Usually, in a company, the first production, when the production is carried out to a certain stage, only began to consider the quality control, and finally over time, the product implied that the problem is slowly exposed, only to appreciate the need for reliability control, only to consider the need for a reliability engineer. As a reliability engineer, in this case, how to implement reliability work? In general, the implementation of reliability is divided into: the preparation of the plan, reliability testing, reliability enhancement, reliability to maintain the four major steps;
In fact, the reliability of the work of the most important, the most effective, the most fundamental is the four major steps above the outside of the fifth step: Reliability Design; but at present, more than 99% of the company (in addition to the military industrial enterprises outside) their reliability design is only stuck in the first four steps, there is no adequate reliability design. We will not discuss how to implement the reliability design here (you prawns in the future work, should take this as the main goal).
Now that you are fortunate enough to be a reliability engineer in a company, all you have to do is the first four steps.
One, the development of reliability work plan
For most companies, the reliability of the work is still only in the beginning stage; quite a part of the company's work in the reliability of the work is also very passive, some of the customer requirements to provide information on the reliability of the data only when the reliability of the work to start doing some even in the product has been returned to the reliability of the work to start doing a lot of companies in the reliability of the work is still blank. Many companies are still blank on reliability. Although the company's leaders began to consider the issue of reliability (otherwise, he would not have recruited you as a reliability engineer), but in terms of the company, the vast majority of personnel are still unfamiliar with the reliability, so the initial planning stage is particularly important.
First, you are recruited by the company as a reliability engineer, responsible for work related to reliability.
Next, you need to publicize the importance of reliability work; reliability work can not be accomplished by the strength of a single person, so that the company up and down every person understands the importance of the reliability of the necessity, especially the importance of senior leadership. Products that are not reliable enough can still be used, so it is easy to be ignored by most people. In addition, it is difficult to see the effect of the reliability work in six months, without the attention of the leadership, it is difficult to proceed smoothly. You can use comparative data (e.g., customer complaint/return rate of previous products, and customer complaint/return rate of products with reliability) to illustrate the importance of reliability at the right time. After that, the preparation of the reliability test plan; in the importance of reliability for the popularity of the introduction, you can do for the company's products to do some reliability testing program. It is recommended that the reliability plan is divided into two parts, the first part is the reliability test program, including the test process, sampling methods, testing methods, results determination and other specific content; the second part is the reliability of the work objectives, this part is of course to write that you want to work during the reliability of the work done in the research and development stage, through the reliability of the company's product quality control through the reliability of the design to reduce product quality, reduce product costs. This one can see the results, the plan must be written, and also leadership signature. The first part is to let the leadership know that you can do a lot of practical things, the second part is to let the leadership know that you have big ambitions.
Finally, the promotion of reliability testing program; this is a more critical step, its main purpose to do is to let the company's employees know the reliability of what to test, in order to enhance the reliability of targeted; through the promotion, discussion, but also to enable the company's employees to reach a consensus on more aspects to reduce the likelihood of detours. Can be discussed with the production technology department, R & D Department of reliability testing work can be given to the marketing department, production, after-sales departments to carry out some of the training work, if necessary, you can also ask other companies to "master" to the company to do some lectures and so on. In short, to let the whole company know that you are a reliability engineer, the benefits of doing so you will soon be able to experience. Remember: do not worry about the content of your speech is too simple (separated from the industry, such as mountains, even if there is an individual understanding of a point deeper than you, but he knows more than you will not be comprehensive), do not worry about the training time is too short (the shorter the better, as long as it is longer than 10 minutes can be), do not be afraid of (no one is perfect, or you have more than a million dollars per year), you are the company's leadership to confirm that specialize in reliability of the experts.
Two, the implementation of reliability testing
After all the preparatory work is done, the second step begins: test the reliability of the product. Before opening the real test, there are some preparations, such as the availability of equipment for testing. Generally speaking, reliability testing is mainly divided into environmental testing and mechanical testing; do environmental testing you need at least one "temperature and humidity alternating box", it is best to have a low-temperature refrigerator; do mechanical testing in the implementation of the test, you should at least have a "mechanical vibration table", it is best to have a "mechanical shock". It is best to have a "mechanical shock table". Generally small companies, in the experimental equipment will not be very perfect, you need to single-handedly build it up (from the temperature and humidity box to the shaker, to the EMC laboratory ....). . If there is no equipment in the company, it is necessary to buy a temperature and humidity box (price is not high, the utilization rate is not low), mechanical vibration table can not buy (higher price, utilization rate is not high; you can pay out the funds to third-party testing). If before you come to the company, the company has sporadically done the reliability test, may have some personnel and equipment, then you in the reliability test, you should apply for this part into your "door", named "Reliability Laboratory" or "Reliability Test Department". When there is a temperature and humidity box, you can start testing. The basic performance of the test; reliability test before the basic performance of the product must make a judgment. After the performance of the test, the product can be divided into three grades: one is a good product, the second is a defective product, the third is a defective product (between good and defective products, in the standard around 20% of the part). Good products can be used to do reliability testing, defective products can not be used to do reliability testing, defective products need to be analyzed (some of them are caused by defects in the production process - this part can not be used to do reliability testing, some of them are just some random phenomena of slight deviations in parameters - this part can be used to do reliability testing). In addition to determining whether it can be used for testing, the main thing is that it can also be used to compare the performance with the reliability test. Reliability testing; according to the test plan, the corresponding product vibration, high temperature and other tests. After each test, the need to measure the basic performance of the product (some tests require the measurement of basic performance in the testing process); and then compare and analyze the changes in basic performance before and after the reliability test to determine the reliability test results. Attention during the test: the test process, so that the equipment automatically record (preferably print) the test environment; test after the measurement of the sample is best with the sample belongs to the stage of the person responsible for. Changes in testing; many reasons, leading to the need for you to work in the actual kind of corresponding changes in some of the tests. See the next section); ③ such as equipment to control temperature and humidity at the same time in the initial rise may be out of range, you can change to set the temperature and then set the humidity; ④ temperature shock test may be a high temperature box, a low-temperature box and artificial to achieve (do not have to spend 300,000 yuan to buy a temperature shock box); ⑤ when the need for humidity in the more than 100 ℃, you can use the autoclave to achieve (to consider the accuracy of the test); ⑤ when the need for humidity above 100 ℃, you can use a pressure cooker to achieve (to consider the accuracy of the test); and so on. And so on.
No matter what kind of changes, you should have detailed change records, test records; the actual work of the experience and the way, you will not be less than me. You will do a better job than me.
Three, reliability growth
You can not just stay in the reliability testing stage, the essence of reliability work is the reliability design, only good reliability design/growth to save costs and improve product quality. Reliability improvement is mainly concentrated in the research and development stage, before finalization. Once the design has been finalized, or enter the mass production stage, and then want to improve the reliability from the design, is already unlikely (too much waste, too high cost). Most of the companies are due to poor product reliability, by the entire market requirements (increased cost of rework, returns increase) before starting to consider the reliability, but at this time the product has been put into the market! At this point you want to take the reliability of these products to a new height has been impossible, all you can do is look at the high return rate, but you must do a good job of the reliability of the next product. It is recommended that initially you focus on one product and do a good job with the reliability of one product. How do you grow reliability? The first thing to master is the production process, the production process, and the method of operation of each process should also be completely understood. This, without explanation, must be done.
In fact, to learn certain techniques, at least you should master the working principle of the company's products. Although you are not the R & D department, but you are responsible for the reliability of the R & D products, completely ignorant of the appropriate technology, the work is difficult to carry out. If it is a component product, each raw material used and the characteristics of the raw material should understand; if it is a system product, the hardware, software, structure should have an understanding of, such as the function of each module, the interface between the module, the function of the software and so on.
Next, to establish a team (to give her a good name), responsible for the reliability of the growth, members of the more good, but at least should include: the company's leadership, reliability engineers, R & D engineers, production technology, logistics personnel each one. The power and necessity of the team I will not say more here. Finally, it is to improve the action; when the test process is bad, we must analyze and improve the bad phenomenon, and standardize the improvement measures, so as to ensure that the quality is improved. The most commonly used method is "test-improvement-test", so the cycle, gradually improve. It should be emphasized that every improvement should be handled seriously and thoroughly, and the data should be used to close the case. Like ISO9000, an improvement usually includes the following steps.
1. Reliability testing; according to the test plan, sampling test;
2. Phenomenon description; this part should be as detailed as possible to describe the adverse phenomena, including the name of the product (hardware and software version number), the time of occurrence, location, to achieve the "chronological record of all the conditions associated with the product";
3.
3. cause analysis; the analysis of the cause, should be traced to the bottom, to find the root cause of the problem, rather than in the phenomenon of conversion between, to "manually generate the cause, the phenomenon can be completely reproduced";
4. improvement actions; according to the analysis of the cause, to take the corresponding measures. At this time, two aspects should be considered: one is whether the existing other products will be such a problem, how to improve; one is how to prevent the subsequent product such problems;
5. Effect confirmation; the main confirmation of two points: one is to improve the implementation of the action; one is to improve the implementation of the action of the product after the implementation of the product will still be such a problem (with the data to prove it).
6. Formation of standards; if confirmed, the improvement measures are effective (defective rate reduction), these measures should be written into the operating specification to guide the subsequent production. Also consider whether this measure is also effective for other similar products and other issues;
7. Sampling and testing.
After many such "test-improve-test", the product will have fewer and fewer defects, and the quality will be better and better. Eventually, when the samples are tested for reliability, there are no defects.
Four, reliability maintenance
Reliability maintenance mainly refers to the large-scale production, product reliability can be stable in the best state; more difficult to do is "stable in the best state", to do this requires a variety of efforts.
1. suppliers
In order to ensure that the supply of raw materials suppliers to stabilize the best state, we can control in four steps:
1. carefully select the supplier to ensure that it meets the "Qualified Supplier Qualification";
2. supply process, the IQC inspection, reliability testing should be strictly enforced;
3. Supply process, IQC inspection, reliability testing should be strictly enforced;
3. All process information **** enjoy; inspection process problems and anomalies should be the first time to notify the supplier to seek improvement, to be proved through a variety of ways to improve the effectiveness of the good, before closing the case;
4. Regular feedback to the supplier of the quality of the status of the meeting to discuss, if necessary.
2. Production process
Production is a process that contains the most "variables", mechanization and automation is to ensure stability of the most effective factors; in the absence of the reality of the full automation of the situation, the production process is mainly the following control points:
1. Inspection of the material put into use in good condition;
2. Check whether the operation of each station meets the operational requirements;
3. Check whether the output of each station meets the requirements of the next station;
4. Check whether the performance of the product meets the requirements of the finished product;
5. Check whether the reliability of the product meets the stipulated requirements;
3. Tests
Tests for the company's products. Various tests. During the testing process, any problem needs to be improved to enhance the quality of the product. The emergence of any problem is to point out a direction for us to move forward; the improvement of the problem, marking the quality of another step up. With this attitude, what else can not be done.