Practical Reliability Engineering for Industry by Dr. Alec
Feinberg
Join
us for a webinar beginning on October 13, 2016 at 8:30 am PDT
Register now!
https://attendee.gotowebinar.com/register/4232184459595864067
This is an intense, practical course for industry focusing
on applying reliability in real world situations. It uses a stage gate
approach to reliability as product transition from the Idea Phase,
Evaluate, Develop, Transition and lastly to the Production Stage. This is a
two-day webinar, which costs $850, (broken down into 4 half days) and
includes course material and reliability software (30-day trial) to
accelerate learning. The material provides depth and exposure to the
industry's reliability science.
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
Idea phase using tools like FMEA, reliability predictions, and reverse
engineering. Here we provide a formal method for providing a detailed
reliability plan for the product. We describe how to develop the plan with
management and engineers so that everyone is involved and sample sizes and
cost are obtained up front. We move into Evaluation stage gate
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. We detail the method of test
design by failure modes. As the product matures and the design becomes
frozen, we move into the Development stage gate where we often do Design
Maturity Testing demonstrating reliability with qualification testing. We
go over the common specification and describe how to design test with and
without specifications. 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 solving quickly. This jump starts
ones capability. We then move into the Transition stage gate. Here we are
concerned with production screening such as HASS. Finally we move into production monitoring
where we monitor reliability with a sampling strategy.
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. We also describe
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.
PART
1: BASIC METHODS IN RELIABILITY
& QUALITY
1. Reliability
& Quality in Today’s Marketplace
○
A Practical Approach to Reliability Implementation
○ Reliability Growth and
ROI
○ Reliability
as a Differentiator
○
The Main Components of a DfRQ Company Program
2. The Stage Gate Approach
○
Idea, Evaluate, Development, Transition, Production
○ Understanding
Each Gate - The Tools for your Program
○ Piecing
it Together - A Value Added Reliability Program
3. Basic Reliability Mathematics (Using DfRSoft Tools)
○
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)
○
Reliability Predictions (Parts Count, Detailed Stress,
Telcordia, Mil Std 217…)
4. Basic Quality Test Engineering (Using DfRSoft Tools)
○
Cpk, Yield, Normal/Lognormal, & Six Sigma Analysis
○ SPC Charts
○ Visual Inspection/Design Release
PART
2: DEMONSTRATING & ANALYZING
RELIABILITY
IDEA
– STAGE GATE
5. Top Down FMEA for Reliability Program
Planning
○ What is a Top Down FMEA
○ Top Down FMEA for Program Planning
○
Team Approach
○ Design
Controls & Recommended Actions
○ How to Make a Program Plan with Top
Down Example
○ Value of Derating (Derating Specs -
DfRSoft Guideline)
5a Bottoms Up Design FMEA
○ Key to a Good DFMEA
○ Most Efficient DFMEA
EVALUATION – STAGE GATE
6 . Design Assessment Reliability Testing
& Reliability Growth (DART - HALT) (DfRSoft Tools)
○ Finding Failure Modes – Test to
Fail Not to Pass
○ Accelerated Reliability Growth
○ Test Design by Failure Modes
○ HALT
○ Design Margin – Load-Stress
Reliability Interference Assessment
○
Electrical Derating DEVELOP - STAGE GATE
7. Advanced Reliability Mathematics (Using DfRSoft Tools)
○ Time Dependent Failure Rate
○ Main Distribution of the Bathtub
Curve, Weibull, Exponential, and Lognormal
○ Introduction to Reliability
Plotting Using Software
8. Accelerated Life Models &
Environmental Profiling
○
Acceleration
Factors & Models (Temperature-Arrhenius, Coffin-Manson Temperature
Cycle, Vibration Accelerated Models)
○
Chi-squared confidence
method for accelerated testing
○ Environmental
Profiling (model for environments with varying stress profiles)
9. Design Maturity Chi-Squared Demonstration
Testing (Using DfRSoft Tools)
○ Testing
for a Reliability Failure Rate Objective?
○
Accelerated Test
Plan Examples
○
Statistical
Confidence Test Plans
RELIABILITY MONITORING
& SCREENING STAGE GATES
10. Reliability
Monitoring and Screening
○ Screening vs. Monitoring
○ Common Screens and Monitoring Tests
○ HASS Screening
11. Field Returns and Device Hours (DfRSoft Tools)
○ Device Hours – Multiple Test Uses
and Field Returns
○ AFR – Most common company metric
○ Field Return– Raw Data Analysis
12. Availability & Sparing (DfRSoft Tools)
PART
3: SPECIAL TOPICS TAYLORED TO THE
CLASS’ NEEDS
13. Advanced CDM ESD Concepts
○ Introduction
CDM compared to HBM
○ Why Ionizers
can be important
○ ESD
versus EOS damage
○ CDM
Case Studies
○ Advanced
Audits/Investigation, Test Fixtures
14. Shock & Vibration (Numerous Exercises)
○ Understanding Gs & gs
○ Vibration testing for Shipping
15. Physics of
Failure 7 Step Problem Solving
16. Physics of
Failure Analysis Tools Detail Analysis Pictures Showing Strengths of
Instruments
○ SEM (FE-SEM, EDS)
○ Digital Microscopy
○ Real Time Radiology, X-Ray Maps
○ Thermal Imaging
○ FTIR
17. Physics of
Failure (Numerous FA Pictures, Industry Lessons Learned and Design Rules to
Avoid Issues)
○ Four
main types of aging
○ Diffusion
- Substitutional, Kirkendall
○ Intermetallics
- Au Embrittlement, Purple Plague
○ Bond
wire failures - non stick, intermetallic
○ ○ Dendritic
Growth, Ag Migration & Electromigration
○ CTE’s
Mismatch, Thermal Fatigue
○ Engelmaier
IPC Solder Joint Life Model, BGAs
○ Electronic
Failure modes from shock, vibration
○ Creep,
Solder Creep, Creep Resistance in Plastics
○ Organic
contamination
○ Popcorn
Cracking, Voiding Delamination
○ Assembly
Errors
○ Solder
Failures (non wetting, grain size, leaching, coverage)
○ Contamination
– Solder non-wetting, Epoxy non-stick
○ Plating
Contamination
○ RoHS Lead
Free Solder Issues
○ Cu
Dissolution
○ PCB
Finishes
○ ESD
& EOS - Dielectric Breakdown
○ Current
Density & Fusing of Bond wires and wires
○ Junction
Temperature Issues & Modeling
18. Putting it all Together
19.
Homework (optional) includes the Solution Set
Dr. Alec Feinberg is the founder of
DfRSoft. He has a Ph.D. in Physics and is the principal author of the book,
Design for Reliability written at M/A-COM. Written in an industrial
environment, it is a very practical book and has a very extensive approach
to the DfR process using a stage gate process since products are developed
in phases. Alec is also the principal developer for DfRSoftware which is
the most thorough reliability tool currently available and is also used to
accelerate learning in his classes. Alec’s industrial experience has
allowed him to provide extensive reliability engineering services in all
areas and on numerous products in diverse industries (AT&T Bell Labs,
TASC, M/A-COM, Tyco Electronics, and Advanced Energy) for over 35 years
that include solar, thin film power electronics, defense, microelectronics,
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 Thermodynamic Reliability
Engineering. Some of the well-known companies that have taken his
courses include Hewlett-Packard,
Sandia National Labs, Canadian Space Agency, Sierra Wireless, Mentor
Graphics, Woodward Industrial Controls, Tyco Electronics, and
Northrop Grumman. Alec has
presented numerous technical papers and won the 2003 RAMS Alan O. Plait
best tutorial award for the topic, “Thermodynamic Reliability Engineering.”
Alec has a new book, Thermodynamic
Degradation Science: Physics of Failure, Accelerated Testing, Fatigue, and
Reliability Applications (due out October 2016, with the publisher John
Wiley & Sons). Alec's
main hobby is jazz harmonica.
|
DATES: October 13, 14, 19 & 20, 2016
TIME: 8:30 am to noon PDT
COST:
$850 per person for 4 days – +5 attendees at $765 each
|
After registering, you will receive a
confirmation email containing information about joining the webinar.
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