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

GM knew its ignition switch failed an internal torque specification before the affected vehicles entered production. Yet the switch was approved, field problems followed, and an improvement costing less than $1 per vehicle was later rejected. Eventually, approximately 2.6 million vehicles were recalled, with enormous financial and human consequences. Chris uses the GM ignition switch failure to make a broader reliability engineering point: finding problems is not enough. Engineers and leaders must act while changes are still inexpensive. Earlier changes the economics—and waiting until testing or customers expose a failure can turn a simple engineering decision into an extraordinarily expensive one.

What does reliability mean when the customer thinks your product has failed even though it still technically works? And how should engineers measure reliability when failures involve software defects or patient safety rather than conventional hardware wear-out? Chris and Enrico continue their examination of reliability metrics by looking at customer ratings, brand reputation, medical devices, and software. They discuss why customer expectations matter, why medical reliability and safety overlap, and why software cannot simply be forced into traditional hardware reliability models. The discussion also highlights a growing systems-engineering problem: reliable products increasingly depend on hardware and software teams working together from the beginning.

Reliability metrics are supposed to help engineers make better decisions—but what happens when the metric itself points you in the wrong direction? Chris and Enrico examine how consumer products, electronics, automotive applications, and defense measure reliability, from warranty claims and FIT rates to MTBF. They challenge assumptions about infant mortality, extremely long predicted component lives, and the usefulness of reducing complex failure behaviour to a single number. The episode makes the case that reliability engineering should start with the business or engineering problem and then select the appropriate metric—not simply inherit whatever metric an industry has traditionally used.

Can generative AI become a useful coach for engineers preparing presentations, podcasts, or other professional communication? Carl and Enrico discuss the role feedback has played throughout their careers and compare traditional human feedback with the increasingly accessible feedback offered by AI. They examine why criticism needs to be accurate and actionable, whether direct negative feedback can sometimes motivate greater improvement, and why professionals should continue asking others for candid opinions regardless of experience. The discussion also considers the limitations of AI feedback: without understanding the purpose and context of a communication, AI may optimize for the wrong objective. Human listeners can also recognize qualities such as passion, credibility, and inspiration that are difficult to capture through a purely structural assessment.

What happens when a reliability engineer works in an organization where problems are hidden, procedures become checkboxes, or management is reluctant to hear bad news? Carl and Enrico discuss what separates a strong reliability culture from one that merely follows processes. They examine the importance of technical competence, speaking openly about risks, using design reviews to create shared ownership, and understanding what managers and other stakeholders actually care about. The discussion also explores how engineers can influence organizations that are resistant to change. Rather than trying to transform culture through procedures alone, the episode makes the case for combining strong reliability methods with communication, practical solutions, stakeholder awareness, and visible project successes that demonstrate why reliability matters.

Decision Room Carry Problem Abstract Dianna and Mojan discuss the decision room carry problem. Key Points Join Dianna and Mojan as they discuss “decision room carrying,” comparing how decisions are made in one room versus how they are executed by the teams responsible for carrying them out. Topics include: Why decisions made in isolated rooms […]

When to Use Sensors Abstract Not every single piece of data is worth collecting. Join Mojan and Dianna as they explore how to think strategically about sensors and monitoring systems. From health tracking wearables that collect “almost too much data” to manufacturing floors transformed by AI-enabled sensors, they discuss when sensors actually drive better decisions—and when […]

A widespread internet outage affecting services such as Microsoft Teams, Zoom, Reddit and Discord wasn't caused by hackers or a software bug—it was likely triggered by damage to critical fibre optic infrastructure. In this episode, Chris Jackson explores how a single hardware failure exposed hidden dependencies throughout the internet and why redundancy is often far more fragile than engineers assume. Through real-world examples from aviation, automotive systems, nuclear power and Netflix's famous Chaos Monkey program, Chris explains how common-cause failures defeat backup systems and why understanding these hidden connections is essential for building truly reliable products and infrastructure.

FMEA & AI: What is the Human Role? Abstract Carl and Dianna discuss the emerging role of artificial intelligence in FMEA, emphasizing that AI should enhance—not replace—the human expertise required for effective risk analysis. Key Points Join Carl and Dianna as they share their experiences with AI support for engineering analyses like FMEA. They conclude […]

How to Select FMEA Abstract Dianna and Carl discuss how to select FMEA. Key Points Join Dianna and Carl as they discuss how to select FMEA strategically, focusing on how to move beyond random or checkbox approaches to provide real engineering value. Topics include: The philosophy of doing fewer FMEAs really well rather than many […]

The Evolving Nature of FMEA Abstract Carl and Fred discuss how the fundamentals of FMEA have remained constant over the decades while the methods, tools, and applications have evolved to better support product development in today’s fast-paced engineering environment Key Points Join Carl and Fred emphasize that successful FMEA depends on critical thinking, knowledgeable teams, […]

AI Techniques and Projects Abstract Dianna and Chris discuss AI techniques and projects they’ve been working on. Key Points Join Dianna and Chris as they discuss why AI in reliability should be treated as a powerful enhancer for pre-existing knowledge rather than a shortcut for the engineering basics. Topics include: AI-assisted FMEA approach that transitions […]

DFR and Reliability Engineers Abstract Enrico and Fred discuss the role of reliability engineers and implementing design for reliability. Key Points Join Enrico and Fred as they discuss how reliability professionals can assist, not do, design for reliability. Topics include: The various tools involved with a good design for reliability program. The problem with a […]

What makes Accendo Reliability valuable? In this episode, Chris and Fred explore how a free, practitioner-driven platform helps engineers solve real-world reliability problems every day. The discussion goes beyond website traffic and content metrics to examine the true value of shared knowledge—helping engineers learn faster, make better decisions, and avoid costly mistakes. They also discuss why practical experience often carries more weight than academic theory alone, and how contributors benefit by building trust and credibility within the industry. If you've ever relied on an article, podcast, webinar, or case study to solve a problem, this episode highlights why knowledge sharing remains one of the most powerful tools in reliability engineering.

Physics-of-failure models are often presented as the ultimate solution for predicting reliability—but are they always necessary? In this episode, Chris and Fred explore a listener's question about finding reliable references for physics-of-failure models, particularly for electronics and PCB assemblies. The discussion highlights the spectrum of available models, from simple empirical equations to highly detailed simulations requiring extensive material and manufacturing data. More importantly, they explain why engineers should start by defining the decision they need to make before searching for increasingly sophisticated models. If you're trying to improve reliability, select materials, design accelerated tests, or understand failure mechanisms, this episode offers practical guidance on when physics-of-failure modeling adds value and when simpler approaches may be more effective.

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 importance of ongoing networking and professional development. Key Points Join Enrico and Fred as they discuss the various ways that getting to know your peers supports your and thier professional development. Topics include: Internal and external networking – really talking to other people Learn and […]

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 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 […]