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How to Lead Design for Reliability (DfR) with Stage Gate Triggers

IMC-2017 Learning Session - 42:19
by Marie Getsug, Jacobs, and George Williams, B. Braun Medical

Asset Management has introduced a few key concepts which require a shift from focusing on initial investment to optimizing the life-cycle cost. The basis for such decisions are rooted in a risk-based and science-based approach to understanding the requirements of the asset throughout its useful life. The risk-based approach drives prioritization and optimization; whereas, the science-based approach honors the Subject Matter Experts (SME’s) experience as well as seeking meaningful data to drive decisions. Both must be applied in the concept and design phases to be effective.

Shifting the Project Management Office (PMO) and the Capital Engineering Process from a mindset of initial cost, scope and schedule to a focus on Total Cost of Ownership (TCO) and Life Cycle Cost (LCC) requires a catalyst for change. Design for Reliability (DfR) answers this requirement with a methodology that blends aspects of statistics, probability and reliability theory, and engineering analysis throughout a product lifecycle to evaluate, predict, and verify the application of robust design. Through application of DfR practices, the demand for highly-reliable systems can be met while insuring that the latest methods for the assessment of robust design and risk-management are properly addressed. The design and concept stage gates become the most significant triggers for DfR and the mechanism for the timely application of each DfR element. Experiences introducing and customizing a DfR Program and toolkit to achieve a Corporate Vision and optimize the performance of the assets throughout their useful life will be shared. Stakeholders with any level of responsibility for these assets are being called upon to contribute their experience in the concept and design phases, core to both Front End Planning (FEP) and DfR. A governance structure that supports, funds and allows for the input of these Stakeholders at these timely stage gates is fundamental to the success of a DfR Program.