1. Martin Shaw – Reliability Solutions www.reliabilitysolutions.co.uk
Reliability Solutions Seminar Managing and Improving Reliability
The Most Effective Approach
Martin Shaw – Reliability Solutions
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2. Reliability Solutions – Background
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3. DAY 1 - AM Agenda Understanding Basic Reliability Theory
Application of Bathtub Curve theory
Importance of Early Life Reliability and the Importance of Exponential and Normal Distributions in Reliability Prediction
Definition of Hazard Rate and its importance in Reliability estimation at RD stage
Understanding MTTF and effect on Product Level Fail Rates
Realising the Importance of Component Reliability and MTTF spec
Combining different MTTF levels for Different Components / Sub-Assemblies
Understanding Accelerated Testing to set up Predictive Testing Models for all
products at RD stage
High Temp Arrhenius model and Activation Energies used for key component
failure modes
Maximising Acceleration Factors by combining Temperature, Thermal Cycling,
Power Cycling and Humidity
Real Life examples of how to calculate Activation Energy level from experimental
work at Product and Component level
Evaluating the effectiveness of different stress test types with the Hughes Test Strength Equation
Developing an Effective Reliability test Strategy , using Modern stress techniques, including Random Vibration and Thermal Cycling
Product Level Case Study with real life examples
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4. DAY 1 - PM Agenda Accelerated Life Test (ALT) Planning
Setting up most effective Design Quality Life Testing to evaluate Design Reliability and using the appropriate
Stress Model to maximise defect detection
Predicting MTTF from reduced Sample Sizes
Relationship of Manufacturing Yield with Early Life Failure Rate
Component Level prediction from Yield data
Using yield performance data from Board and Assembly processes to Predict Warranty Field Fail Rates
How to predict and control Early Life Fails using manufacturing data
Sub-Assy Reliability Stress Testing and making Reliability Testing more effective and Lower Cost
Making Reliability more effective at Sub-Assy level
How to Accelerate Failures by stress testing Control boards, Power boards,
Combining Rel predictions of different Sub-Assemblies to make Total product
Weibull Analysis of Failure data and how to apply to any product failure data
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5. DAY 2 - AM Agenda
Applying DOE using Fractional Factorial techniques to maximise effect of Stress Test with
Reduced samples
Developing best mix of Stress Testing for a any device of product
Setting up strong Design Quality Test Programme and using Design Maturity Measurement to measure Design Capability
High Design Maturity controls Design Reliability
Providing a Key metric for measuring Design Eng success in providing highest level of Design Quality
Predicting Field fail Rates using development test Information from a Design Quality Engineering Test programme
Combining Mil-217 predictions and using Design Maturity Ratings to form an efficient model for accurately predicting product failure rates from design test data
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6. DAY 2 - PM Agenda
Setting up New Product Introduction scoring model to deliver strongest Design Quality into Mass Production to maximise Reliability
Using the ‘Unique’ Reliability Solutions model to bring wide range of measures together prior to Mass Production and ‘scoring’ the product’s readiness for Mass Production
Defining how to develop a new reliability test programme from bottom up to ensure best possible solution
Students learn what to consider and how to optimise the test programme
How to evaluate defect stimulation and detection capability
How to apply statistics in sampling and confidence predictions
How to minimise cost
How to report the testing in a meaningful manner
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7. DAY 3 - AM Agenda (Optional)
Understanding the ‘Holistic’ approach to World Class Reliability and why it is so important with today’s complex products
World Class Reliability CANNOT be achieved purely with testing
It is KEY to understand all the critical elements which contribute towards achieving World Class Reliability
Reliability Solutions has worked and developed the optimum approach and model over the last 20 years
Focuses on 7 Key Focus Items
Reliability Solutions workshop will define how to do this and apply within your own organisation
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