Reliability Lab Testing, Consulting, Training.

Ops a la Carte

Call: (408) 654-0499, x204

Email: info@OPSaLaCarte.com

Engineering Success with Reliable Products.

HALT and HASS Application

HALT & HASS, and HASA Applications Seminar

OBJECTIVES

To answer you question: “How to test reliability”. Specifically targeted for those with the basic education in HALT & HASS, and HASA to show how to apply the techniques on products. We have also introduced the topics of Reliability Demonstration Testing and Accelerated Reliability Testing for comparison purposes.

Download brochure (pdf)

WHO SHOULD ATTEND

This course is intended for those involved in HALT & HASS on products and need a better understanding on how to apply these principles to your particular products. This seminar will be application oriented with case studies and examples in over 50 different industries. The material for the course is based on HALT & HASS results on over 500 products.

OUTLINE

Introduction

  • HALT & HASS as part of an overall reliability program
  • Elements of a Reliability Program and how HALT & HASS fit in
  • Basic Definitions
  • Reliability vs. Cost
  • Product Life Cycle Matrix
  • Why HALT & HASS?
  • Evolution of HALT
  • Probability Ratio Sequential Testing (PRST)
  • Stress for Life (STRIFE)
  • Evolution of HASS
  • Run-In / Burn-In
  • Environmental Stress Screening (ESS)

Highly Accelerated Life Testing (HALT)

  • HALT: How it works
  • HALT: Why it works
  • Benefits of HALT
  • Margin discovery process explained
  • Failure Modes/Failure Mechanisms
  • Testing to the Fundamental Limit of Technology (FLT)
  • Fatigue vs. Overstress / Stress vs. Cycles Plot
  • Rules of thumb for HALT limits
  • Root cause analysis during HALT/Ask Why 5 times
  • Verification HALT
  • Common design problems
  • Sample size for HALT
  • Commercial vs. Industrial vs. Military Grade components
  • Case Studies
  • Summary of Results based on 100 HALTs
  • Fixturing

    • How to fixture
    • Examples of fixturing
    • Fixturing when portions of product are remoted outside chamber

      • Power Supply from rest of product
      • Hard drive from rest of PC
    • Fixturing when portions of product are remoted but still inside chamber

      • PCI card separated from motherboard
      • Hard Disk heads separated from controller
  • Equipment used during HALT/how to choose a chamber
  • HALT Stresses beyond temperature and vibration

    • Humidity
    • Shock
    • Drop
    • Frequency Margining
    • Voltage Margining (AC/DC)
    • Power Cycling
    • Twisting/bending
    • Corrosion
  • HALT Return on Investment (ROI) Calculations
  • Classroom Exercises

Accelerated Life Testing (ALT) and Reliability Demo Test (RDT)

  • Definitions
  • Types of Demonstration Tests
  • Failure Free Testing
  • Sequential Testing
  • Accelerated Life Testing

    • Statistics for an ALT
    • ALT Parameters
    • Acceleration Factor Models
  • HALT vs. ALT: When to Use Which Technique?
  • On-Going Reliability Testing
  • Classroom Exercises

Highly Accelerated Stress Screening (HASS)

  • HASS: How it works
  • HASS: Why it works
  • Benefits of HASS
  • When to start planning for HASS

    • HASS process steps before HALT is complete
    • HASS process steps after HALT is complete
  • Screen tuning/Assuring an effective screen
  • Precipitation/detection screen examples
  • How to avoid wearout
  • Fixturing

    • How to fixture for HASS
    • Examples of fixturing for high volume
    • Examples of fixturing for low volume
  • Sample size for HASS Development
  • What to do with soft failures during HASS
  • Rules of thumb for HASS profile limits
  • HASS Development: 4 different options

    • High volume/small HASS Development sample
    • Low volume/small HASS Development sample
    • Low volume/large HASS Development sample
    • Low volume/using No Trouble Found samples
  • HASS Profile Examples

    • HASS for Wide Operating Limits
    • HASS for Narrow Operating Limits
    • Precipitation-Detection Screens, examples of
  • Root cause analysis during HASS
  • HASS results: examples of failures
  • When to change a HASS profile
  • Alternatives to HASS

    • Burn-In
    • ESS
    • System Level Vibration
    • 5DX x-ray
    • Acoustic testing
  • HASS/ESS Hybrids

    • Board level HASS/System Level Vibration only
    • Temperature Cycling / Vibration separated
  • HASS Return on Investment (ROI) Calculations

Highly Accelerated Stress Auditing (HASA)

  • HASA: How it works
  • HASA: Why it works
  • Benefits of HASA
  • Steps to HASA
  • When to switch from HASS to HASA
  • HASA Example
  • Statistics behind HASA
  • HASA Return on Investment (ROI) Calculations

General Information

  • Thermocouples/Accelerometers
  • Support Equipment

    • Vibration Analyzers
    • Dataloggers
  • Troubleshooting Equipment

    • Strobes
    • Handheld vibration tools
    • Scopes
  • Setting up a HALT lab

    • Writing a Plan
    • Writing a Report
    • List of the best HALT labs for reference
    • Equipment needed for Calibration

Summary of HALT, HASS, and HASA

  • What is required for a Successful Program
  • Champion
  • Training
  • Commitment
  • Management Support
  • Root Cause Analysis

Integrating HALT, HASS, and HASA with the rest of your Reliability Program

  • Analytical tools that support the HALT, HASS, and HASA planning process

    • Predictions, Derating, FMECAs
    • Designs of Experiments (DoEs)
    • Finite Element Analysis
  • Analytical tools that can be used in conjunction with HALT, HASS, and HASA

    • Failure Reporting Analysis and Corrective Action Process (FRACAS)
    • Root Cause Analysis Process
  • Analytical and Testing tools that can be used after completion of HALT

    • Design of Experiments (DoEs)
    • Reliability Demonstration Tests (RDTs)
  • Analytical and Testing tools that can be used to determine when to transition from HASS to HASA

    • Reliability Statistics
    • Control Charts, Paretos
    • Root Cause Analysis

Call Us: (408) 654-0499, x204

Email Us: info@OPSaLaCarte.com

Address: 990 Richard Ave, Suite 101, Santa Clara, CA 95050

Contact Us

Empowering companies to create happy customers, with well-engineered products.

Script

OPS A La Carte, Engineering Success with Reliable Products. We are a leading reliability engineering consulting firm since 2001. We have helped many companies create robust products and elevate them to great success, even become the leader in their industry. We are known for providing the whole gamut of reliability lab testing, consulting, and training. With over 25 reliability engineer-experts around the world, with diverse backgrounds and experience, we serve both domestic and global businesses in all areas of reliability, in depth and width. Hi, my name is Jay Muns, owner and CEO. I have more than 30 years of experience in engineering and business operations.

OPS A La Carte have produced very high-quality results for us, with fast turnaround times. Their engineers are the best in their field, are a pleasure to work with, and their work is of the highest standards available. This has helped us obtain critical product approvals…” We help companies see from outside of their forest and understand what they didn’t know before. Companies come to us out of three scenarios: First, when their products fail. We help put out the fire by identifying problems and providing solutions. Second, after a product is designed, to check the box and move on with getting their product into the marketplace. The best is third: to get engaged early, by including reliability as a part of their initial product design goals. This will save time, money and energy. It is much better to have a worry-free product that addresses reliability issues upfront, than dealing with deficiencies after a product is developed, or worse, already manufactured and sold to the end users. Being proactive with reliability engineering will save a business tons of money and trouble. In all scenarios, you receive professional expertise with integrity and at a fair price. Many of our clients are repeat customers for years because of the value we consistently deliver.

Our ENGINEER-consultants each have over 20 years of experience and perform lab testing, consulting and training based on actual reliability science. They follow well established industry standards, such as “HALT” (highly accelerated life test,) and “HASS” (highly accelerated stress screen.) These engineers evaluate, make recommendations and validate results based on highly relevant lab data, co-relating to real world data. Whether your company has a reliability department or not, you can take advantage of our entire testing-consulting-training package, or any portion of it. We also offer Failure analysis and safety certification services such as UL, CE, and other environmental testing services, like solar, UV, SALT spray testing, ESD (electro-static discharge,) and EMC (electro-magnetic compatibility.)

“Ops A La Carte trained us to use HALT methodology as a proactive tool, to root out key failures in our early and advanced prototypes, and that made it possible for us to deliver dependability that our customers demand, in pilot and production units."“...OPS has played a key role in our evolution from a research company to a manufacturer of ‘mission-critical’ components.” A couple of companies describe our HALT/HASS training as “highly informative, engaging and exciting.” “The benefit far exceeds the price."

Our mission is to enable companies to create their happy customers, with a well-engineered product. By helping our clients understand the real problems and the real solutions, we help improve their careers and reputations. Achieving the win-win-win results for our clients and their customers is our ultimate satisfaction. We have a family-like company culture with positive energy and great teamwork. An improved and reliable product is our own small way to contribute to a better humanity and a slightly better world. Call us at (408) 654-0499, or email us at info@opsalacarte.com, or visit our website www.opsalacarte.com. Thank you!

A couple of our clients' testimonials:

"The expert team at OPS assisted us in evaluating the available reliability testing possibilities, and with their help, we crafted a customized test program precisely sized to meet the needs of our project. The resulting program proved to our team, our customers, and our regulatory auditors that our product was robust, met its reliability goals effectively, and satisfied all safety risk factors."

"...Ops A La Carte worked with us to develop a testing program based on HALT and HASS to effectively assess low-temperature operation capability and screen the boards for assembly and component defects. They then facilitated and supported the HALT and HASS testing effort. It was quicker and more efficient than we had expected. The boards for the first four strings have been delivered. We are looking forward to working with them through completion of the project."