Improving Product Reliability
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Improving Product Reliability Strategies and Implementation Mark A. Levin and Ted T. Kalal Teradyne, Inc., California, USA Improving Product Reliability Wiley Series in Quality and Reliability Engineering Editor Patrick D.T. O’Connor www.pat-oconnor.co.uk Electronic Component Reliability: Fundamentals, Modelling, Evaluation and Assurance Finn Jensen Integrated Circuit Failure Analysis: A Guide to Preparation Techniques Friedrich Beck Measurement & Calibration Requirements For Quality Assurance to ISO 9000 Alan S. Morris Accelerated Reliability Engineering: HALT and HASS Gregg K. Hobbs Test Engineering: A Concise Guide to Cost-effective Design, Development and Manufacture Patrick D.T. O’Connor Improving Product Reliability: Strategies and Implementation Mark Levin and Ted Kalal Improving Product Reliability Strategies and Implementation Mark A. Levin and Ted T. Kalal Teradyne, Inc., California, USA Copyright 2003 John Wiley & Sons Ltd, The Atrium, Southern Gate, Chichester, West Sussex PO19 8SQ, England Telephone (+44) 1243 779777 Email (for orders and customer service enquiries): [email protected] Visit our Home Page on www.wileyeurope.com or www.wiley.com All Rights Reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning or otherwise, except under the terms of the Copyright, Designs and Patents Act 1988 or under the terms of a licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Road, London W1T 4LP, UK, without the permission in writing of the Publisher. Requests to the Publisher should be addressed to the Permissions Department, John Wiley & Sons Ltd, The Atrium, Southern Gate, Chichester, West Sussex PO19 8SQ, England, or emailed to [email protected], or faxed to (+44) 1243 770620. 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British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library ISBN 0-470-85449-9 Typeset in 10.5/13pt Sabon by Laserwords Private Limited, Chennai, India Printed and bound in Great Britain by TJ International, Padstow, Cornwall This book is printed on acid-free paper responsibly manufactured from sustainable forestry in which at least two trees are planted for each one used for paper production. Cary and Darren Kalal To my beautiful wife, Dana Mischel Levin, for her endless love, support, and patience, and to our sons, Spencer and Andrew. Contents About the Authors xv Series Foreword xvii Foreword xix Preface xxi List of Acronyms xxv Acknowledgements xxvii PART I Reliability – It’s a Matter of Survival 1 1 Competing in the Twenty-first Century 3 1.1 Gaining competitive advantage 4 1.2 Competing in the next decade – winners will compete on reliability 4 1.3 Concurrent engineering 5 1.4 Reducing the number of Engineering Change Orders (ECOs) at product release 7 1.5 Time-to-market advantage 8 1.6 Accelerating product development 10 1.7 Identifying and managing risks 11 1.8 ICM, a process to mitigate risk 12 Reference 12 2 Barriers to Implementing Reliability 13 2.1 Lack of understanding 13 2.2 Internal barriers 15 2.3 Implementing change and change agents 16 2.4 Building credibility 18 vii viii Contents 2.5 Perceived external barriers 19 2.6 It takes time to gain acceptance 20 2.7 External barrier 21 3 Understanding Why Products Fail 24 3.1 Why things fail 24 3.2 Parts have improved, everyone can build quality products 27 3.3 Reliability – a twenty-first century paradigm shift 27 References 29 4 Alternative Approaches to Implementing Reliability 30 4.1 Hiring consultants 30 4.2 Outsourcing reliability 31 PART II Unraveling the Mystery 33 5 The Product Life Cycle 35 5.1 Six phases of the product life cycle 35 5.1.1 Mitigate risk 37 5.2 The ICM process for a small company 43 5.2.1 DFx – Design for Manufacturability (DFM), Design for Test (DFT), Design for Serviceability (DFS) and Maintainability, and Design for Reliability (DFR) 44 5.2.2 Warranty 44 References 45 6 Reliability Concepts 47 6.1 The bathtub curve 48 6.2 Mean Time Between Failure 50 6.2.1 Mean time between repair 50 6.2.2 Mean Time Between Maintenances (MTBM) 50 6.2.3 Mean Time To Failure (MTTF) 50 6.2.4 Mean Time To Repair (MTTR) 51 6.2.5 Mean Time To Restore System (MTTRS) 51 6.3 Warranty costs 52 6.4 Availability 53 6.4.1 On-site manufacturer service personnel 55 6.4.2 Customer trained service personnel 55 Contents ix 6.4.3 Manufacturer training for customer service personnel 55 6.4.4 Easy-to-Use service manuals 55 6.4.5 Rapid diagnosis capability 56 6.4.6 Repair and spare parts availability 56 6.4.7 Rapid response to customer requests for service 56 6.4.8 Failure data tracking 56 6.5 Reliability growth 57 6.6 Reliability demonstration testing 58 Reference 62 7 The Reliability Toolbox 64 7.1 The FMEA process 64 7.1.1 The functional block diagram 65 7.1.2 The fault tree analysis 70 7.1.3 Failure modes and effects analysis spreadsheet 73 7.1.4 Preparing for the FMEA 78 7.1.5 Barriers to the FMEA process 80 7.1.6 FMEA ground rules 84 7.2 The HALT process 85 7.2.1 Types of stresses applied in HALT 89 7.2.2 The theory behind the HALT process 90 7.2.3 HALT testing 94 7.3 Highly Accelerated Stress Screening (HASS) 97 7.3.1 Proof Of Screen (POS) 99 7.3.2 Burn-in 99 7.3.3 Environmental Stress Screening (ESS) 101 7.3.4 Economic impact of HASS 102 7.3.5 The HASA process 102 7.4 Summary of HALT, HASS, HASA and POF benefits 103 7.5 HALT and HASS test chambers 104 7.6 SPC tool 105 7.7 FIFO tool 106 7.8 Component derating–afirstlineofdefenseinproduct reliability 108 References 108 8 Why Reliability Efforts Fail 113 8.1 Lack of commitment to the reliability process 113 8.2 Inability to embrace and mitigate technologies risk issues 115 x Contents 8.3 Choosing the wrong people for the job 116 8.4 Inadequate funding 117 8.5 Mil-Std 217/Telcordia – What they really do and why they don’t work 123 8.6 Finding but not fixing problems 124 8.7 Nondynamic testing 125 8.8 Vibration testing too difficult to implement 125 8.9 Late software 126 8.10 Supplier reliability 126 Reference 126 9 Supplier Management 127 9.1 Purchasing interface 127 9.2 Identifying your critical suppliers 128 9.3 Develop a thorough supplier audit process 129 9.4 Develop rapid nonconformance feedback 130 9.5 Develop a Materials Review Board (MRB) 130 PART III Three Steps to Successful Implementation 133 10 Establishing a Reliability Lab 135 10.1 Staffing for reliability 135 10.2 The reliability lab 136 10.3 Facility requirements 138 10.4 Liquid nitrogen requirements 138 10.5 Air compressors requirements 139 10.6 Selecting a reliability lab location 140 10.7 Selecting a HALT test chamber 141 10.7.1 Chamber size 143 10.7.2 Machine overall height 143 10.7.3 Power required and consumption 145 10.7.4 Acceptable operational noise levels 145 10.7.5 Door swing 145 10.7.6 Ease of operation 145 10.7.7 Profile creation, editing, and storage 146 10.7.8 Temperature rates of change 146 10.7.9 Built-in test instrumentation 146 Contents xi 10.7.10 Safety 146 10.7.11 Time from order to delivery 146 10.7.12 Warranty 147 10.7.13 Technical/Service support 147 10.7.14 Compressed air requirements 150 10.7.15 Lighting 150 10.7.16 Customization 150 11 Hiring and Staffing the Right People 151 11.1 Staffing for reliability 151 11.2 Choosing the wrong people for the job 156 12 Implementing the Reliability Process 157 12.1 Reliability is everyone’s job 157 12.2 Formalizing the reliability process 158 12.3 Implementing the reliability process 159 12.4 Rolling out the reliability process 159 12.5 Developing a reliability culture 165 12.6 Setting reliability goals 166 12.7 Training 167 12.8 Product life cycle defined 169 12.9 Concept phase 170 12.10 Design phase 170 12.11 Production phase 171 12.12 End-of-life phase 172 12.13 Proactive and reactive reliability activities 172 References 174 PART IV Reliability Process for Product Development 177 13 Product Concept Phase 179 13.1 Establish the reliability organization 180 13.2 Define the reliability process 181 13.3 Define the system reliability requirement 181 13.4 Capture and apply lessons learned 182 13.5 Risk mitigation 184 13.5.1 Filling out the risk mitigation form 187 13.5.2 Risk mitigation meeting 189 xii Contents 14 Design Concept Phase 191 14.1 Setting reliability requirements and budgets 193 14.2 Define reliability design guidelines 198 14.3 Risk mitigation in the design concept phase 199 14.3.1 Identifying risk issues 199 14.3.2 Reflecting back (capturing internal lessons learned) 200 14.3.3 Looking forward (capturing new risk issues) 201 14.4 Reliability