design for reliability

© 2009 Ops A La Carte 1

Design for Reliability Overview

© 2009 Ops A La Carte 2

was named one of the top 10 fastest growing, privately-held companies in the Silicon Valley in 2006 by the San Jose Business Journal.

owns a private test lab in Santa Clara which specializes in accelerated reliability testing.

is a privately-held professional reliability engineering firm founded in 2001 and headquarted in Santa Clara, California with offices in China, India, Singapore, and UK.

Our CompanyOur Company

© 2009 Ops A La Carte

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Industry PenetrationIndustry PenetrationWe have over 500 customers across 70 different industries, including:

AEROSPACEAIRPORT SECURITYALTERNATIVE ENERGYARMED FORCESAUDIO AND VIDEOAUTOMATIONAUTOMOBILE/TRUCKING AUTOMOTIVE COMPONENTSBIOMEDICALCABLE INDUSTRYCHAMBER MANUFACTURERCOMPUTERSCONTRACT MANUFACTURINGCONTROL SYSTEMSDEFENSE ELECTRONICSDESIGN AUTOMATIONDESIGN FIRMSDISK DRIVESDISPLAY ELECTRONICSELECTRIC METERSELECTRIC UTILITY COMPANYELECTRIC VEHICLESELEVATOR COMPANIES

ENVIRONMENTAL TEST LABFAILURE ANALYSIS LABFOOD INDUSTRYGAMING INDUSTRYGENERATORSGOVERNMENT RESEARCHGPS INDUSTRYHANDHELD METERSKITCHEN APPLIANCESLASERSLEGAL INDUSTRYMEDICAL DEVICESMININGMOBILE PHONEMOTORS AND ENGINESNETWORK APPLIANCESNETWORK SECURITYNETWORKINGOIL EXPLORATIONOPTICAL COMPONENTSPCB MANUFACTURERSPERIPHERALSPOWER SUPPLIES

RADIO/RF/MICROWAVERECREATIONAL PRODUCTSRELAXATION/RECREATIONALRF COMPONENTSRFIDROBOTICS, MEDICALROBOTICS, SEMICONDUCTORSATELLITESEARCH ENGINESECURITY SYSTEMSSEMICONDUCTORSEMICONDUCTOR MFG EQUIPSOCIETIESSOLID STATE STORAGESPACE EXPLORATIONSTORAGE NETWORKINGTELECOMTEST & MEASUREMENTUNDERWATER ELECTRONICSUNIVERSITIESVETERINARYVISION SYSTEMSWATER PURIFICATIONWIRELESS


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2009 Specific Industry Focus2009 Specific Industry Focus

Currently, our top four industries are…

MedicalClean-TechOil and Gas

Defense/Aerospace


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Our Customers in Our Customers in N.AmericaN.America


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Our Consultants in Our Consultants in N.AmericaN.America


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Our Customers Around the Our Customers Around the WorldWorld


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Our Consultants Around the WorldOur Consultants Around the World


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Our Business ModelOur Business Model

We provide Reliability Solutions using:

•Consulting•Training

•Testing


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• Ops Solutions – Ops provides end-to-end solutions that target the corporate product reliability objectives • Ops Individual “A La Carte” Consulting – Ops identifies and solves the missing key ingredients needed for a fully integrated reliable product• Ops Training – Ops’ highly specialized leaders and experts in the industry train others in both standard and customized training seminars• Ops Testing – Ops’ state-of-the-artprovides comprehensive testing services


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assesses a company’s needs and then develops programs to match their needs, using Reliability IntegrationSM to tie the program together.

Consulting ServicesConsulting Services


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Reliability Training/EducationReliability Training/Education- Over 30 different seminars on reliability -

We Offer a Host of Training Courses in Areas of:

• DfX/DfSS Training• Certification Training• Customer Skill Gap Training• Customer Tailored Training• Quality/Manufacturing Training


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Testing ServicesTesting Services• Our own lab facility located in Northern California in the heart of

Silicon Valley. We provide HALT/HASS services on a world-wide basis, using partner labs for tests outside California.

• Second oldest HALT facility in the world, established in 1995(originally owned by QualMark)

• HALT equipment has all latest technology – only lab in region

• Highly-experienced staff with over 100 years of combined experience in HALT and HASS

• Tested over 500 products in over 30 different industries• Our HALT/HASS services are fully integrated with our other

consulting services.


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DESIGN DESIGN FORFOR

RELIABILITYRELIABILITY


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Reliability is no longer a separate activity performed by a distinct group within the organization.

Product reliability goals, concerns and activities are integrated into nearly every function and process of an organization.

Each organization must factor reliability into every decision in order to ensure produce a successful product.

The SituationThe Situation


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Engineering teams must balance cost, schedule, performance and reliability to achieve optimal

customer satisfaction.

The Balancing ActThe Balancing Act

Cost Schedule

Reliability

Performance

Customer Satisfaction


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The Solution is in the following 4 steps:

assess the customer’s situationdevelop goalswrite program planexecute program plan

All focused on developing reliable products and improving customer satisfaction.

The SolutionThe Solution


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Now

Goal

$ unreliability

$ Profits

Assessment

StatisticalData Analysis

Benchmarking

Gap Analysis

Program Plan

complaintsfieldfailures

satisfaction

marketshare

? Unknown ?

The SolutionThe Solution


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Customizing Your SolutionCustomizing Your Solution

You may need to address reliability in these areas:

• Organizational – These companies don’t know where to start, and for this, we start off with an Assessment, and use it to determine how to structure a reliability program.

• Product – These companies have a specific product level problem they need to resolve, from start to finish.


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Organizational Level Organizational Level Individual ServicesIndividual Services


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Solutions PackagesSolutions Packages• Once an organization identifies their corporate reliability objective,

we can choose one of our Solutions Packages to drive results with an end-to-end solution.

• We combine “best in class” industry approaches with a tailored selection of reliability techniques suitable for that organization.

Industry Proven Complete Solutions Value Priced


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Reliability Solutions PackagesReliability Solutions Packagesfor Product Developmentfor Product Development

Next Generation ProductsNew Product LinesProduct ExtensionsProduct RevisionsCritical Component Qualification

The R&D cycle for product creation and enhancement requires integration of key reliability activities across all phases of a program.


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Reliability Solutions PackagesReliability Solutions Packagesfor Product Manufacturingfor Product Manufacturing

Reliability Test Development Manufacturing Performance AssessmentsContract Manufacturer Reliability AuditsRoHS Conversions

As a product transitions to manufacturing, the reliability goals, models and test results become the basis for refining reliability screening, monitoring and reporting.


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Reliability Solutions PackagesReliability Solutions Packagesfor Field Reliability Improvementfor Field Reliability Improvement

First Year Reliability GrowthWarranty AnalysisComponent Obsolescence

Once the product transitions to customer shipments, field data must be monitored in order to drive reliability growth until the targeted reliability objectives can be achieved and sustained.


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Reliability Solutions PackagesReliability Solutions Packagesfor OEM/ODM Deliverablesfor OEM/ODM Deliverables

Test Plan DevelopmentReliability AuditsTest Performance Improvements

Ensuring thatOEMs/ODMs supply components that meet your reliability specifications is one of the keys to successful manufacturing.


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Product Level Product Level Individual ServicesIndividual Services


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Reliability Integration Reliability Integration ServicesServicesfor a Life Cycle Phasefor a Life Cycle Phase

The key to a good reliability program is encompassing reliability activities in each phase of the product life cycle:

Concept, Design, Prototype, Manufacturingand then integrating each of these activities together into a cohesive reliability program.


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Reliability Integration ServicesReliability Integration Servicesin the Concept Phasein the Concept Phase

Reliability Goal SettingBenchmarking & Gap AnalysisTechnology Risk AssessmentReliability Program Plan

Reliability Goal Settingand establishing a planto achieve the goals characterize this phase. Reliability goals are part business decision, part technology capability and part customer driven.


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Key to a reliable product is the many design decisions, and for each decision, designers balance reliability with cost, time-to-market and performance objectives.

Reliability IntegrationReliability Integrationin the Design Phasein the Design Phase

Reliability Models and Predictions (MTBF)Reliability Block Diagramming (RBD)Fault Tree Analysis (FTA)Failure Modes and Effects Analysis (FMEA)Thermal AnalysisDerating Analysis / Component SelectionTolerance / Worst Case AnalysisMaterial SelectionDesign of Experiments (DOE)Finite Element Analysis (FEA)Design for Six Sigma (DFSS)Dynamic Analysis (modal, shock, vibration)Sneak Circuit Analysis (hardware or software)Software ReliabilityWarranty PredictionsMaintainability/Preventive Maintenance AnalysisDesign Review and Retrospective Facilitation


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Discovering design weaknesses and verifying achievement of reliability goals becomes possible with prototypes.

Reliability IntegrationReliability Integrationin the Prototype Phasein the Prototype Phase

Reliability Test Plan DevelopmentHighly Accelerated Life Testing (HALT)Root Cause Failure AnalysisFracture and FatigueDesign Verification Testing (DVT)Environmental Testing and AnalysisPackage Design and TestingRegulatory Compliance Testing and CertificationTest Fixture Design and FabricationThermal Testing and AnalysisAccelerated Life Testing (ALT)Reliability Demonstration Testing (RDT)Closed-Loop Corrective Action Process Setup

HALT Chamber


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As the product transitions to manufacturing, the reliability goals, models and test results become the basis for refining reliability screening, monitoring and reporting.

Reliability IntegrationReliability Integrationin the Manufacturing Phasein the Manufacturing Phase

Highly Accelerated Stress Screening (HASS)On-Going Reliability Testing (ORT)Vendor Reliability Program AssessmentRepair Depot SetupField Failure Tracking System SetupWarranty Performance AnalysisReliability Performance ReportingEnd-of-Life AssessmentLessons Learned Process Establishment

HASS Chamber


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Reliability Integration forReliability Integration forSpecific Product TypesSpecific Product Types

-- SemiconductorsSemiconductors-- SoftwareSoftware


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Even at the Semiconductor Level, Reliabilitymust be considered in each phase of the Semiconductor Life Cycle.

Reliability IntegrationReliability Integrationfor Semiconductorsfor Semiconductors

Development PhaseBIR (Built In Reliability)DFR (Design For Reliability)DFT (Design For Testability)

Product Qual/Volume Prod. Ramping PhaseDevelop Reliability Qualification PlanDevelop HALT ProceduresDesign all h/w for Prod. Reliability QualsDirect the Reliability Qualification ProcessConduct Failure AnalysisDevelop Statistical Bin Limit Control

Product Maturity PhaseReview/Direct Ongoing Reliability MonitorsDirect Failure Analysis/Corrective ActionsPropose Design ChangesEvaluate proposed fab. process changes


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As with the Hardware, Reliability must be considered in each phase of the Software Life Cycle.

Reliability IntegrationReliability Integrationfor Software Developmentfor Software Development

Software Reliability Goal SettingSoftware Reliability Program PlanFacilitation of Team Design Template ReviewsFacilitation of Team Design ReviewsSoftware Failure AnalysisSoftware Fault ToleranceFacilitation of Code Reliability ReviewsSoftware Robustness Testing TechniquesSoftware Reliability Measurements & MetricsUsage Profile-based TestingSoftware Reliability Estimation TechniquesSoftware Reliability Demonstration Tests


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Reliability Integration forReliability Integration forSpecific IndustriesSpecific Industries

- Medical- Clean-Tech- Oil and Gas- Defense/Aerospace


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Reliability IntegrationReliability Integrationfor Medical Productsfor Medical Products

MISSION CRITICAL VALUES• We are committed to Highly ReliableSystems that save human lives• We successfully analyze and test criticalmedical products with confidence• We deliver accuracy and precision to extendproduct and human life for each application• We deliver customized solutions &consultancy to address all program risks


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Our Our MedicalMedical CustomersCustomersHere is a partial list of our

medical customers3M Corporation Abbott Diabetes Care Abbott Laboratories Accuray Inc. Advanced Bionics AeroGenApplied BiosystemsAubrey Group BD Biosciences Boston Scientific CardeonCardiac Assist Cardinal Health CarestreamCochlear CovidienFisher and PaykelHealthcareFlextronics MedicalFrezneus Medical Gatan

GE Healthcare Guava Technologies Guidant Hewlett-Packard HospiraInogenIntrapaceIntuitive Surgical IridexLifescanLumenisLuminetxM2 Medical Mako Surgical MasimoMedtronic Mission Medical NeoGuideNeoVistaNext Safety

OmniCellOrtho-Clinical DiagnosticsPerfint Healthcare DevicesPhilips Presym Inc. Proteus Biomedical Inc. PulmoneticRadiant Medical RespironicsSiemens StrykerSuni Medical SynecorTecan Systems Terumo Medical Corporation ThermageThoratecTriage Wireless, Inc. Tyco Healthcare Ventana Medical World Heart


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Reliability IntegrationReliability Integrationfor Clean Tech Productsfor Clean Tech Products

WHAT IS “GREEN RELIABILITY”• Today, the topic of Green is being discussedeverywhere. But what does it mean to be green?• “Going Green” has many implications from thematerials being used to the type of energy beingused and the quantity being consumed.• And each aspect of “Going Green” hasreliability implications.• Any time we change material properties, thereare inherent reliability risks we must address.


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Our Our CleanTechCleanTech CustomersCustomersHere is a partial list of our CleanTech customers

Armageddon EnergyArtificial MuscleBloom EnergyCamelbakCapstone TurbineCarmanahClipper WindpowerCooligyEchelonEnergy InnovationsGE IonicsGeneral HydrogenHelix WindpowerItronKonarka

National SemiconductorNuventixOptiSolarSan Diego Gas and ElectricSilver Springs NetworksSolar Electric SolutionsSolar JunctionSolFocusSunPowerSylvan SourceTelsa MotorsThompson TechnologyVisyxXandexXantrex


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Reliability IntegrationReliability Integrationfor Oil and Gas Productsfor Oil and Gas Products

MISSION CRITICAL VALUES• Committed to Highly Reliable Systems foroil exploration and production to ensureequipment, tool, and production availability.• Successfully design and test criticalproduction scenarios.• Deliver customized solutions & consultancyto address RCM requirements.


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Our Our Oil and GasOil and Gas CustomersCustomersHere is a partial list of our Oil and Gas customers

Baker Hughes INTEQBritish PetroleumChevronHalliburtonNOVOctioSchlumbergerWestern Geco


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Reliability IntegrationReliability Integrationfor Military Productsfor Military Products

MISSION CRITICAL VALUES• We are committed to Highly ReliableSystems that save human lives• We successfully design and test criticalmilitary scenarios with confidence• We deliver accuracy and precision to extendproduct life for each mission• We deliver customized solutions &consultancy to address Program RAM reqts.


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Our Our MilitaryMilitary CustomersCustomersHere is a partial list of our

Military customers

ArmyACSSApplied SignalBAEBoeingGeneral DynamicsHoneywell DefenseKaiser (now Rockwell)L-3 CommunicationsLockheed Martin

Marvin EngineeringNaval Undersea Warfare Center (NUWC)RaytheonRockwell CollinsSpace Systems LoralTeledyne ControlsThalesUnited Defense (now BAE)


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Design for Reliability is made up of the following 4 steps:

assess the customer’s situationdevelop goalswrite program planexecute program plan

All focused on developing reliable products and improving customer satisfaction.

SummarySummary


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Ops A La Carte, LLCMike Silverman

Managing Partner(408) 472-3889

[email protected]

Contact InformationContact Information

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