Speaking Of Reliability: Friends Discussing Reliability Engineering Topics | Warranty | Plant Maintenance

Analyzing failure data for repairable systems sounds straightforward—until you start asking the right questions. In this episode, Chris and Fred unpack a listener’s challenge: how to model reliability when failed components are repaired and returned to service. The discussion quickly moves beyond Weibull curves and into a more uncomfortable reality—maintenance itself often increases failure risk, at least in the short term. With limited data and multiple failure mechanisms at play, traditional statistical approaches can mislead more than they help. Instead, the focus shifts to understanding failure physics, questioning assumptions, and making practical decisions that actually improve reliability—not just model it.

Modeling Maintenance Benefits Abstract Mojan and Fred discuss how to integrate service plans into reliability target planning. They explore the shift from “worst-case” maintenance schedules to data-driven strategies, highlighting how predictable failure mechanisms and telemetry allow teams to take credit for high availability in their reliability models. Key Points Join Mojan and Fred as they discuss the […]

Why Paper Jams Persist Abstract Mojan and Fred dive into the surprisingly complex world of the “paper jam,” a problem that remains a daily frustration despite decades of high-level scientific research. From Fred’s time at HP to the massive technical laboratories at Xerox, they explore why the interaction between rigid mechanisms and non-rigid, organic media […]

Risk Prioritization in FMEA Abstract Carl and Fred discuss a question from a reader about risk prioritization in FMEA procedure. Key Points Join Carl and Fred as they discuss the role of risk prioritization in FMEA, what is it, and what is the best way to prioritize risk in FMEA. Topics include: Discussion of history […]

Our Unique Role in Reliability Abstract Carl and Fred discuss the ongoing challenge between doing reliability work ourselves and enabling others to accomplish the work. And what is the future human role in the field of reliability, given the advancements in AI? Key Points Join Carl and Fred as they discuss the unique role of […]

Data Gathering Challenges Abstract Enrico and Fred discuss discuss the challenges of data collection in reliability engineering, prompted by a listener working in asset reliability. They explore why gathering useful data is often the most difficult step, how modern connected systems are changing data availability, and why defining the purpose of analysis is essential before […]

2 HALT Objections Abstract Kirk and Fred discuss the value of HALT for a product late in a new product development process. Key Points Join Kirk and Fred as they discuss whether applying HALT yields a good ROI (return on investment) when they are already working on reliability problems discovered during standard development. Topics include: […]

Clarifying a Point About HALT Abstract Kirk and Fred discuss the continued meaning of the acronym HALT, which was originally coined by Gregg Hobbs, Ph.D., P.E., to stand for Highly Accelerated Life Test, which is a misnomer. Key Points Join Kirk and Fred as they discuss a listener’s question about the use of the term […]

Dealing with No Failures Abstract Mojan and Fred tackle the common engineering dilemma of what to do when a test concludes with zero failures. They discuss how to “artificially” assume a failure to benchmark against existing models and how to determine if your product is actually better than expected or if your test was simply […]

Reasons to Model Abstract Mojan and Fred discuss the strategic shift from modeling as a checkbox exercise to using RAM (Reliability, Availability, and Maintainability) models as a driver for proactive decision-making. They explore how modeling forces teams to confront “the weakest link” and align resources where they can have the most impact early in a program […]

Timely Reliability Thinking Abstract Fred shares insights from consulting with over 150 organizations on the perennial struggle between reactive “heroism” and proactive design. Mojan and Fred discuss the measurable benefits of investing in reliability early—such as reduced development time and lower warranty costs—and why 80% of companies still find themselves trapped in a “build-test-fix” cycle. Key […]

Modeling and Testing Abstract Mojan and Fred discuss the benefits of using failure models with testing. They explore the delicate balance between theoretical analysis and physical testing. While robust design starts with analysis, they discuss how testing serves as the ultimate “insurance policy” for decision-makers and why understanding the “Confidence Stack-up” is essential for a […]

One Sample Statistical Paradox Abstract Enrico and Fred discuss a listener’s question about using a single sample for testing. Key Points Join Enrico and Fred as they discuss how to work with a team that only wants to use single sample testing. Topics include: Sometimes a single sample is good enough Modeling and simulation then […]

Reliability Engineering Competencies Abstract Enrico and Fred discuss the essential or basic skills necessary to be a good reliability engineer. Key Points Join Enrico and Fred as they discuss a short list of skills or knowledge necessary to be a successful reliability engineer. Topics include: Reliability statistics and testing knowledge Understanding failure mechanisms and how […]

Why Your Product Requirements are Slipping (and How to Fix Them) Abstract Mojan and Dianna explore the often-murky transition from vague product “needs” to actionable engineering requirements. They discuss where the communication gap typically develops between product management and engineering and how to close it using tools like System and Concept FMEAs. By defining failure as […]

Reliability in Start-up vs. Established Businesses Abstract Dianna and Mojan discuss reliability in start-up vs. established businesses. Key Points Join Dianna and Mojan as they compare the challenges of implementing reliability programs in fast-paced startups versus well-resourced, established corporations. Topics include: the multi-hat reality short-term vs. long-term reliability demystifying the “black box” influencing through options […]

Assume Bugs Abstract Enrico and Fred discuss the idea that no design or development project is perfect. Key Points Join Enrico and Fred as they discuss the need to have an approach and a positive mindset to identify and resolve defects and bugs. Topics include: Assuming the design is perfect is foolish Encourage a positive […]

Effective Leadership Abstract Carl and Fred share their experiences and advices about leadership, and why it is essential to accomplishing reliability objectives. Key Points Join Carl and Fred as they discuss the subject of  developing leadership skills. Topics include: Difference between manager and leader What is the essence of leadership? Leadership is involved in all […]

Writing Skills Abstract Carl and Fred discuss the role of writing skills in conveying information to others and influencing the reliability of products and processes. Key Points Join Carl and Fred as they share their experience in what makes for excellent writing. Topics include: Are younger people losing the ability to write? What are the […]

Customer Expectations Abstract Dianna and Fred discuss the “fuzzy and shadowy” world of customer expectations, discussing how to set reliability requirements that actually keep customers coming back. Key Points Join Dianna and Fred as they discuss customer expectation of reliability. Topics include: The Warranty Trap: why designing a product to only last as long as […]