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

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 a listener’s question about data gathering challenges. Key Points Join Enrico and Fred as they discuss a common problem of finding useful data for reliability analysis within an organization. Topics include: Warranty or repair data is often collected for other reasons, not reliability work. Field data may […]

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 […]

Starting a New Reliability Team Abstract Chris and Fred discuss a few ideas on creating a reliability team in your organization. Key Points Join Chris and Fred as they discuss a few steps to consider when tasked with setting up a reliability team. Topics include: Do you really need a team? It’s about culture and […]

Presenting Skills Abstract Carl and Fred share their experiences in presenting, what they have learned, what is most important in achieving excellent presentations. Key Points Join Carl and Fred, as they discuss the length and breadth of presenting. This is a large subject, so many different aspects are covered in the podcast. Topics include: Don’t […]

Getting and Giving Feedback Abstract Carl and Fred discuss the role of receiving feedback in improving one’s ability to implement the various reliability tasks and methods. They also cover how to give feedback to others, so it is most meaningful. Key Points Join Carl and Fred as they continue to discuss the “soft” skills that […]

Leaving a Team Better Off Abstract Mojan and Fred discuss how reliability engineers can be most supportive in organizations to enable the most value-extraction from them and the team. Key Points Building on the discussion from episode 1138, Mojan and Fred dive into the ultimate measure of a successful Reliability Engineer: making oneself redundant. They […]

What is In it For Them Abstract Mojan and Fred discuss the benefits of Design for Reliability and how to demonstrate them. Key Points Join Mojan and Fred as they tackle the fundamental question in reliability engineering: How do you demonstrate the value of Design for Reliability (DfR) when the benefits are problems that never occurred? […]

Podcast Listens Abstract Kirk and Fred discuss the almost 10 years of Speaking of Reliability podcasts and podcasting in general. Key Points Join Kirk and Fred as they discuss the world of podcasting and the data about listeners and podcast popularity. Topics include: Even though we can know how many subscribers downloaded our podcast, we […]

Early Life Failures Abstract Kirk and Fred discuss the impact of early life failures on the customer Key Points Join Kirk and Fred as they discuss how failures after a customer starts to have confidence in a product it fails, is the most costly and frustrating for the customer Topics include: Out-of-the-box failures can be […]

Pitfalls of Reliability Testing Abstract Enrico and Fred discuss an array of problems that may arise with reliability testing. Key Points Join Enrico and Fred as they discuss reliability testing and problems that may leads to faulty results. Topics include: Accelerated testing and poor acceleration factor models Too few samples to get a meaningful result […]

Build, Test, Fix Abstract Chris and Fred discuss the product design process commonly called build, test, fix. Key Points Join Chris and Fred as they discuss an approach to creating a new product and how relaibility happens. Topics include: Build early and often. Simulate concepts, model ideas, mock up concepts. Test early and to failure. […]

Statistics and Reliability Abstract Chris and Fred discuss a listener’s question on whether or not to study statistics. Key Points Join Chris and Fred as they discuss the value of really understanding statistis as a reliability engineer. Topics include: A grand set of tools to grapple with the world’s variations. The ability to detect and […]

AI & Reliability Use Abstract Philip and Fred discuss a few ideas around using AI for reliability work. Key Points Join Philip and Fred as they discuss how Philip has jumped into using AI for many reliability tasks. Topics include: Creating apps or scripts to accomplish routine tasks quickly Dealing with very, very large dataset […]

Selecting Tests Abstract Dianna and Fred discuss the critical process of selecting appropriate reliability tests, maximizing value while avoiding the common pitfalls of over-testing or testing the wrong parameters. Key Points Join Dianna and Fred as they discuss selecting tests, maximizing value while avoiding the common pitfalls of over-testing or testing the wrong parameters. Topics […]

Capturing Value Abstract Dianna and Fred discuss capturing value, documenting the cost of unreliability, and speaking the language of management. Key Points Join Dianna and Fred as they discuss the often-overlooked necessity for reliability and quality engineers to quantify value, document the cost of unreliability, and speak the language of management. Topics include: Why quantifying […]

Today’s New Reliability Challenge Abstract Mojan and Fred discuss the range of new challenges facing reliability engineering work. Key Points Join Mojan and Fred as they discuss today’s reliability challenges that face today’s reliability engineers and teams. Topics include: Many are challenges that rhythm with the challenges in the past, like shorter development times and […]

Reliability ≠ Testing Abstract Mojan and Fred discuss the idea that a product’s reliability is not the same as doing reliability testing. Key Points Join Mohan and Fred as they discuss the importance of not confusing testing with a product’s actual reliability. Topics include: A product’s reliability exists whether or not we perform any testing. […]

Understanding Assumptions Abstract Carl and Fred discuss why it essential for reliability engineers to understand the assumptions that go into any reliability activity. Key Points Join Carl and Fred as they discuss the broad subject of assumptions. What are they? When are they needed? Why are they important? Topics include: How often do assumptions go […]

Good and Bad Meetings Abstract Carl and Fred discuss what makes some meetings really useful and others a waste of time. Key Points Join Carl and Fred as they discuss how to lead or participate in effective meetings. Topics include: Classes are available on how to run excellent meetings. Leading or participating in effective meetings […]

Roofing Material Failure Abstract Kirk and Fred discuss the recent failure of his roofing tiles and the testing that should have been done for roofing materials that will be used in all geographical locations. Key Points Join Kirk and Fred as they discuss how his roofing failed and the manufacturer going out of business Topics […]