This document summarizes DuPont's tactical approach to front end loading (FEL) for reliability. It discusses distinguishing between quality and reliability, with quality ensuring production works as designed and reliability providing the probability of performing as intended over time. The presentation covers FEL stages 1 through 3, which involve determining maintenance strategies, including reliability goals and engineers in early design, enhancing designs for maintainability, and developing maintenance plans, training, and systems.
This document summarizes DuPont's tactical approach to front end loading (FEL) for reliability. It discusses distinguishing between quality and reliability, with quality ensuring production works as designed and reliability providing the probability of performing as intended over time. The presentation covers FEL stages 1 through 3, which involve determining maintenance strategies, including reliability goals and engineers in early design, enhancing designs for maintainability, and developing maintenance plans, training, and systems.
This document summarizes DuPont's tactical approach to front end loading (FEL) for reliability. It discusses distinguishing between quality and reliability, with quality ensuring production works as designed and reliability providing the probability of performing as intended over time. The presentation covers FEL stages 1 through 3, which involve determining maintenance strategies, including reliability goals and engineers in early design, enhancing designs for maintainability, and developing maintenance plans, training, and systems.
Alfred E. Ogden, MSRE, CMRP DuPont Reliability Engineer MARS Conference 2012 Galveston, TX
Agenda Differentiating 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? 50 60 70 80 90 100 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 Med High High Cost 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 Med High High Cost 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 Low Cost Med Low Med High High Cost 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 Low Cost Med Low Med High High Cost 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