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

FMEA Compensating Provisions Abstract Carl and Fred discuss the concept of compensating provisions in FMEA—design features or operator actions that mitigate the consequences of failures and improve safety. Key Points Join Carl and Fred as they discuss how to identify and evaluate Compensating Provisions in FMEAs. Topics include: Compensating provisions is an FMEA element present in military […]

FMEA Scales Abstract Carl and Fred discuss whether FMEA teams should use the 1–10 Severity, Occurrence, and Detection (SOD) scales in some FMEA Standards, or whether they can tailor the scales to better fit their applications. Key Points Join Carl and Fred as they discuss the essence of FMEA scales and how to apply them […]

AI Names ‘Best’ Reliability Engineers Abstract Kirk and Fred discuss a recent AI search topic: who is the best reliability engineer? Key Points Join Kirk and Fred as they discuss how AI tends to provide answers with some bias towards the person inquiring and maybe a little bit of confirmation bias. Topics include: Why do Fred […]

Electronics in Today’s Vehicles Abstract Kirk and Fred discussed a recent search topic on electronics reliability when we found an article on the durability of automotive electronics. Key Points Join Kirk and Fred as they discuss automotive reliability and how many failure causes stem from variations in the long vertical supply chain in manufacturing. Topics […]

They Are Just Not Listening Abstract “They’re just not listening.” But what if the problem isn’t their ears—it’s their incentives? Join Fred and Mojan as they explore why people resist change, what actually motivates behavior, and how to drive change when you don’t have formal authority. Key Points Join Fred and Mojan as they explore […]

MTBF to Weibull? Abstract Enrico and Fred discuss a listener’s question about the process to convert a MTBF value to a Weibull curve. Key Points Join Enrico and Fred as they discuss a few questions concerning a proposed method to derive a Weibull curve from a MTBF value. Topics include: The available data Making assumptions […]

Best Lessons Learned Method Abstract Capturing lessons learned can be a monumental waste of time—or it can be transformative. Join Fred and Mojan as they explore what separates the two through a cautionary tale: when three engineering teams independently removed electrostatic discharge (ESD) protection from a product to save costs, it nearly bankrupted the division. […]

Damage Modeling Abstract What exactly is “damage” in engineering, and how do you predict when it will end a product’s life? Join Mojan and Fred as they explore damage modeling through the lens of reliability engineering. They discuss why understanding damage accumulation is critical for both designers and field teams, and how monitoring thresholds throughout […]

Weibull and Crow-AMSSA Key Points On the Use of Weibull vs. Crow AMSAA (Crow-AMSAA) for Repairable Systems – Philip Sage introduced the topic after seeing a LinkedIn discussion emphasizing Crow AMSAA over Weibull for repairable systems. – The post initially appeared to strongly advocate against Weibull, but on a closer read, it functioned as an […]

Complex Product Reliability Abstract Enrico and Fred discuss the difference between complex and complicated products and what it means for reliability engineering. Using examples ranging from rockets and home appliances to computers and fountain pens, they explore the limits of component-level analysis, the role of system testing, and why surprises remain unavoidable even in well-engineered […]

What is Reliability? Abstract What is the definition of reliability? Outside of the field of reliability, who defines it or what a failure is? Join Mojan and Fred as they explore how reliability is perceived across the product development ecosystem—from customers to suppliers to design engineers—and why the classic “but it met the spec!” defense […]

Yes, Culture Can Change Abstract Carl and Fred discuss why organizational culture is not fixed, and how reliability-focused leadership, communication, and sustained engagement can gradually transform the way teams think and operate. Key Points Join Carl and Fred as they discuss how reliability culture can change in a company of organization. Topics include: Organizational culture […]

Why Gaps? Abstract Carl and Fred discuss why effective reliability planning begins with identifying the gaps between an organization’s current capabilities and its long-term reliability vision. Key Points Join Carl and Fred as they discuss why identifying gaps are often missed in reliability planning and how to remedy. Topics include: Reliability planning should begin with […]

Networking and Professional Development Abstract Enrico and Fred discuss the value of professional networking in reliability engineering. Drawing from their experiences with Accendo Reliability, they explore how sharing knowledge, contributing content, and engaging with experts outside one’s company can accelerate professional growth, strengthen reliability culture, and create opportunities for both individuals and organizations. Key Points […]

The Reliability Contract Abstract Dianna and Fred discuss the reliability contract: the RE’s role as internal consultant. Key Points Join Dianna and Fred as they discuss the reliability engineer’s role as an internal consultant and why setting clear expectations is vital for project success. Topics include: the three main ways reliability experts provide value  how […]

Reliability and Volume Abstract Dianna and Fred discuss reliability and volume, comparing high-volume products with low-volume high-stakes products. Key Points Join Dianna and Fred as they compare reliability strategies for NASA’s one-of-a-kind lunar instruments versus mass-produced consumer electronics. Topics include: why the definition of reliability remains constant for the customer  how risks shift from craftsmanship […]

Got a Chamber? So… Abstract In this episode of the Podcast, Fred Schenkelberg and Philip Sage explore the importance of aligning test methods with real-world reliability problems rather than defaulting to familiar tools or pre-existing equipment. Through anecdotes from industry experience—including discussions on environmental chambers, vendor testing standards, and engineering challenges in fields like automotive, […]

Right Tool at the Right Time Abstract Philip and Fred discuss a common challenge in reliability engineering: using the right tool—not just the one you’re most comfortable with. Key Points In this episode of Speaking of Reliability, Fred Schenkelberg and Philip Sage explore a common challenge in reliability engineering: using the right tool—not just the one […]

Reliability is Still Important Abstract Kirk and Fred discuss how to keep reliability a priority when dealing with changing suppliers. Key Points Join Kirk and Fred as they discuss shifting suppliers and how to ensure reliability when components or manufacturing locations change. Topics include: If a product was developed using HALT methods, then it should […]

Tradeoffs and Right to Repair Abstract Kirk and Fred discuss right-to-repair laws and the trade-offs for design and manufacturing. Key Points Join Kirk and Fred as they discuss how manufacturers now have to balance making a product reliable and also capable of being repaired by the end-user. Topics include: There can be a big trade-off […]

Changing Conditions and Challenges Abstract Enrico and Fred discuss the many ways working on creating a reliable product is difficult. Key Points Join Enrico and Fred as they discuss the impact of changes in economic forces, which, for one, creates the need to adjust reliability plans. Topics include: The impact of short-term budget tightening. The […]

Lifecycle Target Misalignment Abstract Dianna and Fred discuss the dangers of lifecycle target misalignment and how they impact product engineering and customer satisfaction. Key Points Join Dianna and Fred as they discuss the dangers of lifecycle target misalignment and how they impact product engineering and customer satisfaction. Topics include: The story of a 25-year-old cell […]

Ongoing Projects Abstract Kirk and Fred discuss the 10th anniversary of the publication of Kirk’s book,  Next Generation HALT and HASS: Robust Design of Electronics and Systems. Key Points Join Kirk and Fred as they discuss the reasons and relevance of writing a book on HALT and HASS and why it was intended to be […]

25 Year Old Communicator Abstract Kirk and Fred discuss how, for most electronic equipment, technological obsolescence comes well before devices wear out. Key Points Join Kirk and Fred as they discuss how the vast majority of solid-state electronics have much longer intrinsic lifetimes than their period of technological usefulness. Topics include: For the vast majority […]

Future Reliability Engineering Abstract Mojan and Fred discuss the monumental reliability challenges of a mission to Mars. While the fundamental physics remains the same, they explore why success depends on a more rigorous application of existing methods, autonomous systems, and the shift toward heavy simulation and in-situ repairs. Key Points Join Mojan and Fred as they […]

Best Recommended Option Abstract Chris and Fred discuss which liner is best to use on a centrifugal pump, or make a general recommendation. How do you make a recommendation using reliability performance? Key Points Join Chris and Fred as they respond to a listener who asked how to identify the best liner for a centrifugal […]

Analyzing failure data for repairable systems sounds straightforward—until you start asking the right questions. In this episode, Chris and Fred unpack a listener’s challenge: how to model reliability when failed components are repaired and returned to service. The discussion quickly moves beyond Weibull curves and into a more uncomfortable reality—maintenance itself often increases failure risk, at least in the short term. With limited data and multiple failure mechanisms at play, traditional statistical approaches can mislead more than they help. Instead, the focus shifts to understanding failure physics, questioning assumptions, and making practical decisions that actually improve reliability—not just model it.

Modeling Maintenance Benefits Abstract Mojan and Fred discuss how to integrate service plans into reliability target planning. They explore the shift from “worst-case” maintenance schedules to data-driven strategies, highlighting how predictable failure mechanisms and telemetry allow teams to take credit for high availability in their reliability models. Key Points Join Mojan and Fred as they discuss the […]

Why Paper Jams Persist Abstract Mojan and Fred dive into the surprisingly complex world of the “paper jam,” a problem that remains a daily frustration despite decades of high-level scientific research. From Fred’s time at HP to the massive technical laboratories at Xerox, they explore why the interaction between rigid mechanisms and non-rigid, organic media […]

Risk Prioritization in FMEA Abstract Carl and Fred discuss a question from a reader about risk prioritization in FMEA procedure. Key Points Join Carl and Fred as they discuss the role of risk prioritization in FMEA, what is it, and what is the best way to prioritize risk in FMEA. Topics include: Discussion of history […]

Our Unique Role in Reliability Abstract Carl and Fred discuss the ongoing challenge between doing reliability work ourselves and enabling others to accomplish the work. And what is the future human role in the field of reliability, given the advancements in AI? Key Points Join Carl and Fred as they discuss the unique role of […]

Data Gathering Challenges Abstract Enrico and Fred discuss discuss the challenges of data collection in reliability engineering, prompted by a listener working in asset reliability. They explore why gathering useful data is often the most difficult step, how modern connected systems are changing data availability, and why defining the purpose of analysis is essential before […]

2 HALT Objections Abstract Kirk and Fred discuss the value of HALT for a product late in a new product development process. Key Points Join Kirk and Fred as they discuss whether applying HALT yields a good ROI (return on investment) when they are already working on reliability problems discovered during standard development. Topics include: […]

Clarifying a Point About HALT Abstract Kirk and Fred discuss the continued meaning of the acronym HALT, which was originally coined by Gregg Hobbs, Ph.D., P.E., to stand for Highly Accelerated Life Test, which is a misnomer. Key Points Join Kirk and Fred as they discuss a listener’s question about the use of the term […]

Dealing with No Failures Abstract Mojan and Fred tackle the common engineering dilemma of what to do when a test concludes with zero failures. They discuss how to “artificially” assume a failure to benchmark against existing models and how to determine if your product is actually better than expected or if your test was simply […]

Reasons to Model Abstract Mojan and Fred discuss the strategic shift from modeling as a checkbox exercise to using RAM (Reliability, Availability, and Maintainability) models as a driver for proactive decision-making. They explore how modeling forces teams to confront “the weakest link” and align resources where they can have the most impact early in a program […]

Timely Reliability Thinking Abstract Fred shares insights from consulting with over 150 organizations on the perennial struggle between reactive “heroism” and proactive design. Mojan and Fred discuss the measurable benefits of investing in reliability early—such as reduced development time and lower warranty costs—and why 80% of companies still find themselves trapped in a “build-test-fix” cycle. Key […]

Modeling and Testing Abstract Mojan and Fred discuss the benefits of using failure models with testing. They explore the delicate balance between theoretical analysis and physical testing. While robust design starts with analysis, they discuss how testing serves as the ultimate “insurance policy” for decision-makers and why understanding the “Confidence Stack-up” is essential for a […]

One Sample Statistical Paradox Abstract Enrico and Fred discuss a listener’s question about using a single sample for testing. Key Points Join Enrico and Fred as they discuss how to work with a team that only wants to use single sample testing. Topics include: Sometimes a single sample is good enough Modeling and simulation then […]

Reliability Engineering Competencies Abstract Enrico and Fred discuss the essential or basic skills necessary to be a good reliability engineer. Key Points Join Enrico and Fred as they discuss a short list of skills or knowledge necessary to be a successful reliability engineer. Topics include: Reliability statistics and testing knowledge Understanding failure mechanisms and how […]

Why Your Product Requirements are Slipping (and How to Fix Them) Abstract Mojan and Dianna explore the often-murky transition from vague product “needs” to actionable engineering requirements. They discuss where the communication gap typically develops between product management and engineering and how to close it using tools like System and Concept FMEAs. By defining failure as […]

Reliability in Start-up vs. Established Businesses Abstract Dianna and Mojan discuss reliability in start-up vs. established businesses. Key Points Join Dianna and Mojan as they compare the challenges of implementing reliability programs in fast-paced startups versus well-resourced, established corporations. Topics include: the multi-hat reality short-term vs. long-term reliability demystifying the “black box” influencing through options […]

Assume Bugs Abstract Enrico and Fred discuss the idea that no design or development project is perfect. Key Points Join Enrico and Fred as they discuss the need to have an approach and a positive mindset to identify and resolve defects and bugs. Topics include: Assuming the design is perfect is foolish Encourage a positive […]

Effective Leadership Abstract Carl and Fred share their experiences and advices about leadership, and why it is essential to accomplishing reliability objectives. Key Points Join Carl and Fred as they discuss the subject of  developing leadership skills. Topics include: Difference between manager and leader What is the essence of leadership? Leadership is involved in all […]

Writing Skills Abstract Carl and Fred discuss the role of writing skills in conveying information to others and influencing the reliability of products and processes. Key Points Join Carl and Fred as they share their experience in what makes for excellent writing. Topics include: Are younger people losing the ability to write? What are the […]

Customer Expectations Abstract Dianna and Fred discuss the “fuzzy and shadowy” world of customer expectations, discussing how to set reliability requirements that actually keep customers coming back. Key Points Join Dianna and Fred as they discuss customer expectation of reliability. Topics include: The Warranty Trap: why designing a product to only last as long as […]

Standard Reliability Methods Abstract Dianna and Fred discuss the importance of standard reliability methods within a company, to ensure teams are using effective, proven techniques rather than just following a generic recipe. Key Points Join Dianna and Fred as they discuss standard reliability methods. Topics include: Internal “Cliffnotes” for Reliability: the value of creating short, […]

Trick Questions Abstract Kirk and Fred discuss questions that can reveal some job candidates’ knowledge or lack of understanding of new product reliability development Key Points Join Kirk and Fred as they discuss which questions and how to ask them in a potential reliability engineering position can distinguish those who really understand the process of […]

Getting Hired Abstract Kirk and Fred discuss the process of finding a job in Reliability Engineering Key Points Join Kirk and Fred as they discuss some of the best ways to get into a job that fits with your skills. Topics include: Don’t wait until you need a new job to start connecting with others and […]

Setting up a reliability team sounds like progress—but it often delivers very little. In this episode, Chris and Fred unpack what actually makes a reliability team effective, starting with a simple truth: structure doesn’t matter nearly as much as culture. Instead of focusing on org charts or tools, they explain why reliability must be embedded in decision-making across the organization. The discussion also highlights how to find quick wins—whether through early testing, simple process improvements, or basic data analysis that reveals the real drivers of failure. If you’re serious about improving reliability, this episode will help you avoid the common traps and focus on what actually works.