1. DuPont Design for Reliability Tactical Approach to Front End Loading
Alfred E. Ogden, MSRE, CMRP
DuPont Reliability Engineer
MARS Conference 2012 – Galveston, TX

2. Agenda Differentiating between Quality and Reliability
Value Proposition
“Live” Case Study
DF “X”: Front End Loading Tactical Approach

3. 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.

4. Reliability vs. Initial Cost
What is your Experience of what the shape of this curve would look like?

5. 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

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

7. 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

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

9. 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

10. 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

11. 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

12. 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

13. Questions