50 Ways To Improve Product Reliability

2011 ARS, North America, San Diego
Track 2, Session 7
Begins at 10:30AM, Wednesday, June 8th
50 Ways to Improve Product Reliability

Mike Silverman, Ops A La Carte LLC
Agenda
Introduction
Applied Reliability Symposium, North America 2011
5 min What are the 50 Techniques? 15 min How to decide which are best? 25 min Summary 5 min Questions 10 min
Note that some of this material has been taken from Mikes book How Reliable Is Your Product: 50 Ways to Improve Product Reliability
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Introduction
Reliability is an interesting discipline because there are many techniques you can use to solve problems and create a reliable product. There certainly are guidelines and best practices, but you should determine for yourself the set of techniques that will work within your company.
Introduction, continued
Some of the factors you should consider are: - Size of your company - Company culture - Past experiences - Background education - Marketplace - Customer requirements
Problem Statement
When faced with the challenge of developing a reliability program, many engineers dont understand how to choose the right techniques or how to integrate the techniques together.
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Solution
In this presentation I will review the most popular reliability techniques and explain when to use them (and when not to use them) as well as how to integrate them together into your overall reliability program.
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Reliability Techniques by PLC Phase

Assessment Goal Setting Gap Analysis Benchmark Metrics Block Diagrams Golden Nuggets CONCEPT PHASE
Reliability Plan
FMEA
FTA
Component Selection
Predictions
Thermal Analysis
Derating Analysis
POF DESIGN PHASE
DOE
Tolerance Analysis
Preventive Mainten.
EOL Analysis
Warranty Analysis
FEA
Software Reliability
PROTOTY PE PHASE
Test Plan
HALT
RDT
ALT
HALT-AFR Calculator
RCA
CLCA
MANUFACTURING PHASE
Vendor Assessme nt Lessons Learned

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Outsourcing
HASS
ORT
OOBA
Warranty Returns
T2
Reliability Reporting
Statistics
S7
EDA for Obsolesc
Slide Number: 7
Techniques in the Concept Phase

Assessment Goal
Setting Gap Analysis Benchmarking Metrics Block Diagramming Golden Nuggets Reliability Plan
Techniques in the Design Phase
FMEA FTA Component Selection Predictions Thermal Analysis Derating Analysis Physics of Failure
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DOE Tolerance Analysis Preventive Maintenance End-of-Life Analysis Warranty Analysis FEA Software Reliability
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Techniques in the Prototype Phase

Test
Plan HALT RDT ALT HALT-to-AFR Calculator RCA Closed Loop Corrective Action
Techniques in the Manufacturing Phase
Vendor Assessment Lessons Learned Outsourcing Design Warranty Returns and Manufacturing Reliability Reporting HASS Statistics ORT EDA for Out of Box Audits Obsolescence
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Choosing the Right Techniques

You do not need to use all of the techniques I have described
You must choose the best techniques from this list based on the needs of your company and your product.
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Design Trade-offs
Engineering teams must balance cost, schedule, performance and reliability to achieve optimal customer satisfaction.
Reliability
Cost
Customer Satisfaction
Schedule
Performance
Reliability vs. Cost

To minimize total Life Cycle Costs (LCC), an organization must do two things: 1. Choose the best tools from all of the tools available and apply these tools at the proper phases of the product life cycle. 2. Properly integrate these tools together to assure that the proper information is fed forwards and backwards at the proper times.
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Reliability vs. Cost, continued

OPTIMUM COST POINT TOTAL COST CURVE RELIABILITY PROGRAM COSTS COST
WARRANTY COSTS
RELIABILITY
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Reliability Integration
the process of seamlessly, cohesively integrating reliability tools together to maximize reliability and at the lowest possible cost
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Reliability Integration Concept Phase Example

Integrating Goals with a Reliability Program
The Reliability Program Assessment drives the rest of the activities in your reliability program. The recommendations from the assessment help guide your companys future action for your entire reliability program. At suitable points during your program it also makes sense to reassess your situation to determine how much the gap has shrunk and how close you are to achieving your goals.
Case Example of Concept Phase Reliability Technique

Case Study: Linking Electrical, Mechanical, and Software Reliability together
We were working with a semiconductor equipment company to help improve their reliability on their next generation product. First, we provided a Design for Reliability (DFR) seminar for each of the three different disciplines the electrical group, the mechanical group, and the software group. Then we met with the electrical, mechanical, and software team leads and developed reliability goals.
Case Example of Concept Phase Reliability Technique, cont.

Case Study: Linking Disciplines together, cont
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Next, we started with high level system goals and the apportioned the goals down to each subsystem electrical, mechanical, and software.
Each group lead then took the goal for his subsystem and broke it down further within his area.
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Then we worked with each group lead to put together a reliability program plan to meet his subsystem goals. We rolled each of these different subsystem plans into an overall reliability plan for the product. Then we worked with each group lead to ensure he was on track for meeting his subsystem goals throughout the product development process.

The end result was that our client was able to achieve their reliability goals for each subsystem and for the system as a whole.
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Reliability Integration Design Phase Example

Integrating FMEA within a HALT Plan
FMEA is a great technique to use prior to writing a HALT Plan because the FMEA can identify how different portions of the product can fail so that you can develop tests to validate the mitigation for these failure modes. In addition, the FMEA can point out non-relevant failure modes so that when you are developing your test plan you choose stresses and levels that avoid finding these failures.
Case Example of Design Phase Reliability Technique

Case Study: FMEA Driven Test Plan for a Medical Infusion Pump
RELIABILITY PROGRAM
The infusion pump was an n+1 design We started from the goal and plan Then we performed an FMEA to identify
the
risks of the new elements in the design Then we wrote a test plan to mitigate the risks
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Case Example of Design Phase Reliability Technique, cont.

MEDICAL INFUSION PUMP
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REVIEW NEW ASSEMBLIES/FEATURES
Two new motors - one for the cassette insertion and removal, and one for the air sensor to pinch the tubing in order to detect air bubbles in the line. A new power supply that was larger and also had a battery charging circuit for the new rechargeable battery. A touch screen An 802.11 wireless interface A new rechargeable battery design New software to handle all of these new features

IDENTIFY RELIABILITY RISKS
Using the Risk Analysis process, we identified as many new risks as possible Then we set out to figure ways of mitigating these risks
Design analysis techniques such as FEA, DOE, and Thermal Analysis Accelerated Testing techniques such as HALT, ALT, and RDT
The important element here is that we always had an eye on our goal.

RELIABILITY TECHNIQUES USED
Motors FEA, ALT Power Supply HALT then RDT Touch Screen ALT, Abuse Testing Wireless Interface - HALT Battery Application Specific ALT Software Software FMEA, Software Use Case Testing
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RESULTS
Using this process we saved time and money. We found out issues during the design analysis that would have required a redesign had we found them later in the design, or worse, out in the field We found out issues during the testing that would have set our program back months. End result: We developed and delivered a very reliable product and got it to market faster.
Reliability Integration Prototype Phase Example

Integrating Reliability Prediction and HALT with the HALT-to-AFR Calculator
Two key pieces of information we use for the HALT-to-AFR Calculator are: 1) MTBF results from the Reliability Prediction 2) Operating limits from the HALT
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Reliability Integration Prototype Phase Example, cont.

Integrating using HALT-to-AFR Calculator, cont
The HALT-to-AFR Calculator uses the MTBF number from the Reliability Prediction We recommend that you compare the highest failure items in the Reliability Prediction to the failures you found in HALT. The better the correlation between these two, the more accurate the HALTto-AFR Calculator will be.
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Reliability Integration Prototype Phase Example, cont.

Integrating using HALT-to-AFR Calculator, cont
The HALT-to-AFR Calculator uses the operating limits from the HALT which you directly enter as a data point. The more thorough you are in HALT in expanding the design margins, separating out weaker assemblies, removing protection circuitry or firmware, and providing effective corrective actions, the more accurate the HALT-to-AFR Calculator will be.
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Case Example of Prototype Phase Reliability Technique

Switching from RDT to HALT-to-AFR Calculator
Most companies cant justify using RDT because RDT requires too many samples and the testing takes too long to get the results. Yet HALT in itself isnt capable of determining field MTBF. This is precisely why the HALT-to-AFR Calculator was developed. It saves time and money without compromising the accuracy.
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Case Example of Prototype Phase Reliability Technique, cont.

Switching to HALT-to-AFR Calculator, cont.
Field Failure Rate Estimate - % of Failures/Year Input Matrix 40,000 94 -58 80 3 4 1.06 822954 443657 1691518 Level # 1 2 3 4 5 6 Guard Band Limits Consumer -30 to +80 Hi-end Consumer -30 to +100 Hi Performance -40 to +110 Critical Application -50 to +110 Sheltered -50 to +110 All Outdoor -65 to +110
S7 Slide Number: 34
MTBF (in Hrs) = Product Thermal (Hot in C) = Product Thermal (Cold in C) = Product Vibration (in Grms) = Prod Published Spec Level (see below) = Number of HALT Samples = Steady State AFR, % (HALT Only) = Steady State Field MTBF, Hrs (HALT Only) = Lower 90% HALT Confidence Limit = Upper 90% HALT Confidence Limit = Published Spec 0 to +40 0 to +50 -10 to +50 -20 to +50 -25 to +65 -40 to +85
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Data Verifiy OK OK OK OK OK OK
Key User input Calculated Selection Data Validity
Reliability Integration Manufacturing Phase Example

Integrating Reliability Predictions with HASS
How do you know if HASS is needed and if so, how effective must the HASS be to meet your reliability goals? Your prediction is only accounting for steady state failures and doesnt account for infant mortality failures. Therefore, if you are just barely making your goal after the product reaches steady state, you dont have a chance of meeting your goal before the product reaches steady state unless you have an effective manufacturing screening program.
Case Example of Manufacturing Phase Reliability Technique

Choosing the Correct Stresses for HASS
A computer company asked us to help them determine the best manufacturing screening methodology. They had been using various types of screens for years. Every time a major failure occurred during the manufacturing process, they changed the screen because they thought the screen was inducing the failures.
Case Example of Manufacturing Phase Reliability Technique, cont.

Choosing the Correct Stresses for HASS cont
We had them list the top failures across the product lines of interest. We listed those on a vertical axis.
Then on the horizontal axis, we listed about a dozen different types of screens (including ones they tried in the past plus some they hadnt tried).
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Then we filled out the matrix by marking an x in the boxes for those screens that would be effective at finding each type of failure.
For those that we werent sure about, we researched the failure modes on the internet including past papers written on the subject. The screen that had the most xs in it was deemed the most effective.

Next we determined how to implement this screen within the cost and schedule constraints. Our client ended up with a screen that was significantly more effective at finding manufacturing defects, thereby reducing the number of field failures. The new screen only cost a few dollars more per system.

SCREEN OPTIONS 1
HASA on boards only inside unit -50 to 75C @
2
Unit Burn-In Sample
3
Unit Burn-In 100% 50C, 48 Hours 5,000 810,000 240,000 900,000 ($155,000) ($755,000) 4th
4
No Screen Units
Screen Parameters (initial estimate) 40C/min w/20G 50C, 48 Hours

N/A $ 900,000 0 900,000 $0 $0 2nd $ $
NRE Total Cost of Defects Not Found Cost of Screening per Year Cost of No Screening ROI in 1st Year ROI in 5 Years RANKING (by ROI)
27,800 738,000 30,000 900,000 $104,200 $632,200 1st
5,000 888,750 24,000 900,000 ($17,750) ($68,750) 3rd
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The net effect was that the new screen saved our client thousands of dollars per year.
This example illustrates the power of an ROI Analysis as well as the variables we recommend including in an ROI Analysis.
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Steps to an Effective Rel. Program

1. Assess / Plan 2. Execute 3. Review
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Step 1: Assess Your Needs, Setting a Goal, and Writing a Rel. Program Plan
Initiate a Reliability Program Determine next best steps Reduce customer complaints Select right tools Improve reliability
$ Profits
Program Plan
Goal
market share
Gap Analysis
satisfaction
Benchmarking Statistical Data Analysis Assessment Interviews

field failures $ unreliability
Now
complaints
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? Unknown Reliability ?
T2
A detailed evaluation of an organizations approach and processes involved in creating reliable products. The assessment captures the current state and leads to an actionable reliability program plan.
2008 Ops A La Carte 43
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Step 2: Execute and Collect Metrics

As you execute your reliability program, it is important to have the right metrics in place to assure you are on track to meet your reliability goals.
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Step 3: Review Field Data for Gaps and Modify Your Program Accordingly No technique is perfect. You will miss some failures. The important thing is to quickly determine why you didnt catch the defect and to modify your program to make sure you find it on future iterations of the design or on future designs.
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Conclusion
The key to an effective reliability program is knowing which techniques to use, when and how to use them, and how to integrate them into your overall reliability program.
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Mike Silverman
Mike Silverman, (408) 472-3889, mikes@opsalacarte.com
Mike is founder and managing partner at Ops A La Carte, a Professional Business Operations Company that offers a broad array of expert services in support of new product development and production initiatives. The primary set of services currently being offered are in the area of reliability. Through Ops A La Carte, Mike has had extensive experience as a consultant to high-tech companies, and has consulted for over 500 companies in a variety of different industries including medical, defense, space, energy, consumer, telecom, and many others. Mike just completed his first book on Reliability entitled How Reliable Is Your Product: 50 Ways to Improve Product Reliability Mike has 25 years of reliability, quality, and compliance experience, the majority in start-up companies. He is also an expert in accelerated reliability techniques, including HALT and HASS. He set up and ran an accelerated reliability test lab for 10 years, testing over 500 products for 200 companies in 50 different industries. Mike and his team at Ops have authored and published over 50 papers and 30 seminars on reliability techniques and has presented these around the world including China, Germany, Japan, and Canada. Mike has a BS degree in Electrical and Computer Engineering from the University of Colorado at Boulder, and is both a Certified Reliability Engineer and a course instructor through the American Society for Quality (ASQ) and IEEE, Mike is a member of ASQ, IEEE, SME, ASME, PATCA, and IEEE Consulting Society and currently the IEEE
Reliability Society Santa Clara Valley Chapter President.

Questions
Thank you for your attention.

Do you have any questions?
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2011 ARS, North America, San Diego

Applied Reliability Symposium, North America 2011

Applied Reliability Symposium, North America 2011

Applied Reliability Symposium, North America 2011

Applied Reliability Symposium, North America 2011

Applied Reliability Symposium, North America 2011

Reliability Techniques by PLC Phase

POF DESIGN PHASE

Vendor Assessme nt Lessons Learned

EDA for Obsolesc

Techniques in the Concept Phase

Applied Reliability Symposium, North America 2011

Techniques in the Design Phase

Applied Reliability Symposium, North America 2011

Techniques in the Prototype Phase

Applied Reliability Symposium, North America 2011

Techniques in the Manufacturing Phase

Applied Reliability Symposium, North America 2011

Choosing the Right Techniques

Reliability vs. Cost

Applied Reliability Symposium, North America 2011

Reliability vs. Cost, continued

Applied Reliability Symposium, North America 2011

Applied Reliability Symposium, North America 2011

Reliability Integration Concept Phase Example

Applied Reliability Symposium, North America 2011

Case Example of Concept Phase Reliability Technique

Case Example of Concept Phase Reliability Technique, cont.

Applied Reliability Symposium, North America 2011

Case Example of Concept Phase Reliability Technique, cont.

Case Example of Concept Phase Reliability Technique, cont.

Applied Reliability Symposium, North America 2011

Case Example of Concept Phase Reliability Technique, cont.

Reliability Integration Design Phase Example

Applied Reliability Symposium, North America 2011

Case Example of Design Phase Reliability Technique

Case Example of Design Phase Reliability Technique, cont.

Applied Reliability Symposium, North America 2011

Case Example of Design Phase Reliability Technique, cont.

Applied Reliability Symposium, North America 2011

Case Example of Design Phase Reliability Technique, cont.

Applied Reliability Symposium, North America 2011

Case Example of Design Phase Reliability Technique, cont.

Applied Reliability Symposium, North America 2011

Case Example of Design Phase Reliability Technique, cont.

Applied Reliability Symposium, North America 2011

Reliability Integration Prototype Phase Example

Reliability Integration Prototype Phase Example, cont.

Applied Reliability Symposium, North America 2011

Reliability Integration Prototype Phase Example, cont.

Applied Reliability Symposium, North America 2011

Case Example of Prototype Phase Reliability Technique

Case Example of Prototype Phase Reliability Technique, cont.

Applied Reliability Symposium, North America 2011

Key User input Calculated Selection Data Validity

Reliability Integration Manufacturing Phase Example

Applied Reliability Symposium, North America 2011

Case Example of Manufacturing Phase Reliability Technique

Applied Reliability Symposium, North America 2011

Case Example of Manufacturing Phase Reliability Technique, cont.

Case Example of Manufacturing Phase Reliability Technique, cont.