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Professional Consulting Firms Focused on Reliability Engineering Services, Reliability Management, and Reliability Education. Professional Laboratories Focused on Reliability Testing and Services. Reliability Resources brings it all together. We can assist you in developing and executing any and all elements of Reliability throughout your Organization and your Product’s Life Cycle.

O N E S T O P S H O P I N G F O R R E L I A B I L I T Y S E R V I C E S A N D E Q U I P M E N T

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T A B L E O F C O N T E N T S

Products and Equipment .......................................Page 3 HALT, HASS and HASA ...........................................Page 4 Tradition Testing....................................................Page 6 Reliability Consulting and Education.........................Page 8 Failure Analysis.....................................................Page 10 Physics of Failure Predictions...................................Page 11

Phone: 714-903-1005 Fax: 714-903-1033 E-mail: cbonn@reliability-resources.com Web: www.reliability-resources.com

Clayton Bonn 15661 Producer Lane, Unit H Huntington Beach, CA 92649

R E L I A B I L I T Y R E S O U R C E S

For more information or to request a CD with more details on our products or services contact us by one of the methods below. Click Here

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V I R T U A L P C B P R O T O T Y P I N G T O O L F O R S T R E S S D E T E C T I O N BQR’s fiXstress Only software on the market that allows circuit designers the ability to quickly and effortlessly assess the electrical stresses on each and every part under a variety of conditions.

L E A D F R E E S O L D E R Complete Line of Lead Free Solder and Solder Paste

R E L I A B I L I T Y R E S O U R C E S

E N V I R O N M E N T A L T E S T C H A M B E R S Temperature & Humidity Test Chambers

C U S T O M F I X T U R E S Custom Fixtures for HASS testing

H A S T C H A M B E R S Highly Accelerated Stress Testing [HAST], Custom designed accessories and fixtures, Pressure Cookers, Saturated PCT Chambers

S I M U L A T I O N C H A M B E R S Environmental Testing Equipment, Tempering, Thermal and Humidity, Safety Drying Ovens, Constant Climate Simulation, Communication Software APT-COM®

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Quality Testing Service (QTS), formally QualMark's Huntington Beach Test Center, is now the premier HALT/HASS lab in Southern California. By subjecting products to stresses exceeding those found in the field or performed on traditional test equipment, QTS can essentially accelerate time, saving weeks and months normally spent testing product in real-time. Our team of experienced test personnel assists customers in conducting the best possible test. Services available: • HALT (Highly Accelerated Life Test) • Production HASS (Highly Accelerated Stress Screen) • Production HASA (Highly Accelerated Stress Audit) • Customer Directed Test • HALT/HASS Training • HASS Development • Fixturing • On-Site Consulting

H A L T , H A S S A N D H A S A

HIGHLY ACCELERATED LIFE TESTING SYNOPSIS Highly Accelerated Life Testing (HALT) is a design verification tool for testing electronic and electro-mechanical products. HALT em-ploys thermal and vibration stresses that quickly uncover design flaws and precipitates latent defects that might otherwise be exhib-ited as field failures and warranty problems. A product under test is powered-up and monitored throughout the testing process. A determination of the root cause of any failures found is made during testing (if possible). Repairs are performed “on the fly” and testing continues to widen the operating margins of the product until the fundamental limit of the technology is reached. HALT pushes a product to its true operating limits and beyond. Whereas traditional methods simulate field environments and test products within their specifications, HALT stimulates products be-yond their specifications, significantly compressing the time needed for testing. HALT testing usually takes 3-5 days compared with weeks or months for traditional reliability assessments. HALT, therefore, is a very significant and cost effective process in bringing the highest quality product to market in the shortest period of time.

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Customer Defined Test Services This testing may not strictly follow the HALT and HASS services offered by QTS; instead, it takes a more traditional and selective approach to environmental testing. Customers define and direct the testing process, using the temperature and/or vibration stresses available in a HALT chamber. These stresses include 6 degree of freedom vibration to 60 Grms and Thermal conditions from -100 de-grees C to 200 degress C. We can achieve a thermal ramp rate of 60 degrees C on the product, not just the surrounding air. On-site Services If the customer cannot come to QTS we can come to the customer site. Our testing experts will provide specialized HALT/HASS testing and training on customer equipment at their site. We will provide this train-ing on any QualMark as well as on any non-QualMark test equip-ment. Consulting Services Our staff of experienced engineers will work with customers to conduct the type of tests needed. QTS can help maximize the efficiency and ef-fectiveness of existing protocols and procedures, whatever the customer goals may be. We also offer free educational seminars on HALT and HASS at your site or ours. Free Educational Seminars — Introduction to HALT and HASS

BENEFITS OF HALT

• Reduces R&D costs. • Increases product quality / reliability. • Reduces time to market. • Ability to find and correct defects before your prod-

uct is released (and before your customers find the defects).

• Maximizes Mean Time Between Failures. • Lowers field failures, in-warranty problems, and associated costs. • Ability to confidently increase warranty coverage. • Increase long term profits due to: Higher customer satisfaction

and confidence, increase company image and reputation, and last but not least - repeat customers and increased market share.

H A L T , H A S S A N D H A S A

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T R A D I T I O N A L T E S T I N G

• High/Low Tempera-ture • Solar Radiation • Explosive

• Humidity • Altitude • Atmosphere

• Salt Fog • Decompression • Blowing Rain

• Blowing Sand/ Dust • Icing/Freezing Rain

• Temp/Altitude/Humidity • Fungus

Vibration

• Random • Random/Sine • Package Vibration

• Sine • Gunfire • Transportation Vibration

• Combined • Resonance Search/ Dwell

Shock

• Classical (half-sine, sawtooth, trap-ezoidal) • Transient

• SRS (Shock Response Spectrum)

• Test Conducted in our 6 ft. radius centrifuge

Mil-spec. 810 or DO 160

Socal Testing has over 25 years of proven test experience in the military, aerospace, and commercial industries. We offer a vast array of testing, certification, and consulting services to meet your needs.

Acceleration

Environmental Testing

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T R A D I T I O N A L T E S T I N G

• Mil-PRF-5606 • Mil-7808 • JP4 • 7024

• Mil-83282 • Skydrol • JP5 • Jet A

• Mil-23699 • Kerosene • JP10 • And More...

Qualification Testing for Military and Aerospace fittings, hoses, valves, & controls.

Fluids

• Flow/Pressure Drop • Surge Pressure (10K psig)

• Hydraulic 50 gpm, 5000 psig • Endurance

• Hydraulic/Fuel Impulse • Contaminated Fuel

• 7000 psig capabilities (hydraulic) • Fluid Susceptibility

• Hydraulic Temps. (-70F to 450F) • Icing

• Fatigue (including Rotary) • Leak Test

• Fuel Flow Test (-65F to 140F) • Lightning

• Fuel 400 GPM, 300 Psig • Explosive Atmosphere

• Fire Test (2000F) • Altitude

Hydraulic and Fuel System Component Testing

• Endurance • Ground Bonding • Static Load

• Life Cycle • 400Hz Power • Axial Load

• Pressure Testing • Bearing Testing • Insulation Resistance

• Helium Leak • Proof Load Testing • Load vs. Deflection & Fatigue

• Fire • Radial • Dielectric Withstand-ing Voltage

Mechanical and Electrical Testing

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R E L I A B I L I T Y C O N S U L T I N G A N D E D U C A T I O N

Reliability Services Overview

Reliability Integration is the process of seamlessly and cohesively integrat-ing reliability tools together to maximize reliability and at the lowest possi-ble cost. Reliability Integration for the Organization At the ORGANIZATION Level, Reliability Assessment is a great starting point to determine priorities for improving the reliability program. It is a quick and thor-ough evaluation of most elements of the organization's approach and execution to achieving reliable products. The assessment reveals areas of strengths, weaknesses and opportunities, plus the organization's reliability maturity level. To achieve the desired reliability levels customers demand, an organization must un-derstand the reliability process and manage it as a process. Establishing clear Relia-bility Policies, Goals and resources, the reliability process guides product design and delivery. Periodically, you should examine your current situation by performing a Reliability Program Assessment. Competitive Analysis and careful examination of the customer expectations around reliability help you gage your expectations. Along the way, a suite of Reliability Metrics provide the dashboard to monitor the reliability process. RoHS Reliability Transition Program assures that good practices transfer from the Organizational Level to each Product Team across the Product Life Cycle.

• Reliability Program Assessment • Organization Reliability Goal Setting/Metrics • Competitive Analysis • RoHS Reliability Transition Program Reliability Integration for the Product At the PRODUCT Level, we offer a w ide range of services across a Product's Life Cycle. Our expertise in selecting, applying, and integrating to match your product requirements, plus our skill in educating and mentoring your team gives you the ability to achieve phenomenal reliability growth. Of course, if you already know what you need, you can choose from our List of Ser-vices "A La Carte". Our team can quickly provide expertise, execution, and educa-tion. Hosting workshops, working meetings, hands-on training, coaching, and men-toring are all methods to bring your team up to speed on any of these services.

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Reliability Integration in the Concept Phase • Reliability Goal Setting • Benchmarking/Gap Analysis • Technology Risk Assessment • Reliability Program/Integration Plan • Software Reliability Goal Setting • Software Reliability Program/Integration Plan

Reliability Integration in the Design Phase • Reliability Predictions • Reliability Block Diagrams • Fault Tree Analysis • Failure Modes/Effects Analysis • Thermal Analysis • Derating Analysis/Component Selection • Tolerance/Worst Case Analysis • Material Selection • Design of Experiments • Finite Element Analysis • Design for Six Sigma • Dynamic Analysis (modal, shock, vibration) • Sneak Circuit Analysis • Warranty Predictions • Maintainability/ Preventive Maintenance Analysis • Design Review/Retrospective Facilitation • Facilitation of Team Design Template Reviews • Facilitation of Team Design Reviews • Software Failure Analysis • Software Fault Tolerance

Reliability Integration in the Prototype Phase • Reliability Test Plan Development • HALT • Root Cause Failure Analysis • Fracture and Fatigue • Design Verification Testing • Environmental Testing/ Analysis • Package Design and Testing

• Regulatory Compliance Testing/Certs • Test Fixture Design and Fabrication • Thermal Testing/ Analysis • Accelerated Life Testing • Reliability Demonstration Testing • Closed-Loop Corrective Action Process Setup

Reliability Integration in the Man-ufacturing Phase • Highly Accelerated Stress Screening (HASS) • On-Going Reliability Testing (ORT) • Vendor Reliability Program Assessment • Repair Depot Setup • Field Failure Tracking System Setup • Warranty Performance Analysis • Reliability Performance Reporting • End-of-Life Assessment • Lessons Learned Process Establishment For Software, we offer a wide range of services across a Product's Software Life Cycle - Concept, Design, Im-plementation, or Testing. Our expertise in selecting, ap-plying, and integrating to match your product re-quirements, plus our skill in educating and mentoring your team gives you the ability to achieve phenomenal reliability growth.

Reliability Integration in the Implementation Phase • Facilitation of Code Reliability Reviews • Software Robustness and Coverage Techniques

Reliability Integration in the Testing Phase • Software Reliability Measurements and Metrics • Usage Profile-based Testing • Software Reliability Estimation Techniques • Software Reliability Demonstration Tests

Reliability Integration through Ed-ucation EDUCATION on the best tools for Reliability Engineering.

R E L I A B I L I T Y C O N S U L T I N G A N D E D U C A T I O N

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DfR Solutions has expertise and experience in failure analysis and is a leader in identifying systematic defects (flame retardants, low ESR electrolytics, etc.) that have significantly affected the electronics industry. Effective failure analysis is critical to product reliability. Without identifying the root causes of failure, true corrective action cannot be implemented and the risk of repeat occurrence increases. DfR Solutions takes a systematic approach to failure analysis proceeding from non-destructive to destructive methods until all root causes are conclusively identified. We choose the appropriate techniques based upon the failure information (failure histo-ry, failure mode, failure site, failure mechanism) specific to your product. Our Approach The information-gathering process is the crucial first step in any failure analysis effort. We obtain information through interviews with all the members of your produc-tion team from suppliers, manufacturers, designers, reliability team, management to the end-user. Clarity is brought to the discussion through the use of standard nomenclature: Failure history • All change in bill of materials (BOM), and manufacturing • Time in the product life cycle • Stresses experienced by the product Failure mode • Failure behavior experienced by the observer Failure site • Supposed location of the failure Failure mechanism • Mechanism initiating the failure (not root cause) The next step in failure analysis is to conduct a non-destructive evaluation (NDE) of the product. NDE is designed to provide maximum information with minimal risk of damag-ing or destroying physical evidence. This evaluation method includes: • Visual Inspection • Electrical Characterization • Acoustic Microscopy • Xray Microscopy • Thermal Imaging • SQUID Microscopy And the next step is to conduct a destructive evaluation(DE) to reveal the internal struc-ture of the sample. • Decapsulation • Microsectioning • Focused Ion Beam implementation • SEM analysis DfR Solutions conducts independent component-level testing and supplier eval-uations to help our customers reach their goals of “zero-defects” while staying cost competitive.

F A I L U R E A N A L Y S I S

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P H Y S I C S O F F A I L U R E R E L I A B I L T Y P R E D I C T I O N S

Traditional Reliability Prediction approaches like Mil-Hdbk 217/Bellcore methods focus on de-veloping a simplified average failure rate (FR) or MTBF value that represents the alleged "random constant failure" period of the bath tub curve for individual components. Then the FRs of all the components in a device can be tallied in order to predict the failure rate and reliability of the entire device at various points of a device's life. This info is used by program planners, management, field service logisticians . . . etc. to estimate warranty repair costs and work efforts. But it provides little guidance to the design and process en-gineers to provide info on how to make more reliable products. Instead engineers depend on slow and costly reliability growth techniques (i.e. building and testing prototype parts to find problems and design weaknesses. This is essential a trial and error process for climbing the learning curve on every new product or technology development. Several major shortcomings of predictive approaches are: • Databases of component failure rates are frequently out of date

since it is hard and costly to get updates with good data. • Component FR databases have no data on new or evolving components. • Does not account for the so called "quality defect"/"infant mortality" and the "end or life"/"wear

out" portions of the bath tub curve which can have a considerable contribution, especially in new products.

• The averaged results for the summation of all the components/technologies in a device provides no insight on the specific capabilities or weaknesses of a specific design in a specific set of usage and environmental stress conditions.

Even when the part counting methods were modified with "stress analysis" techniques there was an over simplification and over dependence on thermal stresses and the Arrhenius relationship. Fail-ures related to other type of stress conditions were again under accounted for. Reliability Physicist, scientists who develop and use Physics of Failure know ledge, believe in an ordered universe based on cause and effect relationships. They have found that too many is-sues are incorrectly classified as "Random Constant Rate Failures" issues by statistician in an ef-fort to simplify calculations. Instead, when studied in detail and fully traced back to true root causes and categorized by the underlying failure mechanism, most failure issues are found to be actually due to either quality defects issues, premature wear out issues or weak designs/parts/materials being overstressed. Manufacturing Process PoF - After a capable design is locked in, the PoF process moves to optimizing the capability of the fabrication or assembly process to ensure it consistently produc-es defect free parts with optimum strength characteristics. This can later be confirmed by PoF based first article inspection and evaluation methods to verify that the parts are consistently being produced to design expectations. Product and process engineers who have used PoF techniques, immediately see the benefits and rapidly become strong supporters. This is why PoF is primarily taught in electrical and mechanical engineering programs and only rare in quality/reliability classes (with the exception of course of the Q/R programs at the University of Maryland which is one of the primary PoF research site being funding by the National Science Foundation and Department of Defense). Elsewhere, the emphasis on a random constant failure rate approach has been so strongly embed-ded in Q/R professional that changing to PoF methods has been slow in some segments of the industry. Another reason is that PoF methods produce higher quality/more reliability parts faster than other processes but PoF does not produce program management reliability planning numbers. The R number is still seen as a primary deliverable by many Q/R professional and it does fill a vital program cost/work planning role, despite the vast amount of evidence that documents the inaccura-cy of the numbers produced. However, since the military has started to specify PoF methods in-stead of reliability prediction in major new programs like the F-35 joint strike fighter, this has started to change.

DfR Solutions can perform the POF predictions for you.

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Phone: 714-903-1005

Fax: 714-903-1033

E-mail: cbonn@reliability-resources.com

Web: www.reliability-resources.com

Clayton Bonn

15661 Producer Lane, Unit H

Huntington Beach, CA 92649

R E L I A B I L I T Y R E S O U R C E S

For more information or to request a CD with more details on our products or services contact us by one of the methods below. Click Here