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CAE Solutions DfR, IoT and PLM: How to achieve betterperforming products Chuck Cimalore • CTO, Omnify Software

D

Design for Reliability (DfR) identifies key design parameters and potential failure rates inherent in a design and develops procedures to ensure that a product meets its reliability requirements for the duration of its lifetime. Digital Transformation is impacting product reliability. Trends in product personalization and connected devices make DfR increasingly important in today’s market. Unfortunately, according to LNS Research, most manufacturers lack the reliability technology strategy and top management sponsorship to have successful reliability programs. Successful reliability engineering requires the ability to predict what portions of a product may fail as well as the performance, safety, and economic impacts of failure. It requires transparency to current and past issues to improve predictions, react to failures, and continuously improve. Successful DfR must be supported by effective product management strategies. With the rise of the Internet of Things (IoT) and centralized data management platforms like Product Lifecycle Management (PLM) technology, companies can create a closed-loop, data-driven DfR program to improve predictability and reliability and achieve better-performing products.

An LNS Research survey shows challenges to the successful implementation of DfR practices including lack of top management sponsorship and siloed processes and technology

DfR’s top challenges According to a survey performed by LNS Research, the top four challenges to DfR success are lack of top management sponsorship, late engagement in New Product Introduction (NPI), siloed processes and technology, and poor predictability. Furthermore, research reveals that manufacturers primarily manage DfR data with spreadsheets and electronic documents. • 90% of the companies surveyed manage requirements in spreadsheets and electronic documents • 83% manage FMEAs (Failure Modes and Effects Analysis) in spreadsheets and electronic documents • 70% manage new product test data in spreadsheets and electronic documents Like many product design and development processes, this disconnected, document-centric approach is a significant obstacle to the analytics needed to generate accurate historical reliability statistics and lessons learned. It also creates silos among DfR teams and processes, which reduces

Lack of top management sponsorship

41%

DfR engaged too late in the product lifecycle

41%

Siloed/fragmented processes and technology

33%

Poor predictability of product reliability, availability, maintainability

33% 22%

Poor requirements or specifications management Lack of a corporate-wide process for managing test processes and data

19%

Lack of training/competency

19% 15%

Ineffective metrics

44

No formal, consistent process for managing risks

11%

Lack of visibility to in-service performance and metrics

11%

November 2018 www.designworldonline.com

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