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Introduction to Design for Reliability (Dfr) and Design for Manufacturability (Dfm)

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Introduction to Design for Reliability (Dfr) and Design for Manufacturability (Dfm) Introduction to Design for Reliability (DfR) and Design for Manufacturability (DfM) SMTA North Texas Chapter November 4, 2016 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com © 2004 – 2010 What is Design for Reliability (DfR)? o Reliability is the measure of a product’s ability to o …perform the specified function o …at the customer (with their use environment) o …over the desired lifetime o Design for Reliability is a process for ensuring the reliability of a product or system during the design stage before physical prototype o Often part of an overall Design for Excellence (DfX) strategy 2 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com Why Design for Reliability (DfR)? o The foundation of a successful product is a robust design o Provides margin o Mitigates risk from defects o Satisfies the customer 3 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com When Do Mistakes Occur? o Insufficient exchange of information between electrical design and mechanical design o Poor understanding of supplier limitations o Customer expectations (reliability, lifetime, use environment) are not incorporated into the new product development (NPD) process There can be many things that “you don’t know you don’t know” 4 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com List of DfR Tools and Techniques 5 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com List of DfR Tools and Techniques o Failure Mode Analysis o Failure Mode Effect Analysis (FMEA), Fault Tree/Tolerance Analysis (FTA), Design Review by Failure Mode (DRBFM), Sneak Circuit Analysis (SCA) o Reliability Prediction - Empirical o Design Rules o Design for Excellence o Design for Manufacturability (DfM), Design for Testability (DfT) o Tolerancing (Mechanical, Electrical) o Simulation and Modeling (Stress) o Thermal, Mechanical, Electrical/Circuit o Simulation and Modeling (Damage) o EMI/EMC, EOS/ESD, Physics of Failure, Derating 6 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com Failure Mode Analysis o A process of identifying potential failure modes and appropriate mitigations early in the design process o Likely the most common DfR tool for reliability engineers o These are generic DfR tools o A Strength and Weakness o Strength: Can provide amazing insight o Weakness: Can be a boring, monotonous, no-value, check-the-box activity 7 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com Concept / Block Diagram o Can DfR mistakes occur at this stage? o No………..and Yes o Failure to capture and understand product specifications at this stage lays the groundwork for mistakes at schematic and layout o Important specifications to capture at concept stage o Reliability goals o Use environment o Dimensional constraints 8 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com Limitations of MTTF/MTBF o MTBF/MTTF calculations tend to assume that failures are random in nature o Provides no motivation for failure avoidance o Easy to manipulate numbers o Tweaks are made to reach desired MTBF o E.g., quality factors for each component are modified o Often misinterpreted o 50K hour MTBF does not mean no failures in 50K hours o Better fit towards logistics and procurement, not failure avoidance 9 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com Field Environment (Best Practice) o Use standards when… o Certain aspects of your environment are common o No access to use environment o Measure when… o Certain aspects of your environment are unique o Strong relationship with customer o Do not mistake test specifications for the actual use environment o Common mistake with vibration loads 10 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com Electrical Environments o Often very well defined in developed countries o Introduction into developing countries can sometimes cause surprises o Rules of thumb o China: Can have issues with grounding (connected to rebar?) o India: Numerous brownouts (several a day) o Mexico: Voltage surges 11 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com Know Your Environment (Case Study) o Leader in surgical systems for eyecare o Released latest system with foot pedal for ease of use o Failed to realize how customers would use foot pedal o Moving system across carpet without lifting up foot pedal created large static charges o Using foot pedal to pull system caused cable/connector failures 12 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com Thermal Environments (Case Study): Closed Containers Container and Ambient Temperature 75.0 Temp. Container Temp (°C) Outdoor Temp (°C) Variation 65.0 Trucking 55.0 Container 45.0 Temperature Temperature (°C) 35.0 25.0 15.0 0 50 100 150 200 250 300 350 400 450 Hours 13 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com Dimensions o Keep dimensions loose at this stage o Large number of hardware mistakes driven by arbitrary size constraints o Examples include poor interconnect strategies and poor choices in component selection o Case study: Use of 0201 chip components o Tight dimensional requirements push designer towards wholesale placement of 0201 components o 0201 is not yet an appropriate technology for systems requiring reliability o Result: Major issues at customers 14 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com Part Selection o The process of creating the bill of materials (BOM) during the ‘virtual’ design process o Before physical layout o For some companies, this is during the creation of the approved vendor list (AVL) o Design-independent 15 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com Part Selection (cont.) o KIS: Keep it Simple o New component technology can be very attractive o Not always appropriate for high reliability embedded systems o Be conservative o Reality: Marketing hype FAR exceeds actual implementation o Component manufacturers typically use portable sales to boost numbers o Claim: We have built 100’s of millions of these components without a single return! o Actuality: All sales were to two cell phone customers with lifetimes of 18 months 16 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com Part Selection (cont.) o Even when used by hi-rel companies, some modifications may have been made o Example: State-of-the-art crystal oscillator required specialized assembly to avoid failures one to three years later in the field o Prior examples of where care should have been taken o New technologies: X5R dielectric, SiC diodes, etc. o New packaging: Quad flat pack no lead (QFN), 0201, etc. 17 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com Part Selection (cont.) o As technology progresses, functional performance has become a limited aspect of the part selection process o Other concerns are increasingly taking center stage o Moisture sensitivity level (MSL) o Temperature sensitivity level (PSL) o Electrostatic discharge (ESD) classification o Manufacturability (Design for Assembly) o Plating material o Lifetime / Long-term reliability o Sometimes Physics of Failure is required 18 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com Critical Components o Most small to mid-size organizations do not have the resources to perform a thorough part selection assessment on every part o Does not excuse performing this activity o Requires focusing on components critical to the design o Critical Components: A narrowed list of components of most concern to the OEM o Sensitivity of the circuit to component performance o Number of components within the circuit o Output from FMEA / FTA o Past experiences o Complexity of the component o Industry-wide experiences 19 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com When to do Simulation and Modeling? o With recent improvements in model development (typically biggest time sink), there are few limitations to rapid and robust electrical/thermal/mechanical/reliability simulations of electronic products o Simulation and modeling allows organizations to o Obtain deeper insight earlier in the design process o Quantify price vs. performance for supplier and material selection o Iteration and optimization at minimal cost o Avoid ‘opinioneering’ o Substitute or replace test requirement o Accurately predict field performance o Faster time to market 20 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com Simulation & Modeling Case Study – Virtual Power Cycling 3D Sherlock Model Thermal Analysis Results Lifetime Prediction o EDA → Sherlock → Flotherm → Sherlock → Prediction: 8 hours 21 9000 Virginia Manor Rd Ste 290, Beltsville MD 20705 | 301-474-0607 | www.dfrsolutions.com DfR Conclusions o To avoid design mistakes, be aware that functionality is only the beginning o Mechanical and thermal are just as important as electrical o Maximize knowledge of your design as early in the product development process as possible o Be aware of industry best practices o Do not overly rely on supplier statements o Their view: Reliability is
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