Manufacturing Phase Introduction
As the product transitions to manufacturing, the reliability goals, models and test results become the basis for refining reliability screening, monitoring and reporting. Establishing a Highly Accelerated Stress Screen identifies and eliminates infant mortalities. To protect from time dependant failure mechanism and to monitor the projected life estimates, conduct an On-Going Reliability Test.
Vendors also play an important role in achieving the product reliability goals. Critical components or key vendors may need assistance getting their reliability program started or improved. A Vendor Reliability Program Assessment is a quick way to identify and work to improve vendor reliability.
Set up a Repair Depot, record field performance, and compare to all analyses and tests performed to date. Perform Root Cause Failure Analysis on any deviations. The field performance also feeds into the Field Failure Tracking System which monitors progress toward resolution of each issue.
A Warranty Performance Analysis monitors and compares against goals, plus provides a method to detect and track class defects that have escaped to the field. The tracking system also permits periodic Reliability Performance Reporting which compares field results to the metrics first established in the Reliability Program and Integration Plan.
After the product has been in the field for a period of time, perform a product End-of-Life Assessment to determine when the product starts approaching end-of-life. The Reliability Prediction and Failure Modes and Effects Analysis predict end-of-life and the Reliability Demonstration Test measures end-of-life (for susceptible components). Based on these analyses and tests, as well as the trend of data from the field, you can determine when to alter repair policy and when to start offering upgrades and trade-ins.
Throughout the product life cycle, many decisions are made, some of which will later prove to be incorrect or less than optimal. Establishing a Lessons Learned Process will help to collect the key information so that you learn from each product you develop, thereby increasing the reliability of each successive product.
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
Lessons Learned Process Establishment