World Class Reliability (Bhote)

Table of Contents

Prologue

Part I The Challenge for Industry: Regaining Lost Profits

1. Corporate Paradise Lost and Regained

• The Ten Gold Nuggets for a Dramatic Profit Increase

• The Alphabet Economy

• Business Management - The Bete Noire, the Culprit

• The Ten Gold Nuggets to Make Profits Soar

2. A Breakthrough in Reliability-The Need, Objectives, and Benefits

• Objectives, and Benefits

• The Compelling Need for Reliability

• Causes for Poor Reliability

• The Reach-Out Objectives of True Reliability

• The Overwhelming, Tangible Benefits of True Reliability

• The Future Direction for Reliability

• An Organizational Infrastructure for World-Class Reliability

Part II What Not to do: Current but Ineffective Reliability Methodologies

3. Reliability Mathematics-Complex and Ineffective

• The Bathtub Curve Does Not Hold Water

• The Convoluted Logic of Military Testing

• The Futility of Reliability Mathematics

• The Computer Approach to Reliability

• Reliability Failure Distributions

• Graphical Solutions Using Weibull Plots

• Main Weaknesses of Mathematics Approaches to Reliability

4. Reliability Predictors-Cooking the Books with Reliability Cookbooks

• A Plethora of Reliability Cookbooks

• Reasons for Inaccuracies Among the Handbooks

• A Company's Own Field History - A Better Predictor

5. Reliability Estimators-A Cloudy Crystal Ball

• Failure Mode and Effects Analysis (FMEA)

• Fault Tree Analysis (FTA)

6. Reliability Demonstration-Throwing Money at the Problem

• An Evolution in Reliability Demonstration

• Thermal Cycling: The Dawn of True Reliability Progress

• Single Environment Sequential Tests: Another False Start

7. Highly Accelerated Life Tests-HALT and HASS

• HALT Background

• HALT Methodology

• Highly Accelerated Stress Screening (HASS)

• Other Environmental Stress Screening (ESS)

• Highly Accelerated Stress Audit (HASA)

Part III The Climb to MEOST: The Mount Everest of Reliability

8. Base Camp 1-Design Reliability Infrastructure Design: The Bete Noir of a Company's Failures

• Organization of the Design Function

• Management Guidelines

• Techniques to Capture the Voice of the Customer

• Quality, Cost, and Cycle Time in Design

• Creativity Stimulation: Releasing the Engineer's Bottled-Up, Creative Genie

9. Base Camp 2-Essential Prerequisites for MEOST

• Derating: Oxygen for the Climb to MEOST

• Temperature: The Enemy of Reliability

• Modular Designs

• Design for Manufacturability (DFM)

• Design for Mistake Proofing: Poka-Yoke

• Design for Minimum Variability (High Cpk)

• Design for Robustness: High S/N Ratio

• Design for Maintainability and Availability

• Design for Resale (Residual) Value

• Product Liability Analysis: Preventing Ambulance Chasing

• Destructive Physical Analysis (DPA)

• Field Escape Control

• Mini-MEOST Sampling in Production

• Dealer Feedback and Zero Time Failures

• Field Failure Reliability

10. The Climb to the Mount Everest of Reliability - MEOST

• The Salient Principles of MEOST

• MEOST History, Applications, Successes

• Types of Stresses: Combined vs. Isolated Stresses

• Preamble and Preparations for MEOST

• The Eight Stages of MEOST

11. The Amazing Versatility of MEOST - New Applications and Challenges

• Applications and Challenges

• The Economic Benefits of MEOST

• The Many Uses of MEOST - Its Commandeering of Many Disciplines

Appendix: Laboratory Equipment / Chambers for MEOST

References

Index