Hands-on tools for Warranty and Field Failure Data Analysis A 3-Day Workshop at the University of Bradford For all technical and professional staff with responsibilities in specification, design, planning, product development, and new product launch activities as they relate to complex consumer goods developed in volume. 6–8 December 2010 The business case for avoiding expensive warranty work and potential product recalls is measured not only in terms of the effort, cost and time of executing repairs but equally, if not more importantly, the effect on company reputation and customer loyalty. The University of Bradford Engineering Quality Improvement Centre have developed a process, termed failure mode avoidance, that equips analysts, engineers and managers with the skills needed to identify potential sources of failure and take actions within the design of a product or process to avoid these failures occurring in the field . The analysis of the causes of failure associated with historical warranty failures and product recalls provides a rich source of information in the effort to identify causes of failure and take appropriate countermeasures. Warranty and other field failure data require careful and thoughtful analysis due the nuances that are typical in such data. For example, some failures will be associated with the age of a product while other with the frequency, style and length of usage. Also, by focussing on those products that have failed, field failure data will be incomplete and account needs to be taken of products that have not failed. The BEQIC course in Warranty and Field Failure Data looks at various statistical techniques for the analysis of field failure data that provide useful engineering based information that can be used to solve current problems and establish effective countermeasures to prevent future failure. Course Aim This 3 days workshop style short course aims to develop practical skills in the use of statistical techniques that support warranty and field failure data analysis, with particular emphasis on the engineering interpretation of the results. Workshop Content The workshop provides a detailed analysis of the warranty and field failure data features, focusing on all sources of uncertainty and inaccuracy (record of failure time / mileage, accuracy of failure cause / classification, lack of information about partial failure and unfailed items, lag time between manufacturing / sales / operation). Statistical tools for life data analysis are introduced gradually, with examples and hands on case studies based on helpful excel spreadsheets which will be provided to the Delegates. Weibull and hazard analysis are important tools, which could be used on a broader basis within a company, for example for product reliability demonstration. Analysis Techniques covered The analysis techniques covered in the workshop fall into 3 main groups: • Life Data Modelling: Hazard functions, hazard rate analysis, reliability prediction; • Weibull modelling: Weibull analysis using probability plots, engineering interpretation of Weibull analysis; • Field Failure Data Analysis: Weibull and hazard analysis for incomplete data; statistical analysis for decision making, e.g. product recalls, service scheduling, warranty part supply logistics and cost allocation. Workshop style delivery The focus is to ensure that all delegates leave with sufficient skills to implement the tools and techniques immediately in their workplace. The number of places available on a workshop is limited to enable about 50% of the workshop time to be devoted to delegates practicing the use of the tools. Experienced and effective tutors BEQIC tutors have an industry background and extensive experience of both industry and adult learning. This combination of skills and experience means the tutors are able to present what sometimes may be seen as difficult concepts in a straight forward and easily understandable manner. Coaching and post-training support Comprehensive post training support including consultancy, facilitation and mentoring is provided to individuals and companies to bridge the gap between classroom and workplace practice / reality. Academic accreditation and Postgraduate progression Academic accreditation is based on assessing the achievement of the learning outcomes. Typically this would involve a mini-dissertation or report developed around the application of relevant engineering tools to a test problem. Successful pass of the assessment leads to the award of credits which can be cumulated towards a postgraduate degree with any UK institution participating in the Credit Accumulation and Transfer scheme. There is also an option to undertake a larger workplace based project leading to a PostGraduate Certificate. Successful completion of this course accumulates 10 points. A typical Postgraduate Certificate requiring 60 points and a postgraduate degree 180 points. Training Materials The course materials are developed around realistic engineering scenarios. The workshop style delivery ensures that delegates have sufficient time to practice the tools on an engineering problem. The course materials include useful spreadsheets which the delegates can take away for further reference and use within the workplace. Post training coaching and guidance is provided for completion of the academic assessment. Venue The workshops are run in dedicated facilities at the University of Bradford. The workshops can also be run on Company premises where requested, with learning material customised to the Company context. Accommodation Accommodation is not provided during the course but we can recommend a number of hotels and help you make your reservation if required. Please check current rates with Mr. Fjodors Kosmacevs, EQI Programme Administrator. Alternatively you may arrange your own accommodation as required. Fee and Booking This 3-day Warranty and Field Data Analysis workshop fee is £585 per Delegate including refreshments. To book your place please fill in and return the electronic booking available from our website (www.eqi.org.uk), or contact Mr Fjodors Kosmacevs by email F.Kosmacevs@bradford.ac.uk or by telephone +44-1274-23-6184. For further information about this course please contact Dr Felician Campean (email F.Campean@Bradford.ac.uk, direct line 01274-23-4569), or visit our website www.eqi.org.uk.