The Implementation of NUD Process - Joe Powell - FINAL - REVIEWED

The Implementation of the
NUD Process
How it is used to develop reliable products such as the
Lennox S30 thermostat
26 March 2019 | Joe Powell
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com

Agenda
01 Why and what is NUDS
02 NUDS and FMEA
03 The NUDS Process
04 Lennox S30 and NUDs
05 Summary
06 Questions
9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 2

Copyright of DfR Solutions 2019
Why
• Tool that is part of our DFR process.

• In use for over 10 years.
• Identify risks.
• Begin mitigation sooner, with higher confidence of product success.
• NUDS

What is NUDs
• New: an adjective referring to something recently made, discovered, or created.
• Unique: a state or condition wherein something is unlike anything else.
• Difficult: requiring much work or skill to do or make.

What is NUDs
• New: Just as it implies, anything that is new.

− First time using a material, component or technology.
› Switch, motor or LCD display never used before.
› Plastic material change.
› Newly implemented process.
− First time use in the present design.

› Used in xyz product, now used in abc product but same use and environment profile.

What is NUDs
• Unique:
− Different use of material or component, with different use or environmental profile.
› What was used as an evaporator motor in a furnace, now is used as condenser motor in an
outdoor unit.
• Different ambient temperature, humidity, vibration, dust.
› Same refrigerant pressure switch used in walk-in coolers, now is used in commercial HVAC.
• Also different ambient temperature and humidity, as well as duty cycles and use profile.

What is NUDs
• Difficult: requiring much work or skill to do or make.

− Challenging agency or government regulation requirement.
› Fuel efficiency improvement 20% by 2020 for automobile.
› Phase out of ozone-depleting refrigerants.

NUDs and FMEA
• Supportive and helpful for FMEA and design process, not a replacement.
• Why do we need an alternative?
• FMEA NEVER GETS COMPLETED SOON ENOUGH!!!
Why not?
− People are too busy. Schedule driven.
− FMEA is boring, design is more fun.
− Difficult to get all members to attend.
− Paperwork check box.
− Design engineer not skilled in preparing FMEA.

NUDs and FMEA
• FMEA Output:
− Systematic identification of potential failures modes, and cause mechanisms.
− Manage risks.
− Recommend alternative solutions.
• All important for identifying tests to insure that the product meets all targeted
performance criteria, but especially reliability objectives.
• NUDs can provide the same and sooner.

NUDs and FMEA
Ideal development process with DFMEA
Concept Specification DFMEA Design
Pre-
Production Design Verify Prototype
production

NUDs and FMEA
What really happens with design DFMEA
Pre-
Production
production DFMEA
Design Verify Prototype
THIS DOES NOT WORK FOR RELIABILITY ENGINEERS

NUDs and FMEA
Ideal development process with DFMEA, PFMEA AND S&IFMEA
S&IFMEA PFMEA Design Verify Prototype
Pre-
Production
Production

NUDs and FMEA
What really happens with PFMEA and S&IFMEA
Design Verify Prototype
Pre-
Production
PFMEA and S&IFMEA
Production
THIS DOES NOT WORK FOR ANYONE

HOW DOES NUDs IMPROVE THIS?

NUDs and FMEA
NUDs for design
Concept NUDs
Specification DFMEA Design
Pre-
Production Design Verify Prototype
production
RELIABILITY ENGINEERS CAN BEGIN TEST PLAN ON

HIGH RISK, SPECIAL REQUIREMENT ELEMENTS

NUDs and FMEA
NUDs for Process and Service and Installation
Concept NUDs
Specification DFMEA Design
S&IFMEA PFMEA Design Verify Prototype
Pre-
Production
Production
THIS WORKS FOR P AND S&I FMEAs

Summary to this Point
• New concept, NUDs.

− New
− Unique
− Difficult
• Gets to high risks issues of change quickly.
• Helps reliability engineer develop risks mitigation sooner.
• Not a FMEA replacement.
• Efficient utilization of resources.

NUDs Process
FMEA Diagram
Block Diagram P-Diagram
Interface Failure Mode

DFMEA Form
Matrix Worksheet

NUDs Process
• Utilizes a portion of DFMEA process.

Block Diagram: Describes system relationships.
P-Diagram: Describes external factors.

NUDs Process
NUDs Diagram
Block Diagram P-Diagram
Interface Failure Mode

DFMEA Form NUDs
Matrix Worksheet

NUDs Development Example
Block Diagram Step Input 1 Input 2 Output 1
24V Rectifier/
Regulator circuit
Power Supply
3.3V regulator circuit
HW
Detect ckt 1
Input Detection Detect ckt 2
Detect ckt 3
K5
XYZ Relay Driver R49

Output Drive 1
Control
R46
Regulator Drive
R44
CPU function
Pump Drive
C4
FW GV Drive
D12
D13
LED
PCB R48

NUDs Development Example
P-Diagram Step XYZ Control: Noise

Factors
System Factors New/Unique/Difficult
Input 1 Yes
Input 2 No
Output 1 No
User Factors New/Unique/Difficult

Voltage Surges No
Number of cycles Yes
Wiring Yes
Environmental Factors New/Unique/Difficult

Temperature No Response/
Signal Ideal
Factors Humidity No Function
Vibration No
INPUTS XYZ Control OUTPUTS

NUD Electronic Example
• Cell Phone
− Next years model, what has changed.
Identify and Identify and List Mitigation

Record NUDs Record Risk Method
Table with
Headers
NUD RISK MITIGATION

Breaking of glass. Perform standard drop test.
Display/touchscreen
Scratch resistance. Perform standard scratch

test.
Perform touch sensitivity test.

Touch sensitivity.
Different button supplier Perform standard button press

Meet lifetime button
and increased count of life test with increased number of
presses.
presses. cycles.

NUDs Development, NUD Worksheet Step
• Simple:
List the test,

analysis, method
Identify the you will use to
associated mitigate that risk.
List the NUD risk.
NUD RISK MITIGATION

Pump efficiency > 20 % Fuel economy Redesign -valve size and
shape
Insufficient torque Improve pump flow

NUDs Development
• Two reasons to develop NUD list:

− Type 1: Existing product change, upgrade etc.
− Type 2: New product development.

NUDs Development
Type 1: Existing Product Change
What has
changed?
What is
New Parts? different about
use?
ABC Control
Anything
What worries different about
you? environment?
KEEP ASKING QUESTIONS!! INTERACTIVE DIALOGUE

NUDs Development
Type 2: New Product

New
Processor?
What have we
Different p/s
never done
before? design?
XYZ Control
More cycles
What wakes over lifetime,
you up at night? different relay?
KEEP ASKING QUESTIONS!! INTERACTIVE DIALOGUE

Summary
• NUDs process is straight forward table.

• Uses block diagram and p-diagram of FMEA process to focus thinking.
• Interactive dialogue with designer is important.

How was NUDS used for S30 Testing

NUDs and S30
What is S30

NUDs and S30
HD Display
Over 250 parts Over 135 parts Over 500 parts
Device DFMEA Lines No. of Man Hours

HD Display 290 110
Mag Mount 218 60
Smart Hub 274 73
Total 782 243

NUDs and S30
Display NUD list
NUD Risk Mitigation
Packaging drop test
Breakage for use or dropping
Drop test without packaging
Scratch resistance Test to be developed.
Electronic qualification test, touch
Capacitive Touch
sensitivity test
Display Touchscreen
Chemical exposure with environmental
Chemical Susceptibility
stresses.
UV susceptibility UV testing
Backlight life Analytics for backlighting life.
Viewing angle, brightness and contrast Display testing
Combination of analytics and testing
Life
under adverse conditions.
Battery
Fire Fire test
ESD susceptibility of regulator failure allowing
Electronic qualification test
battery to thermally runaway.
Electronics EMI and Environmental Electronic qualification test
Environmental susceptibility UV testing, thermal shock,
Plastic Housing
Durability and mounting strength. FEA, Plastic
Durability (household chemicals) Durability test to be developed
Microphone and speaker Loudness of speaker Test to be developed.
Sensitivity of microphone Test to be developed.
PC Board Thermal/mechanical stresses FEA, HALT, Thermal Shock.
Unintended operation or not meeting
New Firmware Firmware test
specification
Temperature Sensor Location Poor temperature control Temperature test
Proximiity Detector False triggering Proximity test
9 NUDs

NUDs and S30
Mag-Mount NUD list
NUD Risk Mitigation
Analytics. Test to be
Magnetic support for display Loss of strength over time.
developed.
Corrosion, connection reliability Corrosion test
Magcon Connector
Maintain spring tension Test to be developed.
Communication Bus EMI Electronic qualification test
2 screw wall mount with sheetrock Holding strength to wall versus removal Analytics. Testing to be
anchors strength of display developed.
EMI Electronic qualification test
Humidity Sensor
Accuracy Humidity sensor test
Plastic Housing
Durability and mounting strength. FEA, Plastic
METZ Connector Corrosion, connection reliability Corrosion/connector test
Life Meet Lennox life requirements ALT
EMI
Power supply Electronic qualification test
Handle range of input voltage
Electronic qualification test and
New processor EMI/Environmental/Life
ALT
Communication protocol to HD Display EMI/Environmental/Life Electronic qualification test
Unintended operation or not meeting
New firmware Firmware test
specification
13 NUDs

NUDs and S30
Smart-Hub NUD list
NUD Risk Mitigation
Meet # of pushes Analytics, testing if necessary.
Pushbutton Switch
Meet push force Analytics, testing if necessary.
ESD Electronic qualification test
2 wifi antenna
Gimbal Testing to be developed.
Plastic Housing
Durability and mounting strength. FEA
Linux operating system Intended and reliable functionality Firmware Testing
METZ Connector Corrosion, connection reliability LR-805
Power Sequencer Failure to process correctly during EMI. Electronic qualification test
EMI, environment Electronic qualification test
WIFI Radio
Meet distance requirements Testing to be developed.
LED Meet brightness requirements Half Life calculation
Clear Plastic Lens Clear becomes cloudy over time. UV testing, thermal shock,
SD Card Holder Application SD card becomes dislodged. Package testing, HALT
Life Meet Lennox life requirements ALT
12 NUDs

NUDs and S30
Comparison
Device FMEA Lines (man NUDs (man hrs)
hrs)
HD Display 290 (110) 9 (2.5)
Mag Mount 218 (60) 13 (1)
Smart Hub 274 (73) 12 (2)
Total 782 (243) 34 (5.5)
• Brought to market 1 month earlier with higher confidence of reliability.

• Warranty rate is lower than predecessor.
• No warranty claims due to high risk items.
• Identified unique manufacturing issues, magnet orientation.
Quicker than FMEA, higher confidence of reliability, early.

NUDs
Pros/Cons of NUDs Method
• Pros:
− Quicker path to identifying critical issues/components.
− Efficient utilization of engineering and manufacturing resources.
− Fewer team members to reach critical point.
− Help guide engineering team to prioritize corrective actions.
− Helps focus and prioritize FMEA process.
− Actions underway on addressing high risk items at start of FMEA.
− Help to reduce the time of project life cycle.
− Identify risks at the beginning when costs of change are low.
− Scales to scope of the project.
• Cons:
− Not 100% coverage as FMEA.
− Doesn’t necessarily include historical failure history data.
− There is a chance failure modes can be missed.

Summary
• NUDs: New, Unique, Difficult.

• Uses block diagram, p-diagram.
• Does not replace FMEA.
• Identifies high risk issues at beginning of project with mitigation.
• Efficient use of resources, (S30 3% of FMEA man hours).
• Use for DFMEA, PFMEA, S&IFMEA.
• Quicker to market, higher confidence of reliability.

Speaker Bio
Joe Powell, Reliability Engineer, Fellow

Lennox International
Joe has been with Lennox for 31 years in various positions of design and management of electronic
controls and has spent the last 10 years in electronic control reliability. Previous to Lennox he worked in
electronic design at Ranco Electronics, Luminator, Northern Telecom. Joe holds an Associate and Bachelors
degree in Electrical Engineering and holds 8 patents.
Contact
joe.powell@lennoxind.com
214-460-3966

Questions?


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The Implementation of the

26 March 2019 | Joe Powell

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com

01 Why and what is NUDS

02 NUDS and FMEA

03 The NUDS Process

04 Lennox S30 and NUDs

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 2

• Tool that is part of our DFR process.

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 3

• New: an adjective referring to something recently made, discovered, or created.

• Unique: a state or condition wherein something is unlike anything else.

• Difficult: requiring much work or skill to do or make.

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 4

• New: Just as it implies, anything that is new.

− First time use in the present design.

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 5

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 6

• Difficult: requiring much work or skill to do or make.

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 7

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 8

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 9

Ideal development process with DFMEA

Concept Specification DFMEA Design

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 10

What really happens with design DFMEA

Concept Specification DFMEA Design

THIS DOES NOT WORK FOR RELIABILITY ENGINEERS

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 11

Ideal development process with DFMEA, PFMEA AND S&IFMEA

Concept Specification DFMEA Design

S&IFMEA PFMEA Design Verify Prototype

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 12

What really happens with PFMEA and S&IFMEA

Concept Specification DFMEA Design

Design Verify Prototype

THIS DOES NOT WORK FOR ANYONE

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 13

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 14

NUDs for design

RELIABILITY ENGINEERS CAN BEGIN TEST PLAN ON

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 15

NUDs for Process and Service and Installation

S&IFMEA PFMEA Design Verify Prototype

THIS WORKS FOR P AND S&I FMEAs

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 16

• New concept, NUDs.

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 17

Block Diagram P-Diagram

Interface Failure Mode

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 18

• Utilizes a portion of DFMEA process.

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 19

Block Diagram P-Diagram

Interface Failure Mode

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 20

Block Diagram Step Input 1 Input 2 Output 1

Input Detection Detect ckt 2

XYZ Relay Driver R49

9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com 21

P-Diagram Step XYZ Control: Noise

User Factors New/Unique/Difficult

Environmental Factors New/Unique/Difficult