Applied Reliability Symposium 2009 M Turner

Improving Organization Competitiveness. How Quantitative Accelerated Life Testing Can Present a Value Proposition. Mark Turner, C.R.P. Flextronics International 5:22 PM

Introduction ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Presentation aims $$$

[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Obtaining Reliability Metrics

RDT Methodology Runtime=[c+(0.667x#Failures)]xMTBF Weibull++ Design of Reliability Tests utility can also be used.

[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],An RDT Example

[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Common RDT Problems

[object Object],[object Object],[object Object],Product Design Strategies

Accelerated Life Tests ,[object Object],[object Object],[object Object],[object Object],[object Object]

[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Failure Rates

Acceleration Modeling ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],A Proposed ALT Methodology What activation energy should I use?

A Proposed QALT Methodology Provides flexibility in industrial applications. This methodology will be reviewed in detail, during which an example will be presented… N N Y

Running Example (1) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

The QALT Methodology Flow (1) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],N N Y Conduct Physics of Failure Review

The QALT Methodology Flow (2) ,[object Object],[object Object],Increasing stress N Y N Determine Stress Limits Conduct Failure Analysis

Running Example (2) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],110 100 90 80 70 60 50 40 0 10 20 30 Time (hours) Temperature (ºC) Thermal Profile

Running Example (3) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Running Example (4) ,[object Object],Temperature (°C) Power (W) Failure distribution Maximum stress limit. Remaining below this ensures that any product failures are the result of life acceleration and not due to excessively high stress levels. Destruct Region Design Margin Specification Limits

The QALT Methodology Flow (3) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],N N Y Conduct DOE

The QALT Methodology Flow (4) ,[object Object],[object Object],[object Object],N N Y ,[object Object],[object Object],[object Object],[object Object],Conduct DOE Define Operational Limits & estimate Acceleration Factor

Running Example (5) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Running Example (6) ,[object Object],[object Object],[object Object],Nominal output power, constant input voltage Increased output power, power cycled Increased output power, constant input voltage … #1 #2 #3 #4 #n Chamber 1A Chamber 1B High Stress 1 High Stress 2 Nominal output power, power cycled … #1 #2 #3 #4 #n ... #1 #2 #3 #4 #n Chamber 2A Chamber 2B … #1 #2 #3 #4 #n Temperature ( ° C) 90 80 70 60 50 40 Acceleration Factor 0 5 10 15 20 25 30 35 1A 1B 2A 2B

The QALT Methodology Flow (5) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],N N Y ,[object Object],Define Sample Size & QALT duration

[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Running Example (7) The accelerated life test should be continued to validate the conclusions… Parametric Binomial test duration without acceleration required a duration of 3,750 hours

Derived Product QALT Design ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Derived Product Accelerated RDT ,[object Object],[object Object],[object Object],[object Object],[object Object]

[object Object],[object Object],Derived Product Accelerated RDT One product to market every 6 weeks. OR Five products to market every 4 weeks!

[object Object],[object Object],[object Object],Step Stress Tests t 1 t 2 t 3 Stress 3 Stress 2 Stress 1 f 1 ,d 1 f 2 ,d 2 f 3 ,d 3 F 1-3 : Probability of failure at stress levels 1-3. d 1-3 : Probability of degradation at stress levels 1-3.

Analysis Models ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Eta Beta

Summary ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]

Where to Get More Information ,[object Object],[object Object]

Mark Turner ,[object Object],[object Object],[object Object],[object Object],[object Object]

Questions ,[object Object],[object Object]

Applied Reliability Symposium 2009 M Turner

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