How Reliable is Your Product?

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Happy About, Jan 1, 2012
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Traditionally, the way to test a product's reliability was to build it--and then try to break it. As systems and technologies improved, TAAF (Test, Analyze and Fix) methodologies were developed and adopted. In today's global economy, with its short, technologically-intense product life cycles, TAAF cannot suffice. Reliability can no longer be a step or a series of steps in product development; it is something that needs to be acknowledged up front and built into the product from its very conception. Reliability, in other words, must be 'designed in.'

Product developers now have many tools--software and hardware--at their disposal for building reliability in from the get go. From the organizational point of view, what better way to design in reliability than to make designers themselves responsible for the reliability of their designs? As "Mike Silverman" explains in "How Reliable is Your Product?," this is why the role of the reliability engineer is changing to one of mentor. Product developers are now responsible for going out and finding the best testing tools and then training the designers on their use, so that designers factor and build in reliability at every stage of product design.

Mike has focused on reliability throughout his 25-year career, and has observed the position of reliability in the organization evolve. In this book, he condenses his expertise and experience into a volume of immense practical worth to the engineering and engineering management communities including designers, manufacturing engineers and reliability/quality engineers.

Among other things, Mike discusses how reliability fits, or should fit, within the product design cycle. He provides a high-level overview of reliability techniques available to engineers today. He lucidly discusses the design of experiments and the role of failure management. With case studies and narratives from personal experience, Mike discusses optimal ways to utilize different reliability techniques. He highlights common errors of judgment, missteps and sub-optimal decisions that are often made within organizations on the path to total reliability.

With"How Reliable is Your Product?" "Mike Silverman" has delivered what few have done before--a comprehensive yet succinct overview of the field of reliability engineering and testing. Engineers and engineering managers will find much in this book of immediate, practical value.

 

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Contents

Software Reliability No This Isnt an Oxymoron
205
Prototype Phase
215
Write a Comprehensive Test Plan Dont Just Test to Specs
216
You Cant Start Testing Too Early
220
HALT Who Goes There?
226
Demonstrate Your Reliability
247
Accelerated Life Test ALT for Those LifeLimiting Failures
256
HALT versus ALTWhen to Use Each Technique
266

Goals Arent Just for Soccer and Hockey
41
Benchmark against Your Competition
46
A Gap Analysis Will Tell You Where to Focus Early
52
Metrics The Are We There Yet? Technique
54
Break the System Up into Blocks
62
Golden Nuggets Are the Golden Rule
69
You Need a Plan
72
Design Phase
83
The Precious Diamond of Product Development
84
It Is All a Balancing Act
88
New Technologies Bring New Risks
93
Think How Your Product Will Fail The FMEA Technique
96
FacilitationThe Key to a Productive Business Session
118
A Good Kind of FaultFTA
125
FMEA Should Be Used to Drive Testing
129
Reliability During Component Selection
135
PredictionsBetter Than a Crystal Ball
140
Thermal Analysis and Reliability the Hottest Couple in Town
150
If You Want Your Design to Rate Youd Better Derate
154
Why Do Products Fail?A Physics of Failure Approach
159
You Should Design Your Experiments WiselyThe Magic of DOE
162
Dont Tolerate Tolerance Issues
173
Preventing Failures before They Happen
177
What Happens When Your Product Reaches Its End of Life?
185
Think About Warranty Now
189
Infinite Possibilities with FEA
201
HALTtoAFR Calculator
276
The Difference between Fixing Failures and Taking Failures to Root Cause
287
The Corrective Action System The Backbone of a Good RCA
297
Manufacturing Phase
301
Assess Your Vendors as You Assess Your Own Organization
302
Outsourcing versus InHouse Designing and Manufacturing
305
All Screens Werent Created EqualThe Importance of HASS
313
Manufacturing Metrics with ORT
336
OutofBox Auditing Can Catch the Easy Mistakes
342
Lessons Learned Sounds Like School Only Much Better
346
Lets Take a Look at Our Warranty Returns
351
Management Needs a Report
356
StatisticsMore Than a FourLetter Word
361
When Faced With Obsolete Parts Turn To EDA
365
Summary
369
Recap of Book
370
Software Reliability Growth
375
Summary of HALT Results at a HALT Lab
381
References
391
Glossary of Terms
392
Acronyms
401
About the Author
410
Other Happy About Books
412
A Message from Happy About
414
Back Cover
415

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