DuPont Design for Reliability Tactical Approach to Front End Loading 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?

Reliability vs. Initial Cost Here is an example – What elements will effect its shape and slope Elements that would effect the shape and slope: Available technologies – products that would work Complexity of the processes Range of cost of competing equipment Actual cost vs reliability of competing equipment (cheaper equipment could be more reliable) 5

Maintainability vs. Initial Cost What is your Experience or “Gut Feel” of what the shape of this curve

Maintainability vs. Initial Cost Here is an example – What would effect the shape and slope of this curve? Items that would effect the shape and slope of this curve: Competing technologies (range of available equipment that would work What is required to improve maintainability (layout, spacing, equipment size, etc) Design alternatives available 7

Life Cycle Cost vs. Initial Cost What is your Experience or “Gut Feel” of what the shape of this curve

Life Cycle Cost vs. Initial Cost Here is an example – What elements would effect the shape and slope of this curve? Elements that would effect the shape and slope of this curve: Available choices of equipment that would work Maintenance needs of the equipment Energy consumption of the equipment 9

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