Reliability Test Procedures for Achieving Highly Robust Electronic
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Today’s consumer electronics market becomes highly competitive because of the increase on number of manufacturers and high consumer expectations. These competition causes dramatic cost decreasing. Each cost down work could cause very crucial reliability problems if it is not managed well. Also, consumers’ expectations about reliability of the products are increased. Reliable, trouble-free and robust products satisfy customer needs for a long time. These quality improvements increase sales, reduce rework and services costs, and obtain good brand reputation. However, the manufacturing costs will be increased if it is wanted to produce highly reliable and robust products, which decrease competition capacity against the other manufacturers. This is a big trade off between reliability, robustness and cost. The balance between them must be carefully adjusted. This adjustment can only be done with well organized reliability approval, validation, improvement and measurement ! policy. This paper mainly oriented on reliability improvement procedures for consumer electronic products in a large scale manufacturing plant. The manufacturing plant, mentioned, produced about 10 millions of TV Sets in a year. For such big mass production, an alive and well organized reliability approval, validation and verification process is needed. This process is composed by a series of reliability tests, procedures and lastly, calculations and analysis. All kind of reliability problems found by production quality, outgoing quality, third party customers and end users are well noted, and test procedures can be scrutinized. Also, market returns data is taken as a feedback to recheck our calculation and corrective data for test procedures. Approval and validation tests are arranged mainly according to combination of international standards and company experiences. Approval and validation tests are mandatory tests that have strict pass or fail results. They can be sub-categorized as electrical, environmental and mechanical tests. Generally, electrical tests under this category have not high stress values; equipment is worked at its maximum ratings only. However, environmental and mechanical tests have higher stress values. In parallel with approval and validation, there are two test processes continue, which are called design verification tests and early life period tests. Test stress levels of these test procedures are generally obtained according to aim of the test. The simulation aimed tests generally have more realistic stress levels according to real environment where the equipment will work. They generally have long test durations. Simulation tests, considered, are very similar to Highly Accelerated S! tress Screening – HASS idea. The stimulation aimed tests have extreme stress levels and short test durations, in contrast to simulation tests. A product must be approved from all simulation tests and have no extremely important problem found from stimulation tests. Because of extreme stress levels and similar judgment criteria, the idea of these tests is very similar to Highly Accelerated Life Test – HALT. Reliability approval tests are good examples, where theory comes in to practice.
Keywords: RAMS 2010 Proceedings - Accelerated Life Testing - Failure Analysis - Process Design/Reliability