Design for Reliability Overview Ops A La Carte 1

Transcription

1 Design for Reliability Overview 1

2 Our Company 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. 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. 2

3 Industry Penetration We have over 500 customers across 70 different industries, including: AEROSPACE AIRPORT SECURITY ALTERNATIVE ENERGY ARMED FORCES AUDIO AND VIDEO AUTOMATION AUTOMOBILE/TRUCKING AUTOMOTIVE COMPONENTS BIOMEDICAL CABLE INDUSTRY CHAMBER MANUFACTURER COMPUTERS CONTRACT MANUFACTURING CONTROL SYSTEMS DEFENSE ELECTRONICS DESIGN AUTOMATION DESIGN FIRMS DISK DRIVES DISPLAY ELECTRONICS ELECTRIC METERS ELECTRIC UTILITY COMPANY ELECTRIC VEHICLES ELEVATOR COMPANIES ENVIRONMENTAL TEST LAB FAILURE ANALYSIS LAB FOOD INDUSTRY GAMING INDUSTRY GENERATORS GOVERNMENT RESEARCH GPS INDUSTRY HANDHELD METERS KITCHEN APPLIANCES LASERS LEGAL INDUSTRY MEDICAL DEVICES MINING MOBILE PHONE MOTORS AND ENGINES NETWORK APPLIANCES NETWORK SECURITY NETWORKING OIL EXPLORATION OPTICAL COMPONENTS PCB MANUFACTURERS PERIPHERALS POWER SUPPLIES RADIO/RF/MICROWAVE RECREATIONAL PRODUCTS RELAXATION/RECREATIONAL RF COMPONENTS RFID ROBOTICS, MEDICAL ROBOTICS, SEMICONDUCTOR SATELLITE SEARCH ENGINE SECURITY SYSTEMS SEMICONDUCTOR SEMICONDUCTOR MFG EQUIP SOCIETIES SOLID STATE STORAGE SPACE EXPLORATION STORAGE NETWORKING TELECOM TEST & MEASUREMENT UNDERWATER ELECTRONICS UNIVERSITIES VETERINARY VISION SYSTEMS WATER PURIFICATION WIRELESS 3

4 2009 Specific Industry Focus Currently, our top four industries are Medical Clean-Tech Oil and Gas Defense/Aerospace 4

5 Our Customers in N.America 5

6 Our Consultants in N.America 6

7 Our Customers Around the World { 7

8 Our Consultants Around the World 8

9 Our Business Model We provide Reliability Solutions using: Consulting Training Testing 9

10 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-art provides comprehensive testing services 10

11 Consulting Services assesses a company s needs and then develops programs to match their needs, using Reliability Integration SM to tie the program together. 11

12 Reliability 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 12

13 Testing 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. 13

14 DESIGN FOR RELIABILITY 14

15 The Situation 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. 15

16 The Balancing Act Engineering teams must balance cost, schedule, performance and reliability to achieve optimal customer satisfaction. Reliability Cost Customer Satisfaction Schedule Performance 16

17 The Solution The Solution is in the following 4 steps: assess the customer s situation develop goals write program plan execute program plan All focused on developing reliable products and improving customer satisfaction. 17

18 The Solution $ Profits Program Plan Goal market share Gap Analysis Benchmarking satisfaction Statistical Data Analysis Assessment? Unknown? $ unreliability Now complaints field failures 18

19 Customizing 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. 19

20 Organizational Level Individual Services 20

21 Solutions 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 21

22 Reliability Solutions Packages for Product Development The R&D cycle for product creation and enhancement requires integration of key reliability activities across all phases of a program. Next Generation Products New Product Lines Product Extensions Product Revisions Critical Component Qualification 22

23 Reliability Solutions Packages for Product Manufacturing As a product transitions to manufacturing, the reliability goals, models and test results become the basis for refining reliability screening, monitoring and reporting. Reliability Test Development Manufacturing Performance Assessments Contract Manufacturer Reliability Audits RoHS Conversions 23

24 Reliability Solutions Packages for Field Reliability Improvement 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. First Year Reliability Growth Warranty Analysis Component Obsolescence 24

25 Reliability Solutions Packages for OEM/ODM Deliverables Ensuring that OEMs/ODMs supply components that meet your reliability specifications is one of the keys to successful manufacturing. Test Plan Development Reliability Audits Test Performance Improvements 25

26 Product Level Individual Services 26

27 Reliability Integration Services for 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, Manufacturing and then integrating each of these activities together into a cohesive reliability program. 27

28 Reliability Integration Services in the Concept Phase Reliability Goal Setting and establishing a plan to achieve the goals characterize this phase. Reliability goals are part business decision, part technology capability and part customer driven. Reliability Goal Setting Benchmarking & Gap Analysis Technology Risk Assessment Reliability Program Plan 28

29 Reliability Integration in the Design Phase 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 Models and Predictions (MTBF) Reliability Block Diagramming (RBD) Fault Tree Analysis (FTA) Failure Modes and Effects Analysis (FMEA) Thermal Analysis Derating Analysis / Component Selection Tolerance / Worst Case Analysis Material Selection Design of Experiments (DOE) Finite Element Analysis (FEA) Design for Six Sigma (DFSS) Dynamic Analysis (modal, shock, vibration) Sneak Circuit Analysis (hardware or software) Software Reliability Warranty Predictions Maintainability/Preventive Maintenance Analysis Design Review and Retrospective Facilitation 29

30 Reliability Integration in the Prototype Phase Discovering design weaknesses and verifying achievement of reliability goals becomes possible with prototypes. Reliability Test Plan Development Highly Accelerated Life Testing (HALT) Root Cause Failure Analysis Fracture and Fatigue Design Verification Testing (DVT) Environmental Testing and Analysis Package Design and Testing Regulatory Compliance Testing and Certification Test Fixture Design and Fabrication Thermal Testing and Analysis Accelerated Life Testing (ALT) Reliability Demonstration Testing (RDT) Closed-Loop Corrective Action Process Setup 30

31 Reliability Integration in the Manufacturing Phase As the product transitions to manufacturing, the reliability goals, models and test results become the basis for refining reliability screening, monitoring and reporting. Highly Accelerated Stress Screening (HASS) On-Going Reliability Testing (ORT) Vendor Reliability Program Assessment Repair Depot Setup Field Failure Tracking System Setup Warranty Performance Analysis Reliability Performance Reporting End-of-Life Assessment Lessons Learned Process Establishment 31

32 Reliability Integration for Specific Product Types - Semiconductors - Software 32

33 Reliability Integration for Semiconductors Even at the Semiconductor Level, Reliability must be considered in each phase of the Semiconductor Life Cycle. Development Phase BIR (Built In Reliability) DFR (Design For Reliability) DFT (Design For Testability) Product Qual/Volume Prod. Ramping Phase Develop Reliability Qualification Plan Develop HALT Procedures Design all h/w for Prod. Reliability Quals Direct the Reliability Qualification Process Conduct Failure Analysis Develop Statistical Bin Limit Control Product Maturity Phase Review/Direct Ongoing Reliability Monitors Direct Failure Analysis/Corrective Actions Propose Design Changes Evaluate proposed fab. process changes 33

34 Reliability Integration for Software Development As with the Hardware, Reliability must be considered in each phase of the Software Life Cycle. Software Reliability Goal Setting Software Reliability Program Plan Facilitation of Team Design Template Reviews Facilitation of Team Design Reviews Software Failure Analysis Software Fault Tolerance Facilitation of Code Reliability Reviews Software Robustness Testing Techniques Software Reliability Measurements & Metrics Usage Profile-based Testing Software Reliability Estimation Techniques Software Reliability Demonstration Tests 34

35 Reliability Integration for Specific Industries - Medical - Clean-Tech - Oil and Gas - Defense/Aerospace 35

36 Reliability Integration for Medical Products MISSION CRITICAL VALUES We are committed to Highly Reliable Systems that save human lives We successfully analyze and test critical medical products with confidence We deliver accuracy and precision to extend product and human life for each application We deliver customized solutions & consultancy to address all program risks 36

37 3M Corporation Abbott Diabetes Care Abbott Laboratories Accuray Inc. Advanced Bionics AeroGen Applied Biosystems Aubrey Group BD Biosciences Boston Scientific Cardeon Cardiac Assist Cardinal Health Carestream Cochlear Covidien Fisher and Paykel Healthcare Flextronics Medical Frezneus Medical Gatan Our Medical Customers Here is a partial list of our medical customers GE Healthcare Guava Technologies Guidant Hewlett-Packard Hospira Inogen Intrapace Intuitive Surgical Iridex Lifescan Lumenis Luminetx M2 Medical Mako Surgical Masimo Medtronic Mission Medical NeoGuide NeoVista Next Safety OmniCell Ortho-Clinical Diagnostics Perfint Healthcare Devices Philips Presym Inc. Proteus Biomedical Inc. Pulmonetic Radiant Medical Respironics Siemens Stryker Suni Medical Synecor Tecan Systems Terumo Medical Corporation Thermage Thoratec Triage Wireless, Inc. Tyco Healthcare Ventana Medical World Heart 37

38 Reliability Integration for Clean Tech Products WHAT IS GREEN RELIABILITY Today, the topic of Green is being discussed everywhere. But what does it mean to be green? Going Green has many implications from the materials being used to the type of energy being used and the quantity being consumed. And each aspect of Going Green has reliability implications. Any time we change material properties, there are inherent reliability risks we must address. 38

39 Our CleanTech Customers Armageddon Energy Artificial Muscle Bloom Energy Camelbak Capstone Turbine Carmanah Clipper Windpower Cooligy Echelon Energy Innovations GE Ionics General Hydrogen Helix Windpower Itron Konarka Here is a partial list of our CleanTech customers National Semiconductor Nuventix OptiSolar San Diego Gas and Electric Silver Springs Networks Solar Electric Solutions Solar Junction SolFocus SunPower Sylvan Source Telsa Motors Thompson Technology Visyx Xandex Xantrex 39

40 Reliability Integration for Oil and Gas Products MISSION CRITICAL VALUES Committed to Highly Reliable Systems for oil exploration and production to ensure equipment, tool, and production availability. Successfully design and test critical production scenarios. Deliver customized solutions & consultancy to address RCM requirements. 40

41 Our Oil and Gas Customers Here is a partial list of our Oil and Gas customers Baker Hughes INTEQ British Petroleum Chevron Halliburton NOV Octio Schlumberger Western Geco 41

42 Reliability Integration for Military Products MISSION CRITICAL VALUES We are committed to Highly Reliable Systems that save human lives We successfully design and test critical military scenarios with confidence We deliver accuracy and precision to extend product life for each mission We deliver customized solutions & consultancy to address Program RAM reqts. 42

43 Our Military Customers Here is a partial list of our Military customers Army ACSS Applied Signal BAE Boeing General Dynamics Honeywell Defense Kaiser (now Rockwell) L-3 Communications Lockheed Martin Marvin Engineering Naval Undersea Warfare Center (NUWC) Raytheon Rockwell Collins Space Systems Loral Teledyne Controls Thales United Defense (now BAE) 43

44 Summary Design for Reliability is made up of the following 4 steps: assess the customer s situation develop goals write program plan execute program plan All focused on developing reliable products and improving customer satisfaction. 44

45 Contact Information Ops A La Carte, LLC Mike Silverman Managing Partner (408) mikes@opsalacarte.com 45