Reliability Knowledge

Highly Accelerated Stress Screening (HASS) and Highly Accelerated Stress Audit (HASA) are advanced testing methods used to identify potential defects in full assemblies, while burn-in testing is typically applied at the component level. These tests are designed to expose products to extreme conditions to precipitate failures, allowing for corrective actions before the products reach customers.

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Six Sigma gives you the tools and techniques to determine what’s making the manufacturing process slow down, how you can eliminate the delays, improve the process, and fix further issues along the way. It is a methodology that has seen worldwide adoption. This video also provides detailed examples on how each of the two Six Sigma methodologies work. The example we’ll be considering is how a car manufacturing company is able to achieve its goals with the help of the Six Sigma methodologies, DMAIC and DMADV.

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Designing a proper test for the life of an electromechanical component involves several steps and considerations. Here next steps proposed to do:

Step #1: Define the Test Objectives: Clearly outline the expected functions and specifications of the component. Identify potential failure modes and criteria. This step is crucial to ensure that the test is aligned with the design specifications and customer requirements of the electromechanical device.

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Degradation testing for electromechanical components, such as pumps, valves, and sensors, involves a series of steps to identify wear and tear that could lead to system failure. The goal is to detect these signs of degradation early enough to replace the component before it causes a failure.

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The t-test was first described by William Sealy Gosset in 1908, when he published his article under the pseudonym ‘student’ while working for a brewery. Gosset, an Englishman, developed the t-test and t distribution, and he is considered the “godfather” of the t-test.

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Preventive maintenance is a proactive approach used by industries to ensure the longevity and optimal performance of their assets. It involves regular maintenance tasks such as cleaning, lubrication, parts replacement, and equipment repairs to prevent unplanned downtime.

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HALT (Highly Accelerated Life Testing) is the foundation for the definition of HASS (Highly Accelerated Stress Screening) and HASA (Highly Accelerated Stress Audit).

HALT is primarily used to expose weaknesses in the design of a product by subjecting it to extreme environmental conditions such as temperature, vibration, and humidity, in order to identify and eliminate design flaws and weak points before the product is released to the market.

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Understanding the different types of data and thier respective uses is critical for product delveopment testing and analysis.

Each type of eo f data plays a a role in ensuring that products meet quality standards and fulfill user needs.

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Accelerated Life Testing (ALT) on subcomponents and durability testing for whole products are two strategies used to assess the reliability of products. ALT involves subjecting a product to conditions beyond its normal service parameters to uncover faults and potential failure modes in a short time, allowing engineers to make predictions about its service life and maintenance intervals. On the other hand, durability testing for whole products involves testing the entire product under normal operating conditions to assess its long-term reliability and performance.

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Using highly accelerated stress screening to identify supplier defects before the product is shipped saves time and money.

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The history of Design of Experiments (DOE) can be traced back to the work of various individuals, including Genichi Taguchi, a Japanese engineer and statistician. Taguchi made significant contributions to the field, particularly in the area of robust design, which aimed to improve the quality of products and processes. His work was influenced by the need for quality improvement in post-World War II Japan. Taguchi’s methodology, known as the Taguchi methods, was based on the concept of “robust parameter design,” which aimed to make processes and products insensitive to environmental factors or other variables that were difficult to control.

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Designing a proper test for the life of an electromechanical compoent involves several steps and considerations. Here are six steps that provides an outline to create a meaningful component life test.

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Introduction in ALT:

Accelerated life testing (ALT) is a method used to enhance product reliability by subjecting prototypes to stress levels significantly higher than those encountered in actual use.

By increasing the stress on the component, failure is induced more rapidly, which is equivalent to speeding up the passage of time. This approach is particularly useful when waiting for failures to occur at their normal rate is not feasible, such as when a manufacturer needs to release a product to the market soon and cannot afford to spend several years performing a reliability test.

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A short video defining accelerated life testing or ALT.

An introduction to ALT or accelerated life testing. ALT is a method used to enhance product reliability by subjecting prototypes to stress levels significantly higher than those encountered in actual use. In short, it’s a way to accelerate time.

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Some history:

The executives of the Powertrain Organization (transmissions, chassis, engines) wanted a methodology where teams (design engineering, manufacturing engineering, and production) could work on recurring chronic problems. In 1986, the assignment was given to develop a manual and a subsequent course that would achieve a new approach to solving identified engineering design and manufacturing problems.

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