TOP EVENTS:Print Version

Fall 2011

Ops A La Carte LLC
Ph:
(408) 654-0499
Website: www.opsalacarte.com

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Theme for this newsletter:
What Is and What Is Not DfR?

 


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IN THIS ISSUE
COURSES/SEMINARS - PRG Cert Prog, CQE, Free Webinars
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EVENTS - PRG BBQ, MD&M, Colo Tech L&L, ASTR, ASQ
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SPECIAL OFFERS - One Hour of Free Consulting, Self Assessment
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NEWS - OPS in your area, HALT Calc, Book Interview, OH
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FEATURED SERVICE - What Is and What Is Not DfR?
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RELIABILITY BLOG - Highlights of Last Quarter's Blogs
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PROBLEM SOLVER - Simulation
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PARTNER'S CORNER - BE Analytic, MGBS, MU Sigma
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JOB OPENINGS - Ops A La Carte, Enecsys, Murata

MESSAGE FROM THE FOUNDER

Welcome to our 27th quarterly newsletter. Our newsletter comes out the first week of March, June, September, and December. Comments and suggestions are always welcome.

This quarter, I will be traveling around the US and the world giving seminars and visiting with clients. I will be visiting Boston, New Jersey, San Diego, Denver, Milwaukee, Chicago, Minneapolis, Australia, and India. See news for exact dates. Whenever OPS visits a city, we offer 1 hour of free consultation to help you with any aspect of your reliability program. See Special Offers section for details.

We just received a great endorsement for our HALT Calculator from our client Enecsys. We recently added more data to the model and more is still needed. If you have HALT data with corresponding field data, please contact us. Anyone that contributes data to our tool gets free use of it. We are working on a cloud based version of the tool that will be released prior to ASTR.

In August, we started the semi-annual Certified Reliability Engineer (CRE) Certificate course. We have been teaching this course twice a year for 14 straight years. Four years ago, we started teaching the course via webinar and now the webinar attendees outnumber the live attendees.

Also in August, I was interviewed on BlogTalkRadio for my new book. Host Wayne Hurlbert also gave a great review for my book "How Reliable Is Your Product: 50 Ways to Improve Product Reliability".

In June, we presented at both the Applied Reliability Symposium (ARS) as well as the Prognostics and Health Management (PHM) Conference. In June, I also gave a one day course on Medical Reliability Testing at MD&M East. I will be giving the same seminar at MD&M Chicago on Sept 22 and MD&M Minneapolis on Nov 2.

Also in June, we held our annual Open House to over 100 visitors. This was our biggest open house in our 10 year history, which is fitting because the open house was in honor of our 10 year anniversary along with our partnership with Chart. The event was co-sponsored by the IEEE CPMT & Reliability Society. Pictures

Our Free Webinars are getting an increasing number of attendees. Last quarter, we held free webinars on Design for Six Sigma and Prognostics. This next quarter we will be holding a webinar on Integrating Simulation with Reliability and a webinar on Solar Reliability. The webinars are held once a month.

We hope you enjoy the following newsletter. Our next newsletter will come out the first week of December. Thank you for your continued support and interest.

- Mike Silverman, Managing Partner/Founder

COURSES

 Product Realization Group (PRG) Certification Program 
Date(s): Tuesday, September 27, 2011 to Tuesday, November 29, 2011
Time: 6pm-8pm two nights a week (Tues/Thurs) for 10 weeks
Instructor: 5 different modules, 5 different PRG instructors
Length: 10 weeks
Cost: $995.
Location: Foothill College, Los Altos, CA

Class Dates
PRC-01: Engineering Development Sept. 27th
PRC-02: Product Reliability Oct. 11th
PRC-03: Data Mgmt. & Collaboration Oct. 25th
PRC-04: Supply Chain Management Nov. 8th
PRC-05: Business Compliance Nov. 29th

You can grow the knowledge and skills of your people by providing the following learning experience - Benefits to Participants:

  • What is the Product Realization Process?
  • How to effectively bring new products to market?
  • What are the tools for collaboration and team based development?
  • Learn Current Best Practices
  • Gain Continuing Educational Units (CEU’s)
For more information on schedule and program specific content see the website www.productrealizationgroup.com

2011 Free monthly Webinar Series

About Event: Each month, we will bring you a free webinar topic. Below is our current line-up for the remainder of 2011. You can click on the registration page for each event.

Tuesday Oct 11th, 11:30am-12:30pm PST- Integrating Simulation into a Reliability Program, by Ops A La Carte and Tribal Engineering. Simulation and testing often go together as part of a strong reliability program. Finite element simulation provides data and insights that would be difficult or impossible to obtain from testing alone. Simulation gives results for all components, including those that are inaccessible, and over a wide range of conditions. The results from simulation can be critical parts of accelerated life test programs such as HALT and ALT. In this seminar, we will show you techniques to integrate these tools into a reliability program to optimize your reliability results.

Register at: https://www2.gotomeeting.com/register/304753322

Thursday November 10th, 9-10am PST - Reliability in the Universe of Solar Products, by Ops A La Carte and Concurrent Design, part of the ASQ Reliability Society webinar series.

The universe of solar products is large and expanding rapidly. Of all of the emerging clean tech industries, the solar industry is one of the most challenging from a reliability engineering perspective because the industry is innovating so rapidly. Customers (and investors) are demanding very high reliability products, commonly requiring a minimum 25-year operating life.

Each aspect of a solar product must be considered for reliability. For example, in a solar power installation, the cells, the panels, the trackers, the inverters, even the installation itself, there are opportunities for failures. Join us for a quick trip through the Solar Universe and the many faces of Reliability Engineering in this rapidly expanding sector. The presentation will include technical information on the benchmarking, reliability, life cycle and end-of-life susceptibility of components in solar products.

Register at: https://www1.gotomeeting.com/register/393083536

SEMINARS

 Course: Certified Quality Engineer (CQE) Preparation Course 
Date(s): Oct 18 - Nov 29, 2011
Time: 6pm-10pm one night a week, 7 weeks
Instructor: Pat MacMahon, Ops A La Carte
Length: 7 weeks
Cost: $1295. We offer 25% discount for those taking via webinar or for unemployed or for students
Location: San Jose, CA / Offered via webinar for out of town students.

Description: Becoming certified as a Quality Engineer (CQE) can be valuable to your employer and your career. We are offering this Exam Preparation Course. Students have found it very valuable in preparing for the exam. Even if you are not planning on taking the exam but need a good, in-depth course in Quality Engineering, this can benefit you substantially.

Course Webpage: CQE_Course by Ops A La Carte. For more info or to register, please Contact Us Info

 Course: MIL-STD-810 Testing seminar 
Date(s): September 19-22 in New York, Cincinnati Nov 1-4, and Jupiter Florida Nov 14 -17
Time: All day
Instructor: Steve Brenner, Ops A La Carte

Details can be found at www.equipment-reliability.com

For information on other course offerings go to: Ops A La Carte Schedule. All our courses are offered as tailored seminars at our customer's location. To view a list of all all seminars, go to Ops Course List

EVENTS

2011 PRG BBQ - Friday, September 09, 2011 - 10am - 2pm

About Event: Please join us for PRG’s 4th Annual BBQ and Symposium.  This is your opportunity to network with industry peers, learn about the latest industry developments, and meet the PRG’s members in an informal setting while enjoying some delicious food.

The goal for this event is to create a forum for individuals and businesses involved in the Product Realization Process to gain knowledge, network, and have fun.

For more info, please Contact Us Info

 Medical Design and Manufacturing (MD&M) San Diego - Tuesday, Sept 13, 2011, 11:30am-12:30pm

We will be giving a seminar called "When the Standard Doesn’t Fit".  Register at: www.medeviceforum.com

For more info, please Contact Us Info

Colorado TechDev Lunch and Learn - Reliability and EMC Seminar - Friday, Sept 16 - 10am - 1:30pm

About Event: This seminar will focus on the integration between Reliability and Electromagnetic Compatibility (EMC). The points of discussion will be the following:

- Engineering resources are focused on innovation to solve customer needs.
- Failing Regulatory Compliance Requirements results in missing critical product launch dates.
- Reliability directly impacts financial health and quality reputation.
- EMC and Reliability considerations are ignored until critical milestones and costs are threatened.

This event is being sponsored by the following groups.

For more info, please Contact Us Info

 Medical Design and Manufacturing (MD&M) Chicago - Thursday, Sept 22, 2011, 8am-4pm

We will be giving a seminar called "Medical Device Reliability Testing".  Register at: MD&M

For more info, please Contact Us Info

Accelerated Stress Testing and Reliability (ASTR) Workshop - Sept 28-30, 2011

About Event: ASTR 2011 will provide a forum for ASTR knowledge and share ideas that address intra- and inter-industry endeavors to limit and eliminate field failures of products through accelerated testing techniques. OPS' will be exhibiting at the event and several OPS consultants will be presenting at the event, including the following topics:

- Application of HALT for Reliability Evaluation of Electronics Modules, by Peter Arrowsmith, Ops A La Carte
- Electromechanical Device Design Methods for Reliability Improvement, by Lou LaVallee, Ops A La Carte
- Useful Synergies Between Prognostics and HALT and HASS, by Mike Silverman, Ops A La Carte

For more info, please Contact Us Info

ASQ Silicon Valley Section Quality Conference - Friday Oct 21, Santa Clara, CA, 7:30am - 7:30pm

About Event: The theme for this year is "On The Road to Performance Excellence"

OPS' will be exhibiting at the event and several OPS consultants will be presenting at the event.

For more info, please Contact Us Info

 Medical Design and Manufacturing (MD&M) Minneapolis - Wednesday Nov 2, 2011, 8am-4pm

We will be giving a seminar called "Medical Device Reliability Testing".  Register at: MD&M

For more info, please Contact Us Info

SPECIAL OFFERS We will be visiting a number of cities this next quarter, including Boston, New Jersey, San Diego, Denver, Milwaukee, Chicago, Minneapolis, Australia, and India. Please refer to the News section for the exact dates.

We will provide you 1 hour of Free Consultation with no strings attached. We will give you our expert advice on any issues you are having or trying to avoid.

In addition, we will offer you a free copy of Mike's book "How Reliable Is Your Product: 50 Ways to Improve Product Reliability" just for giving us the opportunity to speak with you.

Also, we have developed a new Self-Assessment tool. If you take it, we will also give you a free book.

If interested, Contact Us Info

NEWS

BELOW ARE NEWS HIGHLIGHTS FOR THE PAST QUARTER. MORE DETAILS FOR EACH ITEM CAN BE FOUND AT NEWS.

All presentations that we gave can be found on the technical download section of our website at Technical Papers.

Sep 5, 2011

Ops A La Carte's Managing Partner Mike Silverman will be traveling around the US and the world giving seminars and visiting with clients. He will be in the following locations:

Sept 6 - Boston
Sept 7-8 - New Jersey
Sept 13-14 - San Diego
Sept 15-16 - Denver
Sept 19 - Milwaukee
Sep 20-22 - Chicago
Oct 24-27 - Boston
Oct 31-Nov 2 - Minneapolis
Nov 7-11 - Sydney, Australia
Dec 12-17 - India (Bangalore, Delhi, Bombay)

Whenever OPS visits a city, we offer 1 hour of free consultation to help you with any aspect of your reliability program. Please let us know if you would like for us to visit your company.

Sep 2, 2011

HALT Calculator Testimonial

Enecsys endorses HALT Calculator with this testimonial

"Enecsys has adopted the Ops A La Carte AFR calculation technique as it is impractical to conduct MTBF demonstration tests on highly reliable products such as solar micro inverters. Furthermore, using an MTBF number in isolation fails to provide any meaningful product life metrics. The Enecsys reliability engineering process is one that integrates multiple test and analysis approaches, of which the AFR calculator represents a component part, placing Enecsys in the unique position of being able to present AFR metrics to the solar industry. We have found this technique to be easy to use and due to the fact that it takes into account the significant HALT margins that we have achieved, we are satisfied that it delivers accurate and meaningful results. Enecsys plans to continue using the AFR calculator on future products, and embracing this technique underlines Enecsys' commitment to continuously improving micro inverter reliability, while being positioned firmly at the forefront of micro inverter reliability engineering technology."

Mark Turner, Director of Reliability, Enecsys

Aug 20, 2011

Ops' starts the semi-annual Certified Reliability Engineer (CRE) Certificate course. We have been teaching this course twice a year for 14 straight years. Four years ago, we started teaching the course via webinar and now the webinar attendees outnumber the live attendees. This semester we started a new private tutoring program for students that can't attend the lectures due to the time zone difference. The program consists of one-on-one tutoring sessions plus access to our recorded sessions.

For more information on our CRE Course, go to: CRE Class

Aug 9, 2011

Ops A La Carte's Managing Partner Mike Silverman was interviewed on BlogTalkRadio on Mike's new book "How Reliable Is Your Product: 50 Ways to Improve Product Reliability". You can listen to the recording

Host Wayne Hurlbert also reviewed Mike's book. Other reviews can be found at All Book Reviews

June 23, 2011

Ops A La Carte presents at annual IEEE Prognostics Conference, Denver. Here is the link to the presentation and paper.

Useful Synergies between Prognostics and HALT and HASS - Presentation
Useful Synergies between Prognostics and HALT and HASS - Paper

June 16, 2011

OPS holds annual Open House to over 100 visitors. This was our biggest open house in our 10 year history, which is fitting because the open house was in honor of our 10 year anniversary along with our joint partnership with Chart. The event was co-sponsored by IEEE.

The open house had a barbeque, RC car races, seminars on Advanced HALT Techniques, and poster sessions on reliability solutions and chamber/piping techniques. Great education AND lots of fun !! We also gave away an IPAD and the winner was Larry Pennington. Pictures below are highlights:

More Open House Pictures

June 10, 2011

Ops A La Carte presents on two topics at annual Applied Reliability Symposium, San Diego. Here are links to both presentations:

50 Ways to Improve Product Reliability
What is DfR and What is Not DfR

June 6, 2011

Ops A La Carte gives one day course at Medical show MD&M in New York on Medical Reliability Testing. We will be giving this course two more times this year:

MD&M Chicago - Thursday, Sept 22, 2011
MD&M Minneapolis - Wednesday Nov 2, 2011

For more information on news, please visit our News Page or call (408) 654-0499.

 

What Is DfR and What is Not DfR ?

Reliability is no longer a separate activity performed by a distinct group within the organization. Product reliability goals, concerns and activities are integrated into nearly every function and process of an organization. Each organization must factor reliability into every decision in order to ensure produce a successful product.

The old Test-Analyze-and-Fix philosophies no longer have a place in today’s design process due to continuous cost reduction pressures and reduced design cycles.

The motivation to implement a Design for Reliability (DfR) process include:

  • Higher Demand for Reliability that cannot be achieved using previous reliability techniques
  • Faster time to market
  • More emphasis on reducing cost
  • Fast moving technology, which creates new risks to development programs.
Successful implementation of the DfR process will reduce the product development cycle, lower the design cost, and improve customer satisfaction.

Reliability professionals these days are becoming more and more familiar with the term Design for Reliability (DfR).  Increasing number of companies advertize DfR as part of their design process and more and more web-based and life training is offered on the DfR methods.  However, what truly is Design for Reliability?  Despite the previous work done on this subject. DfR has not yet been fully defined.  It is still a work in progress.  In an attempt to clarify the subject of DfR this paper discusses what does and what does not constitute the Design for Reliability process and lays out the key steps in achieving a reliable design.

Since this term is often misused and misplaced, let us first define what the Design for Reliability is not:

  • Making a list of all possible reliability activities and then trying to cover as many as possible within the timeframe of the product development process.
  • Using only certain selected tools from the “DfR toolbox” (see Section 2 for more details)
  • Assuming that product reliability is the sole responsibility of a reliability engineer (reliability engineer is the guide and mentor but not the owner – designer should be the owner).
  • Completing the analytical work but delay test and verification until the system testing stage.
  • Getting product into test as fast as possible to test reliability into the product (Test-Analyze-&-Fix)
  • Only working on the in-house design items and not worrying about vendor items
  • Working in silos between Electrical, Mechanical, Software and other functional areas (even if they apply some or most of the DfR tools).
  • Not looking at interactions between groups and not taking a system level viewpoint.

Design for Reliability (DfR) is an emerging discipline that refers to the process of designing reliability into products as opposed to the Test-Analyze-and-Fix philosophy, which unfortunately still exists in today’s design process. DfR encompasses several tools and practices and describes the order of their deployment that an organization needs to have in place in order to drive reliability into their products. 

Specifically, DfR is:.

  • A process which begins from the very early stages of the design and should be integrated into every stage of this process.
  • Setting goals at the beginning of the program and then developing a plan to meet the goals.
  • Having the reliability goals being driven by the design team with the reliability team acting as mentors.
  • Providing metrics so that you have checkpoints on where you are against your goals.
  • Writing a Reliability Plan to drive your program.
  • The process which begins from the very early stages of the design and should be integrated into every stage of this process.
  • Using the best available science-based methods to achieve reliability.

The major phases of a DfR Program typically contain the following steps:
1.  Identify
2.  Design
3.  Analyze
4.  Verify
5.  Validate
6.  Monitor and Control

This information was presented more fully at this year's Applied Reliability Symposium. You can find a copy of this full presentation at DFR_Presentation.

More information about this topic can be found in Mike Silverman's book How Reliable is Your Product?  50 Ways to Improve Product Reliability. The book is available for purchase at SuperStar Press or Amazon.com. You can preview the First 3 Chapters at 50 Ways to Improve Your Product Reliability.

Below is a summary of the Best of our Blog for last quarter - highlights of the best blog topics we had.

If you would like to contribute to our blog, please eitherContact Us Info or go to

INTEGRATING SIMULATION INTO A RELIABILITY PROGRAM

The first webinar this quarter is on Integrating Simulation Into a Reliability Program. The first 5 people to name a simulation technique other than FEA they have used effectively within a reliability program and how wins a new signed copy of Mike's book "How Reliabile Is Your Product: 50 Ways to Improve Product Reliability"

BE Analytic is a leading Engineering services provider focused on Reliability & Safety Engineering services for Aerospace, Automobile, Medical Science , Oil&Gas, Nuclear, HVAC, Industrial Products, Marine and Power Generation Industries. It is initiated by group of eminent scientists and experienced engineers in Bangalore, India. Our innovative and versatile approaches towards design & development help our clients reduce their overall development costs, cycle time and de-risking by optimized utilization of engineering resources. Ops A La Carte partners with BE Analytic to help execute projects for our clients in India.

MGBS is a consulting company enhancing performance of corporations, professionals, and students across the world over a decade. Ops A La Carte partners with MGBS for Lean Six Sigma (LSS) projects.


MU Sigma are experts in Business Strategic Planning, Leadership Jumpstart, Lean Enterprise, Six Sigma for Process Improvement, Marketing for Six Sigma, DFSS-Innovation training and consultation to build business competencies and enhance overall performance. Our consultants came from GE, Motorola, Dell, ITT and Honeywell with rich expenses to create customer value. Our all program is customized for business revenue and margin growth. Ops A La Carte uses MU Sigma to help execute projects in Taiwan.

Senior Reliability Consultant

Ops A La Carte is looking for Senior Reliability Consultants around the world to join our team of consultants and work on some of the most exciting and challenging projects in the industry.

If interested, email us via our Ops Job Search Contact Form or call (408) 654-0499.

Component Engineer, Taiwan // Reliability & F/A Engineer, N. California

If interested, email to Mark Turner at mark.turner@enecsys.com

Failure Analysis Engineer (Mansfield, MA)

If interested, email to Don Gerstle at Don.Gerstle@murata-ps.com

Ops A La Carte's newsletter goes out to over 18,000 subscribers. If you would like to put an ad or job opening in next quarter's "Reliability News", fill out our Job Openings Form or call at (408) 654-0499.

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