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How HA and FMEA Relate

How HA and FMEA Relate Abstract Dianna and Carl discuss the relationship between Hazard Analysis (HA) and Failure Mode and Effects Analysis (FMEA). Key Points Join Dianna and Carl as they discuss the how HA and FMEA relate and how they can work in synergy to create safer products. Topics include: Fundamental differences and similarities How HA can effectively quantify risk by calculating the probability of harm, a dimension often missing from FMEA Practical techniques for identification and collective ownership of ideas Early HA and FMEA in a project can drive design decisions, prioritize testing, and improve overall risk management Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques to field data analysis approaches. Download Audio RSS Show Notes Hosts Carl Carlson and Dianna Deeney delve into the often-misunderstood interface between Hazard Analysis (HA) and Failure Mode and Effects Analysis (FMEA) and how HA and FMEA relate. While often seen as separate activities, they discuss how these two crucial processes can be integrated to enhance product safety and efficiency. Effective risk management planning, starting at the beginning of a project, is key to successfully aligning HA and FMEA. FMEA typically begins with item identification, followed by describing functions and then failure modes. In contrast, Hazard Analysis often starts by listing high-level hazards such as electrical or physical risks, taking a top-down, system-level view that considers the product’s environment and users. Although a hazard itself can sometimes function as an effect in an FMEA, a significant difference lies in their outputs: HA can lead to a quantifiable probability of harm by combining the likelihood of a hazardous situation with the likelihood of harm given that situation. FMEA, on the other hand, provides a qualitative severity assessment and the likelihood of occurrence of a failure mode and its associated cause, but not the overall likelihood of harm. HA and FMEA can complement each other; for instance, a hazard analysis can inform an FMEA to ensure no critical hazards are missed, or high-severity FMEA findings can prompt a thorough HA. Ultimately, integrating these analyses helps teams prioritize design activities and testing efforts based on a clearer understanding of potential risks. The post SOR 1097 How HA and FMEA Relate appeared first on Accendo Reliability.

How FMEA Worksheets can Help (and Hinder)

How FMEA Worksheets can Help (and Hinder) Abstract Chris and Carl discuss FMEA worksheets (we know … boring) … but can be incredibly helpful and useful. So what are they and how do they help us? Key Points Join Chris and Carl as they discuss FMEA worksheets, which are an important part of a Failure Mode and Effects Analysis (FMEA) that help us identify the potential issues with a product or process before they become issues – meaning we can (hopefully) help us design them out of existence when it is cheap and easy to do. Topics include: What is a FMEA worksheet? … it is a table that documents the conduct of a FMEA, including things like functions, tolerances, failure modes, defects, their corresponding likelihoods along with things we can do to address them. What is ‘pre-population’? Before you conduct a FMEA, there will likely be a list of things that we might already know about how our process or product might fail. ‘Pre-population’ involves putting these failure scenarios into yor worksheet before you start your FMEA. BUT … humans are not good at seeing what is missing. In other words, if we see that a FMEA worksheet already has some ideas about how something might fail, our brains often struggle to brainstorm more ways. The solution? Keep any existing knowledge in the ‘back pocket’ of the facilitator, allowing the team to brainstorm everything from scratch, and then see if there is anything missing from those pre-existing ideas. What are the media you can use? Software or spreadsheets. There are FMEA software packages out there that construct FMEA worksheets for you. Or …  you construct your own using a worksheet (Chris prefers spreadsheets as you can tailor them to your product, process or system). Chris’s tip? Start with a COMPLETELY BLANK SPREADSHEET for your team – except for a single ‘remarks’ column. This might sound crazy, but it is less intimidating. You need to have a list of column headings prepared and also in your back pocket, but if you insert and label columns as you go it helps the team focus. It also means the ‘remarks’ column is always ‘right there’ and not to the right of 20 + empty column headings. Carl’s tip? Before starting the workshop, hand out a bunch of yellow post-it notes and give them around 45 minutes to come up with as many issues that are going to ‘keep them up at night.’ Put them up on a wall, take a photo of them, write them down or do whatever you need to keep them at the forefront of everyone’s minds during the workshop. Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques to field data analysis approaches. Download Audio RSS Show Notes The post SOR 1096 How FMEA Worksheets can Help (and Hinder) appeared first on Accendo Reliability.

Reliability Engineering and Artificial Intelligence

Reliability Engineering and Artificial Intelligence Abstract Carl and Chris discuss the changing opportunities and challenges with AI and reliability engineering. What are the positive interactions, and where should we be concerned? Key Points Join Carl and Chris as they discuss their views on the roles that AI can play in reliability programs. Topics include: What are the limitations of AI in supporting reliability programs? One concern is if AI is being oversold, and replaces necessary human involvement. Another concern is the possibility of AI moving a company towards mediocrity. AI can be useful to help ensure you don’t miss something critical. AI cannot perform an FMEA. It can augment an FMEA. It can provide excellent input to FMEA. Discussion around having an AI bot as part of an FMEA team. However, it may lessen creativity. Humans cannot see what is missing. AI generated input can retard human innovation and creativity. For this reason, it may help to begin with human creativity before bringing AI generated input. The purpose of FMEA is not to fill out a form. It involves surfacing risk, and reducing risk to an acceptable level. FMEA helps to improve the design or manufacturing process. Example: ask AI if MTBF is a good reliability metric. The answer is not very useful. Tip: review the citations listed with AI responses. Tip: Use AI to fill in the gaps, not the other way around. Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques to field data analysis approaches. Download Audio RSS Show Notes The post SOR 1095 Reliability Engineering and Artificial Intelligence appeared first on Accendo Reliability.

Show Me the Money

Show Me the Money Abstract Greg and Dianna discuss how quality and reliability engineers can become AI boomers NOT doomers.  Engineers are being challenged with AI.  What can and should we do to survive and even prosper in the age AI disruption. Key Points Join Greg and Dianna as they discuss AI opportunities. What can you do to become an AI boomer. Topics include: Stories of career disruption. What is the human in the loop or middle. Tips and tools to become an AI boomer. Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques to field data analysis approaches. Download Audio RSS Show Notes The post SOR 1094 Show Me the Money appeared first on Accendo Reliability.

Quality and Reliability Disrupted

Quality and Reliability Disrupted Abstract Dianna and Greg discuss your employability in the AI age.  So, let’s run a hypothetical.  You’re a 22 year old mechanical engineer.  You do robotic quality and reliability with a knowledge half-life of 4 years.   That means by the time you’re 26 knowledge in your domain has doubled.  Let’s say, you’re now 30.  Knowledge in your domain has quadruped.  Problem:  you have not updated your knowledge skills and abilities.  Are you still employable. Key Points Join Dianna and Fred as they discuss what we all face nowadays.  Technology is running ahead of our abilities.  And, how do we stay current?  Topics include: What is the half like of knowledge? What are examples of knowledge disruptions? How does it impact and why it matters to you? Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques to field data analysis approaches. Download Audio RSS Show Notes The post SOR 1093 Quality and Reliability Disrupted appeared first on Accendo Reliability.