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

A Greyspace Focus Abstract Mojan and Fred discuss decision-making situations when there is no clear must or must-not-do. Key Points Join Mojan and Fred as they discuss how to handle the grey areas when setting priorities or allocating resources. Topics include: How deep into an FMEA should you take action? Not all components are critical […]

What can microscopic structures tell us about the reliability of an engineering component? Mojan and Enrico explore two powerful material characterization techniques: scanning electron microscopy and X-ray computed tomography. They explain how electron microscopy reveals fracture surface details, while tomography allows engineers to reconstruct internal structures without relying solely on surface observations. Drawing on practical experience with fiber-reinforced polymers, they discuss how fiber clustering can influence fatigue crack initiation and how voids affect mechanical performance. The episode also examines the challenges of interpreting tomography results and quantifying defect severity, demonstrating why understanding material microstructure is essential for effective failure analysis and reliable product design.

Failure analysis should explain not only how a component failed, but why the failure occurred in the first place. Mojan and Enrico explore how material science and reliability engineering work together to uncover root causes and prevent recurring problems. They compare fracture analysis in metals and polymers, discuss the challenges of interpreting damage mechanisms, and examine how material characterization techniques can reveal hidden defects. The conversation also highlights a critical manufacturing challenge: components made from the same material and geometry can behave differently because of processing conditions. The episode shows why effective failure analysis requires combining physical evidence, statistical analysis, and manufacturing knowledge rather than relying on a single observation.

Plastics provide exceptional design freedom, but ensuring their reliability requires understanding how materials behave under real operating conditions. Mojan and Enrico discuss why material selection, manufacturing processes, and reliability requirements must be considered together from the earliest design stages. They explore mission profiles, load paths, and damage mechanisms including fatigue, creep, and stress relaxation, explaining how multiple mechanisms can affect the same component. From plastic gears and sealing elements to injection-molded parts, the discussion highlights why early design reviews and engineering judgment are essential. The episode demonstrates that reliable plastic design begins with understanding how a component is loaded and how it might eventually fail.

How can engineers measure reliability maturity throughout product development—and when should a project be stopped because its reliability is not good enough? Responding to a listener question, Chris and Enrico examine the value and limitations of reliability KPIs, project gates, and demonstration testing. They explore why early design decisions often require informed judgment rather than precise numerical targets, and why detailed reliability analysis should focus on the most significant failure mechanisms. The discussion also challenges the reliance on final demonstration tests, explaining why statistical confidence is not a substitute for understanding how and why a product might fail.

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AI and the 6-Steps Part 2 Abstract Carl and Fred  continue to discuss the use of AI in achieving high reliability. This podcast episode  continues the six-step reliability engineering process, focusing primarily on Step 4 (methods), Step 5 (planning), and Step 6 (execution). Key Points Join Carl and Fred as they discuss how AI can […]

AI and the 6-Steps Part 1 Abstract Carl and Fred explore how AI can be integrated into the six-step reliability engineering process, emphasizing that AI should be treated as a powerful tool that assists humans rather than replacing human judgment, experience, and critical thinking. This is part one of two parts. Key Points Join Carl […]

Material selection can determine whether a component performs reliably throughout its intended life. Mojan and Enrico compare experiences from consumer electronics, automotive systems, robotics, and plastics engineering to explore the relationship between materials and reliability. They discuss failure analysis, damage mechanisms, engineering requirements, supplier influence, and the practical challenges of introducing alternative materials into production. The episode highlights why engineers should treat material selection as an early Design for Reliability decision rather than simply continuing with materials used in previous product generations.