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
100
90
80
Reliability
70
60
50
Low Cost Med Low Med High High Cost
Reliability vs. Initial Cost
Here is an example – What elements will effect its shape and slope
Reliability vs Initial Cost
100
90
80
Reliability
70
60
50
Low Cost Med Low Med High High Cost
Maintainability vs. Initial Cost
What is your Experience or “Gut Feel” of what the shape of this
curve
Maintainability vs Initial Cost
100
90
80
70
Maintainability
60
50
Low Cost Med Low
Med
High
High
Cost
Maintainability vs. Initial Cost
Here is an example – What would effect the shape and slope of
this curve?
Maintainability vs Initial Cost
100
90
80
70
Maintainability
60
50
Low CostMed Low Med
High
High
Cost
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
100
90
80
70
Life Cycle Cost
60
50
Low
Cost
Med
Low
Med
High
High
Cost
Life Cycle Cost vs. Initial Cost
Here is an example – What elements would effect the shape and
slope of this curve?
Life Cycle Cost vs Initial Cost
100
90
80
70
Life Cycle Cost
60
50
Low
Cost
Med
Low
Med
High
High
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