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This is an intense four-day webinar, which includes course material and reliability software (30-day trial) that makes learning fast. In today's rapid paced lean business environments, people are busy so the class is compacted to save down time and get engineers and managers back in the office to use the tools that they have learned. However, this is not a birds-eye view. The material provides depth and exposure to the industry's reliability science. We believe there is no better DfR course offered today.
We start with basic methods in reliability & quality, providing full explanation of how to grow reliability in a commercial environment and translate that into ROI dollars. Reliability growth starts in the design phase using tools like FMEA, reliability predictions, and reverse engineering. We move into demonstrating and analyzing reliability in the testing phase with prototypes, we describe how to organize an effective DART (design assessment reliability testing) plan that includes HALT and HASS development. A full or partial overview on HALT is available depending on class interest. Reliability statistical analysis is key and is accessible to the student through our professional DfRSoft software tool. Each student has the software to follow along during the course to help problem solve quickly. This jump starts ones capability.
Test methods such as temperature, temperature cycle, humidity, shock and vibration and how to analyze your test using this software, for both physics and statistics problems are demonstrated for all accelerated testing, with clear exercises. The concept of test design by failure modes is presented. Examples are given. All the key accelerated test models (Arrhenius, Humidity, Thermal Cycle, Electromigration) are provided and illustrated. Both simple and advanced reliability math is overviewed and taught efficiently with software examples. The concept of design maturity testing using accelerated test methods and Chi-squared test planning and analysis, again with software exercises, are used to assess products failure rate/MTTF. We include Quality tools such as Cpk, lot sampling, sparing, availability and normality analysis. Overview methods to analyze field return data to derive an MTBF. As part of reliability analysis, we present special topics tailored to the classes needs. This includes Physics of Failure, what equipment to use and when (SEM, Auger, X-RAY, XRF, Focused Ion Beam) etc. Numerous failure analysis pictures are shown to see first-hand the challenging failure modes and how their mechanisms are identified using such equipment. Other topics include a strong overview in understanding in Shock and Vibration, Advanced ESD methods, RoHS challenges, and parametric reliability analysis.
Dr. Alec Feinberg has a Ph.D. in Physics, is the founder of DfRSoft and is the author of the book, Design for Reliability. He has provided reliability engineering services in all areas of reliability and on numerous products in diverse industries that include solar, thin film power electronics, defense, micro-electronics, aerospace, wireless electronics, and automotive electrical systems. He has provided training classes in Design for Reliability & Quality, Shock and Vibration, HALT, Reliability Growth, Electrostatic Discharge, Dielectric Breakdown, DFMEA and Thermo-dynamic Reliability Engineering. Alec has presented numerous technical papers and won the 2003 RAMS Alan O. Plait best tutorial award for the topic, “Thermo-dynamic Reliability Engineering.”
DAY 1- BASIC METHODS IN RELIABILITY & QUALITY
Reliability in Today’s Marketplace
· A Practical Approach to Reliability Implementation
· Reliability Growth and ROI
· Reliability is a Differentiator
· The Main Components of a DfR Company Program
The Stage Gate
· Idea, Evaluate, Development, Transition, Production
· Understanding Each Gate - The Tools for your Program
· Piecing it Together - A Value Added Reliability Program
Basic Reliability Mathematics
· MTBF/Failure Rate Basics
· Failure Rate Conversion (FITs, FMH, MTBF, PPM, AFR, %Failure)
· System Reliability Analysis & Block Diagrams (Series, Parallel, Redundancy for K of N, Active/Standbys)
· Allocation (equal apportionment and by complexity)
· Reliability Predictions (Parts Count, Detailed Stress, Telcordia, Mil Std 217…)
Basic Quality Test Engineering
· Cpk, Yield & Normality/Lognormal, and Six Sigma Analysis
· SPC Charts
· Lot Sampling (Hypergeometric, Binomial, Risks, OC) and Double Sampling
· Visual Inspection/Design Release
Failure Modes Effects Analysis (FMEA)
· FMEA Terms
· Top Down FMEA for Program Planning
· DFMEA (focus on design controls & actions)
· DFMEA (streamline with an environmental approach)
· Keys to a good FMEA (without wasting everyone’s time)
· Value of Derating (Derating Specs - DfRSoft Guideline)
DAY 2 - DEMONSTRATING & ANALYZING RELIABILITY
Advanced Reliability Mathematics
· Time Dependent Failure Rate
· Main Distribution of the Bathtub Curve, Weibull, Exponential, and Lognormal
· Reliability Plotting (Life data analysis, censored data)
· Key Reliability Functions (CDF, PDF, Hazard Rate)
Field Returns and Device Hours
· Device Hours – Multiple Test Uses and Field Returns
· AFR – Most common company metric
· Field Return – Raw Data Analysis
· Field Return – Weibull Analysis, Mixed FM, (two populations)
· Mixed Modes Analysis (field returns)
Availability & Sparing
Design Assessment Reliability Testing & Reliability Growth (DART - HALT)
· Finding Failure Modes – Test to Fail Not to Pass
· Accelerated Reliability Growth
· Multi-Test Reliability Growth Assessment Methods (new Chi-Squared Reliability Growth analysis method)
· Test Design by Failure Modes
· HALT & HASS (Basics)
· Design Margin – Load-Stress Reliability Interference Assessment
· Safety Factors & Derating (mechanical & electrical stress assurance)
Design Maturity Testing
· Will Your Product Meet its Reliability Objective?
· DMT Test Plans
· Statistical Confidence
Accelerated Testing
· Acceleration Factors & Models (Temperature-Arrhenius, Peck Temperature-Humidity, Coffin-Manson Temperature Cycle, Modified Frequency Temperature Cycle, Vibration Accelerated Models, General Power Law Model)
· Chi-squared Confidence Method for Accelerated Tested
· Environmental Profiling (CALT like model environments with varying stress profiles)
· Statistical Qualification Planning
DAY 3 - SPECIAL TOPICS TAILORED TO THE CLASS NEEDS
Special Topics – Included with Course
Advanced ESD Concepts
· ESD Protection Methods
· ESD Protection Devices, Design Protection Methods
· ESD Advanced CDM Issues
· Advanced Audits/Investigation, Test Fixtures
Shock & Vibration
· Understanding Gs & gs
· Drop Shock and Specifications
· Sine Vibration & Analysis
· Random Vibration and PSD Analysis
· HALT - ED Shaker: how they differ and advantages of each
Physics of Failure Analysis Tools - (Detail Analysis Pictures Showing Strengths of Instruments)
· SEM (FE-SEM, EDS)
· Digital Microscopy
· Focused Ion Beam
· Real Time Radiology, X-Ray Maps
· C-SAM
· Thermal Imaging
· FTIR
· Scanning Auger
· Atomic Force Microscopy
· SIMS
· Other Tools Including ESD Simulator
· Sample Preparations
DAY 4 - SPECIAL TOPICS TAILORED TO THE CLASS NEEDS (cont.)
Physics of Failure (Numerous FA Pictures, Industry Lessons Learned & Design Rules to Avoid Issues)
· Diffusion - Substitutional, Kirkendall
· Intermetallics - Au Embrittlement, Purple Plague
· Bond wire failures – non-stick, intermetallic
· Eight Types of Corrosion - Area effect and Prevention
· Dendritic Growth, Ag Migration & Electromigration
· RoHS Issues
· Contamination – Solder non-wetting, Epoxy non-stick
· Stress-Strain – Vibration, CTE’s
· Popcorn Cracking, Voiding Delamination
· ESD & EOS - Dielectric Breakdown
· Solder Failures (non-wetting, grain size, leaching, coverage)
· BGA, Tin Whiskers
· Current Density & Fusing of Bond Wires
· Junction Temperature Issues
RoHS Challenges
· Making RoHS Work, What you need to know
Parametric Reliability
· Component Drift Analysis Methods & Sample Size Advantages
Physics of Failure 7-Step Problem Solving
Putting It All Together
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