World Class Reliability: Using Multiple Environment Overstress Tests to Make it Happen / Edition 1

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Overview

"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."

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Product Details

  • ISBN-13: 9780814407929
  • Publisher: AMACOM Books
  • Publication date: 3/19/2004
  • Edition number: 1
  • Pages: 224
  • Product dimensions: 5.90 (w) x 9.10 (h) x 1.00 (d)

Meet the Author

Keki Bhote (Glencoe, IL), one of the creators of Motorola’s Six Sigma, is President of Keki R. Bhote Associates, a company specializing in quality, reliability, and profit improvement. He is the author of 17 books, including The Power of Ultimate Six Sigma. Adi Bhote (Glencoe, IL), a 13-year Motorola veteran, is Vice President of Keki R. Bhote Associates. Keki Bhote and Adi Bhote are the coauthors of World Class Quality.

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Table of Contents

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 Bête Noire, The Culprit
The Ten Gold Nuggets to Make Profits Soar
2 A Breakthrough in Reliability-The Need, Objectives, and Benefits
The Compelling Need for Reliability
Causes of Poor Reliability
The Reach-Out Objectives of True Reliability
The Overwhelming, Tangible Benefits of True Reliability
The Future Direction for Reliability 000
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 Mathematical 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 Bête Noire of a Company's Failures
1. Organization of the Design Function
2. Management Guidelines
3. Techniques to Capture the Voice of the Customer
4. Quality, Cost, and Cycle Time in Design
5. Creativity Stimulation: Releasing the Engineer's Bottled-Up, Creative Genie
9 Base Camp 2--Essential Prerequisites for MEOST
1. Derating: Oxygen for the Climb to MEOST
2. Temperature: The Enemy of Reliability
3. Modular Designs
4. Design for Manufacturability (DFM)
5. Design for Mistake Proofing: Poka-Yoke
6. Design for Minimum Variability (High Cpk)
7. Design for Robustness: High S/N Ratio
8. Design for Maintainability and Availability
9. Design for Resale (Residual) Value
10. Product Liability Analysis: Preventing Ambulance Chasing
11. Destructive Physical Analysis (DPA)
12. Field Escape Control
13. Mini-MEOST Sampling in Production
14. Dealer Feedback and Zero Time Failures
15. 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
The Economic Benefits of MEOST
The Many Uses of MEOST-Its Commandeering of Many Disciplines
Appendix: Laboratory Equipment/Chambers for MEOST
References
Index
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