Career Episode 3: Improving X-ray Device Reliability Report

This report presents a competency demonstration, specifically Career Episode 3, detailing a project undertaken at Philips Healthcare to improve the reliability of X-ray devices through a predictable design framework (DFR). The project, spanning from February 2014 to May 2015 in Pune, India, involved the implementation of DFR principles to reduce warranty costs by approximately 40%. The author, in the role of Manager Mechatronics, led a team to analyze historical data, identify failure modes using Weibull analysis and DFMEA, and implement best practices. The report outlines the project's objectives, including improving reliability prediction, reducing warranty costs, and analyzing failure rates. The author's responsibilities included providing technical guidance, managing the team, and driving the adoption of the new framework. The report highlights the use of engineering simulation, collaborative work, and the successful establishment of a predictable design process, ultimately leading to a reduction in design cycle time and warranty costs. The project faced initial resistance to change, which was addressed through communication and training. The project's success is reflected in the reduction of warranty costs and the establishment of a DFR framework for future applications.

COMPETENCY
DEMONSTRATION REPORT
Career Episode 3
HIRANMAY DASH

CE 3.1 Project Information
Name of the project: Improving the product reliability of X-ray device through
predictable design
Location of the project: Pune, India
Project Duration: February, 2014 to May, 2015
Organization: Philips Healthcare
Role and Designation during the time: Manager Mechatronics
CE 3.2 Project Background
CE 3.2.1 Characteristics of the project
This project was targeted mainly for the development of framework for predictable
design of the X-ray machines at the Philips Healthcare in Pune to make the device reliable with
the help of DFR framework. This would help the process of warranty cost incurred by the
company to reduce by a factor of ~40%. Saving this money would help the company to make a
better profit in the market. I was asked to provide guidance and manage the entire team of
talented engineers responsible for the improvement procedure of the project. I had worked on
this project to help in the analysis of the historical data and the procedures used for the
implementation of the project. The company had asked me specifically due to my skills as a DFR
expert and my engineering leadership, which I was able to complete as per the requirements.

CE 3.2.2 Objectives developed for the project
For the completion of the project as per the requirements of the client I had developed the
following list of objectives:
 To improve the reliability prediction for X-ray device in early stage of design
 To save the warranty cost by 40%
 To analyze the historical data to find the failure rate of the products
 To analyse the warranty cost and the call rate analysis of the X-Ray devices.
CE 3.2.3 My area of work
For the completion of the project I had worked on the process of finding a reliable
prediction process for the reduction of the warranty cost of the products by a factor of 40% for
the company. I was leading a team of specialist and technicians for the project by providing them
with the proper guidance and technical strategy to implement in to the project so as to make the
project successful. I had also helped my team mates to compile a report based on the historical
data for the proper assessment of the major areas which needed to be taken care of by us. I had
lead the team to the success with the help of my team management skills and my design
engineering skills in the field of reliability study and other successful projects.

CE 3.2.4 Project Group
Figure 1: Team Member associated in this project
CE 3.2.5 My responsibilities throughout the project
During my time on the project I had worked on the process of implementing a procedure
to reduce the design uncertainty as well as the reduction of the warranty cost of the products so
as to finally reduce the cost by a percentage of 40%. I had led the team of specialist in analysing
the historical data utilizing Reliasoft tools to find the failure mode which had led to the down
time of the devices being developed by the company. I had also explored other major industries
best practices to implement predictable design. I had then worked on the process of
implementing the guidance to my team members for the project to be successful.

CE 3.3 Distinctive Activity
CE 3.3.1 Comprehending the theory of the project
The project had been based on the process of finding a design and development
framework for the X-Ray machines being developed by the company which would be able to
reduce the time of development as well as reduce the warranty cost and increase the life of the
product. The company had asked me to work on their development process as well as the
warranty cost for the products. I had studied the previous approach of the design to test. This
process made the maximum number of mistakes recognized during end of the development
process. Thus, I had shifted the process to predictable design. The new process led to the
reduction high product development cost as well as time to market. I had considered the fact that
there are enormous tools and engineering simulation methods can be used for the understanding
of the system availability and reduce the down time for the support to the customer. I was able to
complete the project with the help of lack of reliability process for the improvement of the part
replacement during the product life cycle.
CE 3.3.2 Engineering knowledge and skills applied in the project
For this project I had used my knowledge of design engineer as well as the knowledge of
DFR which I had gained from my experience in the field of such large project during my career.
I had implemented the historical data analyses with the help of Weibull for the failure rate
calculation. I had conducted requirement gathering and performed the P-diagram and DFMEA
for the failure mode investigation.

CE 3.3.3 Accomplishment and task performed
I had worked on the reliability confidence test on the X-Ray product being developed
with the help of the new as well as the old development process. This made the comparison of all
the details of the machines to be analysed properly and then proceed with the next phase. We had
also conducted the Weak-link analysis with Lambard predict which helped in the strengthening
of the working process of failure rate calculation of the new parts. At the end of the project we
were able to compile the predictable design framework, warranty cost and the call rate analysis
of the new equipment developed.
CE 3.3.4 Identified issues and their solutions
3.3.4.1 Issues
During my time on the project I had faced only one problem related to the team with
whom I was working with. When I had started my project work I was working with a group of
Engineers. They were showing the resistance to change and hence reluctant of grasping the
theory and the procedure which I was willing to follow for the project. This led to more effort to
implement the framework.
3.3.4.2 Solutions
Upon careful discussion on the need of DFR with the team members and superiors, I was
able to convince them to follow the framework and trained them on reliability. This made the
process to speed up easily and thus made the project within the deadline and as per the
requirements of the Philips management team.

CE 3.3.5 Plan to produce creative and innovative work
As the machine which I was asked to review was a complex one and had already faced a
lot of drawbacks in the form of warranty discounts being raised. This is the reason which forced
me to analyse the historical data of all the defective products for the understanding the specific
portion of the machine to focus on so that the cost can be reduced as well as enhance customer
satisfaction for the new product. We have put new innovative design such as robust housing
design for detector and etc thru predictable design framework.
CE 3.3.6 Collaborative work
For the completion of the project I had worked with a team of 6 members including me.
My team was comprised on Reliability architect, Mechatronics design Engineers and Test
Engineer. This team had been composed by me which helped me to work with them and
complete the project within the deadline and established predictable design process according to
the objectives set out during the initiation of the project. I had worked with my team to study the
historical data, use new tools for engineering simulation and subsequently find the process to be
used by the company for the completion of the project.
CE 3.4 Project Review
CE 3.4.1 Project Overview
At the end of the project it can be said that my team has been able to complete the project
as per the requirements of the customers. The end deliverables were as per the requirement of the
customer. At the end of the project I was able to conclude that the project had received a speed

up in the process of development and the warranty cost of the product had been reduced by a
factor of 30%. We have established design for reliability framework for future uses.
CE 3.4.2 My contribution to work
During the completion of the project I had worked on the process of finding a reduced
design life cycle time as well as a process to reduce the warranty cost of the products being
developed by the company by a factor of 30% for the company. I had guided my team in the
processes to follow for the completion of the project as per the requirements of the customer. I
had also helped in the analysis of the historical data of the company to understand the process
being used and the points where the failure of the product has been found the maximum number
of times widely known as Pareto analysis. This helped in the focusing of our work on a small
number of areas of the company’s product development procedure. I also drove change
management to drive the change to adopt the new framework.