Short Course # PD-8

Design for Serviceability

Custom designed instruction for professional development of all engineers and other technical professionals.

Instruction content designed around the needs identified by the customer.

Instruction delivery is (5) half-day morning sessions.

Topics covered

  1. Design for serviceability (DFS)
    1. Definition of DFS.
    2. Definition of service in general.
    3. Potential benefits.
    4. Avoiding the need for service.
    5. Product life cycle.
    6. Service needs and maintainability.
  2. Design for serviceability (DFS) and other competing design priorities
    1. Design for f
    2. unction.
    3. Design for marketability.
    4. Design for low cost.
    5. Design for reliability.
    6. Design for manufacturing.
    7. Design for assembly.
    8. Design for disassembly.
    9. Design for safety.
    10. Design for product liability.
    11. Design for regulatory compliance (emissions, fuel economy, safety and other regulatory requirements).
    12. Design for recyclability and environment.
    13. Design for sustainability.
  3. Business case for "Design for serviceability"
    1. Design cost and potential Product life cycle cost.
    2. Higher financial benefits with minimal cost impact in early design stage.
    3. Gaining competitive advantage.
    4. Serviceability and customer satisfaction.
    5. Culture for promoting DFS.
    6. Warranty cost reduction.
    7. Total service cost reduction beyond warranty coverage period.
    8. Serviceability and vehicle resale value.
    9. Service costs for product life cycle integrated with design and marketing costs.
  4. Reliability concepts
    1. The bathtub curve (Infant mortality, useful service life, accelerated wear-out and durability failures).
    2. Mean time between failures.
    3. Mean time between repairs.
    4. Mean time between maintenance.
    5. Mean time to failure.
    6. Mean time to repair.
    7. Mean time to restore system.
    8. Reliability of service.
    9. Reliability after service.
    10. Repeat repairs.
    11. Repair costs.
  5. Reliability toolbox
    1. Failure mode and effect analysis (FMEA) process.
    2. Design FMEA.
    3. Manufacturing Process FMEA.
    4. Serviceability FMEA.
    5. Barriers to FMEA process.
    6. FMEA ground rules.
    7. Design verification.
    8. Serviceability verification.
    9. Manufacturing process verification.
    10. Production quality and control.
  6. Service requirements
    1. Regular preventive maintenance (Oil and filter change, Fluid fills, Lubrication).
    2. Periodic scheduled service for wear-out items (Brake service, muffler etc.).
    3. Service due to road hazards (Tire damage, broken hoses etc.)
    4. Minor collision related service.
    5. Major collision related service.
    6. Environmental damage related.
    7. Product reliability issues.
    8. Product quality issues.
    9. Product safety, regulatory compliance issues.
    10. Product liability issues.
  7. Service infrastructure and parts management
    1. Access to service facilities and service infrastructure.
    2. Service parts management.
    3. Service tools.
    4. Module exchange vs. repair of components.
    5. Remanufacturing of modules.
    6. Remanufacturing of parts.
    7. Recyclability of serviced parts.
  8. Service process management
    1. Owner/operator service items (Fluid checks, Tire pressure checks, etc).
    2. Minor garage service items.
    3. Major service items.
    4. Service parts management.
    5. Skill requirements for service personnel.
    6. Training and certification of skilled service technicians.
    7. Onboard and remote diagnostic capabilities.
    8. Fix it right the first time.
    9. Help desk and service support (24 hours/7days a week).
  9. Warranty Analysis
    1. Coding of warranty data for problem analysis.
    2. Analysis of warranty data for:
      1. Problem definition.
      2. Extent of the problem.
      3. Relationship to certain regions of the country.
      4. Relationship to the date the vehicle is built, the plant where it is built and the climatic condition and geographical location of vehicle usage.
  10. Design for serviceability guidelines
    1. Minimum number of component layers.
    2. Components requiring service closer to the surface.
    3. Minimum number of connections between sub-assemblies.
    4. Minimum variety of components and fasteners.
    5. Easy access for conventional tools for service.
    6. Minimum need for special service tools.
    7. Low service parts cost.
    8. Low service labor cost.
    9. Minimum down time while vehicle is in service.
    10. Warning system for service need.
    11. Limp-home features designed-in to product.
    12. Onboard diagnostics (self and remote).
  11. Hardware review and hands-on service exercises
    1. Review of vehicle hardware requiring service.
    2. Vehicle-on-hoist review.
    3. Oil change and chassis lubrication experience.
    4. Brake service experience.
    5. Exhaust System service experience.