HALT, HASS, and HASA Explained

Harry W. McLean

Description

This groundbreaking resource book is the place where readers will find all that is required to implement a successful accelerated reliability program.
It has been prepared with both novices and experts in mind. It has been written so that either can find information that will aid them in their quest to produce high-reliability products without getting bogged down in equations. HALT, a process for the ruggedization of preproduction products, and HASS, the production screen for the products once they have been characterized in HALT, are the primary focal points in this book. For those wishing to delve into more advanced topics, three versions of a production audit, HASA, are also included. These may be of interest to the high-volume producer or to those who wish to audit their overall production processes rather than to screen all of the products.
Author Harry McLean shares the knowledge he has acquired in helping employers and clients manufacture products which far exceeded stated reliability expectations as soon as they were released into production. Many who are using these techniques are included in the world’s top 50 electronic and electromechanical companies and have seen their market share climb from “the dust in the rear of the pack” to be the industry leader in a short time. Others have used HALT, HASS, and HASA techniques to increase warranty coverage for their products three times the industry norm and still reduce their overall warranty expense as well as to dramatically increase their market share. Others have used them to assist in the winning of the coveted Baldrige award.

Sujets

• Business
• Qualité, hygiène, sécurité, environnement
• Total Quality Management
• Gestion et management
• Economics

Informations

• Publié par: ASQ Quality Press
• Date de parution: 12 décembre 2008
• Nombre de lectures: 0
• EAN13: 9780873897631
• Langue: English
• Poids de l'ouvrage: 2 Mo

Extrait

HALT, HASS, AND HASA EXPLAINED

Also available from ASQ Quality Press:

The Certified Reliability Engineer Handbook Donald W. Benbow and Hugh W. Broome

Concepts for R&R Studies, Second Edition Larry B. Barrentine

The Certified Quality Engineer Handbook, Third Edition Connie M. Borror, editor

Failure Mode and Effect Analysis: FMEA From Theory to Execution, Second Edition D.H. Stamatis

The Weibull Analysis Handbook, Second Edition Bryan Dodson

The Quality Calibration Handbook: Developing and Managing a Calibration Program Jay L. Bucher

Reliability Statistics Robert A. Dovich

Root Cause Analysis: Simplified Tools and Techniques, Second Edition Bjørn Andersen and Tom Fagerhaug

The Metrology Handbook Jay Bucher, editor

Product Liability Prevention: A Strategic Guide Randall L. Goodden

The Quality Toolbox, Second Edition Nancy R. Tague

To request a complimentary catalog of ASQ Quality Press publications, call 800-248-1946, or visit our Web site at http://www.asq.org/quality-press.

HALT, HASS, and HASA

EXPLAINED

Accelerated Reliability Techniques Revised Edition

Harry W. McLean

ASQ Quality Press Milwaukee, Wisconsin

American Society for Quality, Quality Press, Milwaukee 53203 © 2009 American Society for Quality All rights reserved. Published 2009 Printed in the United States of America

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Library of Congress Cataloging-in-Publication Data

McLean, Harry W., 1946– HALT, HASS, and HASA explained : accelerated reliability techniques / Harry W. McLean.— Rev. ed. p. cm. Includes bibliographical references and index. ISBN 978-0-87389-766-2 (hardcover : alk. paper) 1. Reliability (Engineering) 2. Accelerated life testing. 3. Vibration—Testing. 4. Strains and stresses. I. Title. TS173.M42 2009 620.00452—dc22 2009005544

ISBN-13: 978-0-87389-766-2 No part of this book may be reproduced in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. Publisher: William A. Tony Acquisitions Editor: Matt Meinholz Project Editor: Paul O’Mara Production Administrator: Randall Benson

ASQ Mission: The American Society for Quality advances individual, organizational, and community excellence worldwide through learning, quality improvement, and knowledge exchange.

Attention Bookstores, Wholesalers, Schools, and Corporations: ASQ Quality Press books, videotapes, audiotapes, and software are available at quantity discounts with bulk purchases for business, educational, or instructional use. For information, please contact ASQ Quality Press at 800-248-1946, or write to ASQ Quality Press, P.O. Box 3005, Milwaukee, WI 53201-3005.

To place orders or to request a free copy of the ASQ Quality Press Publications Catalog, including ASQ membership information, call 800-248-1946. Visit our Web site at www.asq.org or http://www.asq.org/quality-press

Printed on acid-free paper

Contents

Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 1 The Importance of High-Reliability Products at Market Introduction—How and Why to Do a HALT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . An Overview of HALT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Comparisons of Products with and without HALT . . . . . . . . . . . . The HALT Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold and Hot Step Stress. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rapid Thermal Transitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . Vibration Step Stress. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Combined Stresses in HALT. . . . . . . . . . . . . . . . . . . . . . . . . . . Other HALT Stresses and Special Situations. . . . . . . . . . . . . . Verification HALT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A Perspective on Implementing Corrective Action as a . . . . . . . . . Result of HALT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A Proposal for Managing HALT Limits and Issues. . . . . . . . . Using the Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Comments Regarding the Various Vibration Tables. . . . . . . . . Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HALT Summarized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Illustrating the Value of HALT . . . . . . . . . . . . . . . . . . . . . . . . . . . . Some Thoughts Regarding Ruggedizing a Product Prior to HALT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Recording of Failures and Corrective Action . . . . . . . . . . . . .

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xv xvii xix

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19 19 20 23 24 25 25 28

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Contents

Troubleshooting Products under Stress Conditions . . . . . . . . . . . . Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 2 Highly Accelerated Stress Screen—HASS . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The ABCs of Building Robust Products . . . . . . . . . . . . . . . . . . . . Production Product Stress Screen HASS . . . . . . . . . . . . . . . . . . . . Why Does HASS Work? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rate of Change of Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . Acceleration Factor for Thermal Cycling . . . . . . . . . . . . . . . . . . . Which Stress Levels Are Appropriate? . . . . . . . . . . . . . . . . . . . . . Precipitation and Detection Screens . . . . . . . . . . . . . . . . . . . . . . . . Precipitation Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Detection Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A Comment on HASS Profiles or Screens. . . . . . . . . . . . . . . . . Proof of Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fixture Characterization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The HASS Profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Defect Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Life Determination in Proof of Screen. . . . . . . . . . . . . . . . . . . Screen Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cables for HASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HASS Summarized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Some HASS Successes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A Word of Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 3 Beyond the Paradigm of Environmental Stress Screening—Using HASA . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Statistical Process Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Statistics—The System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scenario 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scenario 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A Control Chart for the HASA Process . . . . . . . . . . . . . . . . . . . . The Monitoring System Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problems Uncovered through HASA . . . . . . . . . . . . . . . . . . . . . . . An Observation on Using Equation 3.1 . . . . . . . . . . . . . . . . . . . . . Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chapter 4 Refinements on Highly Accelerated Stress Audit (HASA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 35 37 37 38 38 39 41 42 42 43 45 45 46 48 48 49 51 51 52 54 56 57 58 59 60

61 61 62 64 66 68 68 69 70 71 74 74

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Contents

Background and Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application of the Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A Graphical Tool for Detecting Defect Level Changes . . . . . . . . . Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction to an Improved HASA Process . . . . . . . . . . . . . . . . . HASA Process Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Typical Lot Acceptance Sampling Plan . . . . . . . . . . . . . . . . . . . . . HASA Acceptance Sampling Plan . . . . . . . . . . . . . . . . . . . . . . . . .

vii

76 77 81 84 85 85 86 87

Chapter 5 The Equipment Required to Perform Efficient Accelerated Reliability Testing . . . . . . . . . 93 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 System Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Turbulence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Heating96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 A Comparison of LN Systems and Compressor Systems 2 for HALT and HASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 The Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Product Accessibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Ducting Air102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work-Area Audible Noise Level102. . . . . . . . . . . . . . . . . . . . . . . . Serviceability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Maximum System Capabilities. . . . . . . . . . . . . . . . . . . . . . . . . 103 Post-Sales Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Auxiliary Equipment, Operator Safety, and ESD . . . . . . . . . . . . . 103 Failure Analysis Lab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Why Develop an In-House Failure Analysis Capability?. . . . . 105 Initial Analysis107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metallographic Sample Preparation108. . . . . . . . . . . . . . . . . . . . . Advanced Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Failure Analysis Conclusion112. . . . . . . . . . . . . . . . . . . . . . . . . . . Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Chapter 6 How to Sell New Concepts to Management . . . . . . . 115 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 The Situation Today . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 The Proposed Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Addressing Potential Management Concerns . . . . . . . . . . . . . . . . 120

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The Savings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Chapter 7 Some Commonly Asked Questions and Observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 How Would Someone Compare ESS and HASS? . . . . . . . . . . . . . 129 What Is HALT in a Few Words? . . . . . . . . . . . . . . . . . . . . . . . . . . 130 How Would One Compare Product Qualification Methods and HALT? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Is HALT for Quality Improvement or Is It Intended to Replace RGT and MTBF Tests? . . . . . . . . . . . . . . . . . . . . . . . 132 Is There Any Merit to Subjecting a Product to Stresses Far Beyond Its Design Specifications? . . . . . . . . . . . . . . . . . . . . . . 132 What Are Product Specific and Generic Stresses? . . . . . . . . . . . . 133 If HALT and HASS Are So Great, Why Isn’t Everyone Using HALT and HASS? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Is One HALT Enough? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 At What Product Level Should HALT Be Performed? . . . . . . . . . 135 Who Should Be Involved with the Accelerated Reliability Program? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Physically, Where Should HALT Be Performed? . . . . . . . . . . . . . 137 How Many Units Are Required, and What Can Be Done With Them Once We’re Finished with HALT? . . . . . . . . . . . . 138 Why a Cultural Change May Be Required in Order to Perform a Successful HALT . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Can a Conventional Chamber and Vibration Table Be Used to Perform a HALT? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Are All Six Degrees of Freedom Shakers the Same? . . . . . . . . . . 141 Are There Any Known Problems in Applying Product Temperature Ramp Rates of60°C per Minute? . . . . . . . . . . 142 Are There Any Advantages to Performing Sequential Rather Than Combined Stress Regimens? . . . . . . . . . . . . . . . . 142 Do HALT and HASS Just Uncover Electronic Defects? . . . . . . . 142 Can HASS Eliminate My Production Steady State, Elevated Temperature Burn-in? . . . . . . . . . . . . . . . . . . . . . . . . 143 At What Levels of Temperature and Vibration Can I Consider the Product Robust? . . . . . . . . . . . . . . . . . . . . . . . . . 143 How Can You Justify Doing HALT on Products with a Very Short Field Life? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 What Are the Yearly Maintenance Costs for the HALT Chambers? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Can the Results of HALT Be Used to Accurately Estimate Field Life? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Contents

ix

Appendix A The Derivation of Equation 3.1 . . . . . . . . . . . . . . . . . 147 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Trademarks and Service Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

About the Author. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163 Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165