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On this episode…
Renaud is joined this week by two attention-grabbing company who’ve been on the podcast earlier than: Clive Greenwood a high quality advisor at WWMG associates who’s a Six Sigma Black Belt and has a particular deal with medical units and product compliance and Sofeast’s head of New Product Improvement, Andrew Amirnovin who has a background in electrical engineering and a eager deal with product reliability.
The subject is the long-term prices of poor product high quality and reliability, and so they’ll be analyzing some actual unreliable and poor high quality product examples, the various issues attributable to poor high quality and reliability, methods and tricks to forestall these points, and find out how to assemble an efficient high quality administration system.
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🎧 The Lengthy-Time period Prices of Poor High quality & Reliability 🎧
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Present Sections
00:00 – Greetings & in the present day’s matter
01:16 – Clive & Andrew introductions and trade expertise
03:59 – Some real-life examples of merchandise that suffered from unhealthy high quality and reliability
- The Samsung Word 7 with exploding batteries. The price of the issue to Samsung was over US$5.3 billion and untold injury to their fame!
- The Boeing 737 Max with software program points that induced them to crash. Over 300 individuals died in crashes, once more costing Boeing an enormous quantity in reputational injury and billions in prices.
- Masks to be used as PPE within the battle in opposition to Covid that have been completely unsuitable and unsafe to be used as medical units and have led to quite a few world courtroom circumstances and wholesale adjustments to how the provision chain is monitored.
11:17 – Individuals usually deal with high quality, however not reliability. A mistake?
Clive: The designer ought to present an in depth DFMEA that units the roadmap for high quality. Widespread certifications like ISO 9001 speak about understanding the client requirement, on this case, a product that works and is dependable. The full price of high quality consists of each the price of good high quality (COGQ) and the price of poor high quality (COPQ) and product repairs and remembers can rapidly take prices out of your management.
Andrew: To make sure high quality & reliability, throughout improvement contemplate find out how to make the design extra dependable, the way you’ll take a look at for reliability, and put in place manufacturing controls. An instance is the Nokia drop take a look at that led to design adjustments to the telephones the place it grew to become commonplace for them to disintegrate on affect (case comes off and battery pops out).
17:28 – The best way to make a dependable product and stop high quality & reliability points?
Andrew: Make a dependable product design, use case eventualities for the product, DFR, use dependable supplies and parts, observe the DFX course of. Design FMEA for threat evaluation. FEA (finite component evaluation). Choose parts from suppliers with reliability and high quality methods. Analyze and monitor subject failures. Reliability testing must be found out to check any and all methods a consumer may use the product. HALT and HASS accelerated testing are notably efficient for testing reliability by accelerating potential points to allow them to be discovered throughout improvement and never within the subject.
Clive: On provider choice – a product is barely nearly as good as its weakest hyperlink. If that weakest hyperlink was chosen resulting from worth over high quality the product dangers failing. Suppliers want a acknowledged high quality system that may be audited and verified. Patrons usually purchase the most affordable potential parts with high quality as an afterthought if in any respect, nevertheless, it must be one of many first.
27:27 – The place do design engineers go flawed?
Andrew: Throughout improvement, engineers can get tunnel imaginative and prescient and don’t have a look at the massive image about how the product might be used within the subject by the client and by which environments. These affect high quality and reliability. High quality and reliability groups want to teach the engineering workforce to deal with buyer necessities, how the product will probably be examined and evaluated, and extra. With out doing this there are a lot of dangers forward.
Clive: The elemental facet of producing is that the design to fabricate has to have a high quality restrict. A enterprise with a long-term outlook should equate low-cost with throwaway merchandise (cellphones the place the battery is poor after about 18 months, for instance) as reliability doesn’t actually include a decrease price.
Andrew: Low-cost Christmas lights with unsafe wiring that might result in electrocution is an instance of irresponsible product improvement the place security wasn’t thought of. Because of this ‘low-cost merchandise’ must be averted when high quality and reliability are desired. For normal client merchandise, their reliability ought to no less than cowl the guarantee interval.
34:34 – Compliance requirements
Clive: A product ought to adjust to worldwide or nationwide requirements of the placement it’s going to be bought in. There isn’t a black or white. Laypeople don’t normally perceive requirements, although, and are extra concerned about worth which will be put above security and reliability.
37:22 – A listing of typical prices of poor high quality as soon as a foul product hits the sphere
- Delivery and restoration prices
- Rework or re-engineering
- A complete recall of merchandise (inflicting irreparable injury to fame)
- Elevated inspections
- Storage for returns
- Manpower allotted to deal with RMA, rework, and restore
- Lack of gross sales and income
- Buyer dissatisfaction
- Tarnished model picture
- Excessive guarantee price
- Authorized charges & monetary fines or damages (for questions of safety and buyer accidents)
39:39 – The instance of a faulty toy and the way it affected the model
An organization was supplying toy prepare units and generally the Chinese language producer missed a screw from the field. They didn’t assume it was a giant drawback, however clients would complain bitterly, particularly, say, if it meant the toy couldn’t be used as a Christmas present. The model has to ship single screws by air which was expensive in labor and transport prices (US$50 per time per screw) and so they nonetheless obtained poor on-line evaluations that broken their model.
42:47 – The connection between the design and high quality & reliability groups
Clive: Being led by accountants fairly than high quality individuals leads to loads of the failures mentioned on this episode.
Andrew: There may be usually rivalry between design and reliability & high quality groups. The previous might say that the latter examined the product too exhausting and broke it. The artwork of a reliability engineer is to plan the right take a look at plan that catches points with out giving a false failure and proves that there’s a problem from one construct to the following to the design workforce who can then go and repair it. This will get a design workforce on-side as they then see the standard & reliability workforce as serving to them keep away from embarrassment.
Renaud: The obeya system is the place info and actions (corresponding to what’s flawed and must be mounted) are made clear to everybody and the groups work collectively on them. That is management with high quality and reliability in thoughts.
47:45 – Course of threat evaluation
Clive: IPCDA – ‘establish’ and plan a strategy to take a look at points.
Renaud: Deming says 85% of points can solely be mounted by administration as they should put the methods in place.
Andrew: Pareto evaluation. Generally only one or 2 points are inflicting 80% of the failures. The reliability engineer must establish that essential element to the design workforce and as soon as it’s mounted so many points gained’t reoccur.
50:51 – The 8D corrective motion course of
Clive: At what factors did the necessity for corrective actions begin. You assume that the client used the product inside its limitations, however that’s exhausting to show.
Andrew & Clive: In the event you discover points within the subject, the engineer usually fails to report it to the design who’re engaged on the brand new product based mostly on the one which has failed. This leads to the brand new product having the identical situation because the outdated one as a result of the design workforce didn’t know. An absence of an obeya system means there isn’t good communication between departments and buyer complaints within the subject don’t get again to a design workforce.
55:26 – Wrapping up
Renaud: Administration has to set the suitable system and make info and suggestions accessible to the suitable individuals so design, high quality, reliability, and procurement employees all work collectively effectively. With out this basis, an organization can’t be anticipated to develop and promote good merchandise.
Andrew: From a design and improvement point-of-view it’s essential to have a means of figuring out points earlier than the product goes to manufacturing and of verifying and validating supplies and parts. Pilot runs, devising inspection factors throughout manufacturing, putting in incoming QC, doing a primary article inspection, ongoing reliability testing, and so on. All of those processes have to be in place to seek out reliability and high quality points earlier than a product leaves the manufacturing facility.
Clive: Don’t overlook that your prototype is a key instrument to inform you if and the way the product fails.
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