dupont design for reliability tactical approach to front end loading alfred e. ogden, msre, cmrp...
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DuPont Design for Reliability Tactical Approach to Front End Loading
Alfred E. Ogden, MSRE, CMRP
DuPont Reliability Engineer
MARS Conference 2012 – Galveston, TX
AgendaDifferentiating between Quality and Reliability
Value Proposition
• “Live” Case Study
DF “X”: Front End Loading Tactical Approach
Distinction Between Reliability and Quality
Quality assures that the production line will work after assembly and as designed.
Reliability provides the probability that the production line will perform its intended function for a designated period of time without failure under specified conditions.
• Reliability looks at how long the equipment will work as designed, which is a very different objective than that of traditional quality control.
• Different tools and models apply to reliability that do not necessarily apply to quality and vice versa.
Reliability vs. Initial Cost
What is your Experience of what the shape of this curve would look like?
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60
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100
Low Cost Med Low Med High High Cost
Reliability vs Initial Cost
Reliability
Reliability vs. Initial Cost
Here is an example – What elements will effect its shape and slope
50
60
70
80
90
100
Low Cost Med Low Med High High Cost
Reliability vs Initial Cost
Reliability
Maintainability vs. Initial Cost
What is your Experience or “Gut Feel” of what the shape of this curve
50
60
70
80
90
100
Low Cost Med Low MedHigh
HighCost
Maintainability vs Initial Cost
Maintainability
Maintainability vs. Initial Cost
Here is an example – What would effect the shape and slope of this curve?
50
60
70
80
90
100
Low CostMed Low MedHigh
HighCost
Maintainability vs Initial Cost
Maintainability
Life Cycle Cost vs. Initial Cost
What is your Experience or “Gut Feel” of what the shape of this curve
50
60
70
80
90
100
LowCost
MedLow
MedHigh
HighCost
Life Cycle Cost vs Initial Cost
Life Cycle Cost
Life Cycle Cost vs. Initial Cost
Here is an example – What elements would effect the shape and slope of this curve?
50
60
70
80
90
100
LowCost
MedLow
MedHigh
HighCost
Life Cycle Cost vs Initial Cost
Life Cycle Cost
Front End Loading
FEL 1
• Determine the desired Maintenance Culture and Preliminary Maintenance Strategies
• Add a Maintenance Team Leader to the Project Team and Assign a Reliability Engineer too
• Include specific and realistic Reliability Goals in the Project Objectives
• Model the Preliminary design to determine equipment availability – Reliability Requirements & Possibilities
Front End Loading
FEL 2
• Add Reliability enhancing design elements into Project Design and Equipment Selection
• Assure that Maintainability is a significant consideration in the design process
• Develop the Maintenance Plan for the Equipment
• Upgrade the Model with the more complete design information – use results to guide refinements to design
Front End Loading
FEL 3
• Develop a Maintenance Materials Strategy
• Increase Maintenance Craft Specialist involvement in review and analysis of designs and equipment selection to assure Maintainability and Reliability
• Determine Maintenance Training needs
• Start Building the Equipment and Parts Master Data
• Develop the Bills of Material
Questions