5F 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 4 4

5 Agenda Understanding the business Reliability Planning Testing Planning How to built the program? Elements of the program Processes in the program Training of the people First 90 days 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 5 5

6 What is obvious? Defining Customers requirements Driving customer requirements in to the product, service or solution. Validation and Verification of customers requirements Measuring success Having a learning organization Ability to bring technologies and reliable products to market faster than our competitors We want a process that can be translated into customer loyalty 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 6 6

7 Corporate Strategies Must not be a Panacea Concurrent Engineering Six Sigma Design for Six Sigma Total Quality Management Panacea Cycle Idea relating to obvious Cult (Gurus and Followers). o o o o Popular Acclaim Disenchantment Repudiation Refined Acceptance 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 7 7

8 Creating the process culture Are our products Reliable? Do we use the right technology? Do our products have the right functionalities? 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? How do we measured? Let s define our strategy and culture 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 8 8

9 How do we execute /implement the program We should nurture a learning process 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! 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 9 9

10 Let s s define Success.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 a) Process drives customer Loyalty 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 10 10

11 Impact of Reliability to IR - CC Highest reliability is not the most economical 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 11 11

12 Impact of Reliability to our customers Best reliability is defined by customer 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 12 12

13 Business Environment Influence of Globalization 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. Regarding Product vs. Solutions Strategy The entire development process must be considered o o o Is it a managed process? Is process design incorporated or integrated with product design? What approaches to both process and product verification and validation are employed? 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 13 13

14 Supplier Engagement Program Suppliers fully integrated into the development process allows for faster learning process 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 14 14

15 Barriers to Reliability Programs 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 Leadership do not live with their implementations 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 15 15

16 Minimum Reliability Metrics 1) Warranty as % of sales Good starting point Correlates cost of quality to revenue Affected by currency fluctuations Affected by Operational Actions 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 Not affected by currency fluctuations and operational actions In the future, as the organization matures, it should move to a Reliability Allocation goal. 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 16 16

17 Results _ Achieved with the program Values are modified Metrics help to define the Strategy Note: Relative Data _ No actual 6 Simpósio Internacional de Confiabilidade - SIC 2008 Developing a Reliability Centre Culture 17 17

18 Forecasting of Future Warranty Makes sense for the following reasons Cost avoidance of field issues Prediction of required warranty reserves Spare Part management 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 o Univariate vs bivariate (Time and stress level based) 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 18 18

19 Processes and analysis need to be value added Is not what you do but. how you do it? 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 19 19

20 Reliability Program Strategic Objectives 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 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 o Maximize Customer's Product Availability 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 20 20

21 People Capabilities We should treat every action as an opportunity for learning about what to do but also, more important, about how to think 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 21 21

22 Reliability Engineering Vision Statement To provide a product failure-free experience to the end costumer 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 22 22

23 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. 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 23 23

24 Reliability Engineering Strategy 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 24 24

25 System Reliability Strategy Products Service Solutions 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 25 25

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 (SPC) Customer Satisfaction (VOC) Control Plan Lessons Learned 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 26 26

27 Creating a a Signature Process BEGINNIN G Process Established IMPROVING Process Deployment SUCCEEDING Functionality alignment LEADING Learning 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 27 27

28 Reliability Centered Culture DFSS methodology is oriented to avoid problems by eliminating issues that can occur. Primary goal is to eliminate manufacturing defects 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. 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 and utilization levels 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 28 28

29 The concept The Strategic Approach Design for Reliability Starts with the Idea phase of the product development cycle. Uses physics-of-failure techniques to design out potential problems Reliability Verification Test ensures meeting customer s reliability objectives\ o o Process Reliability Design Maturity Testing Analytical Physics Collects knowledge about product physics of failure o o Understanding how customer use affects product performance Understanding environmental conditions 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 29 29

30 Design Assessment 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). Performed at system or subsystem level to component level. Stress levels must simulate environmental application and stress level of usage. 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 30 30

31 Development Phase Demonstrate level of product Reliability Provide statistical significant Test Plans (Balance Reliability with add-on cost) Provide plan to guide Test Engineers 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 31 31

32 Product Reliability Cycle We can accelerate our development process (internal and suppliers) by creating technically sound validation processes (ALT) and Robust Design Techniques Defining critical design variables, we can help manufacturing in controlling Quality. Reliability Techniques can be used to develop EXPERT/ SMART Systems. 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 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 32 32

33 The Building Blocks CUSTOMER Field Test support Warranty Analysis (opportunities) (Projects / PIP) Tracking of Field Failure Modes (Database) Periodic Customers Surveys (30, 90 and 180 days) Audit Program Q &R Maintainability and PM requirements Service Repair Metrics (MTTR, System Availability) FRACAS 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra

34 Reliability and Test Strategy 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 Leverage regional test equipment and capabilities to support global product development, productivity and sourcing initiatives Develop component, sub-system and system test parameters for accelerated life testing based on operational profiles Develop product operational profiles to identify and control potential failure modes Reduce customer operational costs by maximizing component expected life 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 34 34

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36 Product Development Process (NPD) Reliability process needs to be fully integrated. Process needs to be flexible to manage change in market needs. 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 36 36

37 Project scope based on Risk 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 37 37

38 Development Tasks 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 38 38

39 TEST ENGINEERING STANDARD OPERATING PROCEDURE (TESOP) Plan Test Conclude 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 39 39

40 Knowledge based Product Development 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 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 40 40

41 Reliability Analysis You improve product reliability via analysis and verified via testing 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 41 41

42 Non destructive Evaluations Non destructive testing Equipment is high fidelity Modal Radiography Ultrasonic Etc History of applications Health Monitoring Integrated sensing Equipment with less fidelity. Less subjective 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 42 42

43 Health Monitoring Commercial applications are driving the need for health monitoring technology. Reliability Centered Maintenance (Condition-based maintenance) Monitoring is based on customer product utilization. 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 43 43

44 Design Based on Historical Data 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 44 44

45 Analysis vs. Testing Analytical tools guide the testing optimization process. Optimization analysis improve the cost and speed of the development process. Improve Testing effectiveness using Accelerated life testing or Stress Step Testing, Highly Accelerated Stress Screening Electronic DOE using Monte Carlo Simulation 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 45 45

46 How to Start?... First 90 Days Promote Yourself Make a mental break from your old job Accelerate Your learning Markets, products, technologies, systems, structures Match Strategy to situation Challenges and Opportunities Secure early wins ID opportunities and Create Value Negotiate Success Productive Working relationship Achieve Alignment Organizational Architect Your organization in alignment with peers organizations. Build your team Right and Smart people Smarter than you!!... Engagement and Empowerment.. It is ok to make mistakes Create coalitions Influence people 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 46 46

47 Biographical Sketch 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. 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 47 47

48 Thank You 6 Simpósio Internacional de Confiabilidade - SIC 2008 Título da Palestra 48 48