DfR Solutions Reliability Designed and Delivered

In the highly competitive electronics market, product quality and reliability are critical and can only be achieved by implementing comprehensive design reviews as product development gating functions.

DfR Solutions has seven design review services that combine industry best practices, fundamental manufacturing knowledge and Physics of Failure (PoF) design science to provide detailed feedback and solutions that assure products launch to customer reliability expectations:

Design for Reliability (DfR)

Ensures product or system reliability during the design stage, well before physical prototype. DfR Solutions offers Design Failure Mode and Effects Analysis (DFMEA), Component Derating, Empirical Prediction, Physics of Failure DfR and PCB design services, along with expert guidance, flexibility and automation.

Failure Modes and Effects Analysis (FMEA)

Methodically identifies failure modes and determines their effects on product design and operation in order to mitigate risk. While FMEA value is sometimes brought into question given variables that can produce unsatisfactory results, DfR Solutions subject matter experts have developed unique approaches to design review based on failure modes to maximize activity in all four FMEA categories: Design Failure Mode and Effects Analysis (DFMEA), Failure Mode Effects and Criticality Analysis (FMECA), Failure Mode Effects and Diagnostic Analysis (FMEDA) and Design Review by Failure Mode (DRBFM).


Complementary practices occurring on either side of manufacturer specifications with the goal of ensuring the component operates reliably in the intended use environment. DfR Solutions couples our extensive derating and thermal uprating experience with industry standards to maintain critical functionality operation parameters, provide a margin of safety from deviant lots and achieve desired reliability – all of which helps in component selection and qualification for a reliable product in any environment.

Physics of Failure (PoF)

This technique is used to predict reliability and improve product performance in Design for Reliability practice. This is accomplished by leveraging the knowledge and understanding of the processes and mechanisms that induce failure, as opposed to the more traditional statistical approach which makes no attempt to understand why something failed. The concept of Physics of Failure, also known as Reliability Physics, involves the use of degradation algorithms that describe how physical, chemical, mechanical, thermal or electrical mechanisms evolve over time and eventually induce failure. The specific term arose from an attempt to better predict the reliability of early-generation electronic parts and systems; however, the concept of Physics of Failure is common in many structural fields.

Design for Manufacturability (DfM)

We make sure your design is not only reliable but that it can be manufactured without defects. While the burden for defect-free manufacturing is often placed on the component suppliers and contract manufacturers, designing your product to be manufacturable is a critical step in the process — and one that is often overlooked. Drawing upon our extensive knowledge of electronics manufacturing and years of experience in auditing contract manufacturers, DfR Solutions has developed a comprehensive review of manufacturability that goes far beyond the typical computer-generated design rules available in most EDA packages.

Design for Affordability (DFA)

A critical step in the Design for Excellence (DfX) process, as it ensures lowest total ownership costs for end users and optimized profit margins for manufacturers. Design for Affordability is particularly vital when repairable systems are involved as design decisions made during system development greatly influence end user lifecycle costs.


A systematic process for evaluating business processes and performance metrics against best in class industry performance and/or proven best practices from other industries. Benchmarking not only evaluates how well an organization is performing, it is pivotal in setting standards, goals and plans for improving processes that lead to better organizational and business performance.

Design Review

…I enthusiastically recommend DfR Solutions…”

DfR Solutions, specifically Drs. Craig Hillman and Nathan Blattau, has actively worked with me and other solder experts as part of an Independent Review Team (IRT) to determine the root cause and corrective action for a solder joint failure on a space vehicle electronics box. The IRT effort required reviewing, analyzing and drawing conclusions froma variety of detailed visual and X-ray inspections. It also required detailed Finite Element Analysis (FEA) of the various solder joints in the electronics assembly. Dr. Hillman excelled in using his detailed knowledge of electronics assemblies and solder joints to help focus the team and drive to conclusions and recommendations. Dr. Blattau’s FEA expertise was instrumental in converging the analysis efforts of various teams through his knowledge of fatigue damage and the modeling of the creep behavior of solder. It is because of the positive experience with Drs. Hillman and Blattau that I can enthusiastically recommend DfR Solutions to others with similar needs.

Joseph Barker, Engineering Manager/Consultant
Northrop Grumman Corporation

The DfR team was highly professional…

DfR Solutions provided a design review of our high value measurement system and recommended many ways to improve reliability through design modification, component changes, improved specifications and test plans. We were very pleased with the results of their analysis. The DfR team was highly professional and we will continue to use their services again and again.

Kent Kalar, CEO,
SensorTran, Inc


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