HALT as a Field Service Tool

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1 HALT as a Field Service Tool By John Cooper, CRE Sr. Reliability Engineer Ops A La Carte johnc@opsalacarte.com

2 INTRODUCTION HALT is used to better understand design margins, and to uncover failure modes linked to field failures. Operating Limits and Destruct Limits are discovered which characterize normal products, similar to SPC control limits. These Operating & Destruct Limits are then used later on field return units to quickly identify any possible drift in product performance relative to the established control limits.

3 INTRODUCTION This process was used on a set of products which had previously been through HALT, and now had been in a trucking collision, and exposed to stress factors: shock, and then exposure to humidity. Those units were processed with HALT to look for any shift in the operating limits or destruct limits Units were also inspected under a microscope to detect any visual indications of the effects of humidity.

4 Discussion The Product Products are a high end, consumer networking device, designed for indoor use. Life Requirement: 7 years or more. Product had been through HALT, establishing Operating & Destruct Limits HALT Calculator was used previously to establish AFR

5 What Happened? A shipment of products were in route to customers warehouse, when the truck was involved in a collision. Product was subjected to the shock of the collision, and exposed to 3 days of rain Retail packaging boxes showed signs of moisture Numerous discussions followed with insurance, the supplier, anxious OEM customers, and the HALT lab!

6 The Plan Products were to be sorted out based on visual damage to retail packaging Units would be subjected to the HALT process, looking for a shift in Operating or Destruct Limits Units would be visually inspected at the PCB Assembly level, looking for evidence of moisture damage

7 Execution Products were sorted out by visual damage to retail packaging damaged vs undamaged Samples of each were delivered the HALT lab for inspection & testing One damaged unit was subjected to the complete HALT process A number of damaged and undamaged units were subjected to just the HALT Thermal tests (undamaged as a control). Units were inspected under microscope for evidence of moisture damage

8 HALT Results Data Operating & Destruct Limits Stress Condition Original HALT Post-Collision HALT Cold Temperature Operating Limit -75 C -70 C Hot Temperature Operating Limit +115 C +95 C Vibration Operating Limit above 50 Grms above 50 Grms Cold Temperature Destruct Limit below -75 C -80 C Hot Temperature Destruct Limit above +115 C above +115 C Vibration Destruct Limit above 50 Grms above 50 Grms

9 Inspection Results Products were inspected under microscope, looking for evidence of moisture related effects Traces of visual effects were noticed, possibly due to manufacturing process (no clean flux) No clear evidence of moisture damage

10 Evaluation of Findings There is a reduction of the Operating Limits, although not large Evaluation of shift in HALT Operating Limits and Destruct Limits continue Preliminary finding is that there is no evidence that shift is due to truck collision or exposure to moisture Visual Examination does not indicate effects due to truck collision and exposure Units will be re-examined, and followed for additional field return data

11 Conclusion Use of HALT Process as a field return evaluation tool offers potential Failure Analysis and Root Cause are important follow up tools (as with basic HALT)

12 FUTURE OF HALT AND HASS HALT and HASS offer use as effective field failure analysis tools Both require initial test results, with Operating & Destruct Limits

13 CONTACT INFO John Cooper Senior Reliability Engineer Ops A La Carte johnc@opsalacarte.com (650) Confidence in Reliability

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