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How to Eliminate the Need for Failure Analysis

Posted by Greg Caswell on Nov 30, 2016 7:50:00 AM

Eliminating-Failure-Analysis.jpgNearly one-fifth of electronics designs that are tested fail. That means nearly one-fifth of electronics designs are reworked or scrapped in favor of a new design. The resulting production delays and cost overruns mount, further threatening profitability in an automotive industry that’s already grappling with the margin-shrinking impact of increasing price-based competition. 

With so much on the line, predicting possible failure events before they happen and mitigating risk during the design phase is paramount. Using Physics of Failure-based software tools helps you do so by:

Knowing how a specific design will behave in your specific environment

Clearly defining the use environment in three focused areas provides clarity around desired and anticipated outcomes:

  • Life cycle: Automotive applications are expected to last 10-15 years. Is that window an acceptable life cycle for the component in question? If not, what is satisfactory?
  • Duty cycle phases: What scenarios will a vehicle encounter that could affect reliability: time driven v. time parked, garage v. outdoor parking, weather, road conditions, etc.?
  • Events: Which stresses will be introduced into the use environment: shock, vibration, temperature cycling?

Using a combined testing approach

Testing to specifications and using Physics of Failure-based software do not have to be mutually exclusive approaches to reliability. In fact, by substituting the assumptions about design risk and use environment found in specifications testing with the PoF-based certainty of knowing how long it takes a component to fail and that it will consistently fail as expected leads to powerful outcomes. The latter can be verified against industry standards to calculate probability to failure and accurately determine reliability.

Applying the knowledge to design activity

Even the most accurate data is ineffective if it simply gets filed away post-testing. Thorough analysis of what met and perhaps didn’t meet expectations – materials/features, stresses, temperature fluctuation – and using that input to adjust designs will prevent future occurrence.

Including collaborative engineering through the supply chain

In essence, your supply chain is an extension of your commitment to end user satisfaction. Effective communication about reliability is key, and using Sherlock Automated Design Analysis™ software ensures transparency and open dialog while simultaneously protecting design files and proprietary information. 

Sherlock Automated Design Analysis™ software is a direct route to predicting failure before it happens and ensuring reliability in automotive applications. Learn more in Implementing Physics of Failure into the Design Process. Click the button below to download your free copy.

Best Practices in Implementing PoF in the Design Process Webinar

Topics: Sherlock