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Quality Control Management

Improving Product Reliability: Strategies and Implementation by Mark A. Levin, Ted T. Kalal

By Mark A. Levin, Ted T. Kalal

The layout and manufacture of trustworthy items is a massive problem for engineers and bosses. This publication fingers technical managers and engineers with the instruments to compete successfully during the layout and construction of trustworthy know-how items.

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Additional info for Improving Product Reliability: Strategies and Implementation (Quality and Reliability Engineering Series)

Sample text

Products are transported to fail. Assemblies arrive at the customer’s destination only to be found inoperative because something broke during shipment. This is often a function of shipping cartons or crates that were not designed to stand the stress of shipping shock and vibration. The shipping carton can be a major cost item in the whole cost picture of a product. Sometimes, manufacturers save on these costs only to suffer even greater losses from returned goods from the customer. Manufacturers should require that the shipping carton be part of the total design effort.

This phenomenon is similar to that of a long-term investment in a retirement account. In the beginning, the retirement investment is small and the amount routinely contributed does not appear to bring you any closer to that final goal. However, over time this amount becomes significant as it begins to grow exponentially. The same effect will be seen within the company once the organization begins to see the benefits of reliability. The internal barriers are the most difficult to overcome in implementing an effective reliability program.

For example, a large and expensive industrial product requires a high amount of airflow to cool the machine. When the fan stops working, the machine fails. In this example, a 20-dollar fan caused a multimillion-dollar system to stop producing products. The failure results in your customer having a complete production shutdown with significant unrecoverable dollar losses to the business. Design engineers should know this and expect it to happen because fan manufacturers specify fan-life expectancies.

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