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HALT/HASS/HASA and Practical Design FMEA Training Course |
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| Objectives | For whom intended | Outline | Documentation | Lecturer | Registration | |
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Training Course description
This Highly Accelerated Life Test (HALT) training course presents the concepts, methods and tools to perform HALT. HALT identifies weaknesses in design elements so that weaknesses can be removed by redesign before mass production. Students will learn the differences in stress testing as tests have evolved over decades of product improvement evolution. We completely describe the stressors, why they are used and how. Practical areas, i.e. mechanical fixturing, smart attachment techniques, local cooling, instrumentation and data recording are covered in detail. HALT planning is discussed and a practical spreadsheet (that will greatly help the new HALT practitioner to not overlook any of the details in the actual HALT) is presented.
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The Highly Accelerated Stress Screening (HASS) section moves on to applying stress techniques to the manufactured product. HASS ensures that no manufacturing deviations creep into the end product. Highly Accelerated Stress Audit (HASA) is a HASS auditing strategy that allows for high volume manufacturing while still ensuring that a highly reliable product is being shipped. Several HASA techniques are discussed. A Proof of Screen (PoS) tool that ensures the stressors in HASS/HASA are not too harsh and yet not too weak is discussed. PoS ensures that not too much product life is removed during the HASS and HASA processes.
Design (FMEA) Failure Modes & Effects Analysis is a structured analysis method that can be used on any product. The concept can be used
(1.) on the design itself,
(2.) on the process that will be used to manufacture the product and even
(3.) on field failures.
The FMEA discovers design and safety shortcomings at the earliest stage of product development, usually right at the design review stage, before prototype hardware is created. |
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Objectives
The training course objectives are
(1.) to show the value in using these proactive techniques and
(2.) to create understanding of practical techniques that will greatly increase the reliability of end products. |
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For whom intended
This training course is intended for all new product designers, reliability engineers and quality engineers so that design weaknesses in their current designs can be identified before locking in these errors prior to ramp. This also helps to remove legacy design elements that may well have been carried from design to design. |
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Training Course Outline
Day 1
FMEA Class Overview:
A Failure Modes & Effects Analysis (FMEA) is a structured method to study a design or process that seeks to anticipate and minimize unwanted performance or unexpected failures.
Functional Block Diagrams (FBD):
Much like an operational flow diagram that emphasizes Inputs, Outputs and the Process flow of the device being FMEAed
Exercise & Review:
The class will develop a FBD in small teams for a device that is specified in the class. Each team’s effort is reviewed by the class.
Fault Trees (FT):
A Fault Tree is produced from the FBD with an easy-to-use Excel spreadsheet.
Exercise & Review
The class will develop a fault tree from the FBD using the Excel spreadsheet. Each team’s effort is reviewed by the class.
Failure Modes & Effects Analysis (FMEA):
An FMEA is produced to identify the weak areas in the product. An action Item list follows to assign tasks for later corrective action. Three areas are emphasized: (1) Severity of the failure mode, (2) Detectability of the failure before shipping, and (3) probable occurrence of the failure mode in the field.
Exercise & Review:
In teams the class will develop an FMEA from the FBD and FT. Each team’s effort is reviewed by the class.
Assign corrective action tasks:
The class will weigh the results of the FT and develop a list of what needs to be improved upon and what doesn’t.
Day 2
Highly Accelerated Life Test (HALT):
HALT Defined - Temperature/Vibration/Voltage Stress - Voltage Margining - Clock Rate Stress - Hard & Soft Failures - Combined Stress
The Number of Units required for HALT:
One is not enough - You must test to failure - Quantity needed for HALT – Gold Unit - Time to perform HALT
HALT Planning:
HALT Planning Action Item List - Weekly Meetings
Fixturing:
Specific mechanical fixtures - Universal Fixtures - Subassembly - Full Unit
HALT Lab Requirements:
Liquid Nitrogen – Tank - Multiple Dewars - Nitrogen Hose - Nitrogen Gas Purge – Air Purge - Power - Floor Space - Oxygen Detector(s) - Shop Air - Exhaust Air
HALT Mitigations to Isolate Test Areas:
Using Shop Air - Mitigation Boxes - Best RTV adhesives - Best tape for strapping DUTs
Recommended Tools:
Toolbox – Torque Wrench- Strobe Light – High Torque Power Drill – Digital Camera Microscope
Liquid Cooling:
Water - 3M Liquids (non HFC) - Chiller Requirements
HALT Report:
When Done - What is Included – Data Tracking Sheets
Day 3
Highly Accelerated Stress Screening (HASS):
Stress Levels Defined - Product Specification Range – Precipitation of Defects - Detection Screen - HASS Profile - Number of Units HASSed before HASA
Proof of Screen (PoS):
Determining Acceptable Fraction of Life Removed - Number of Units Required - PoS on One Unit - PoS during HASS - Salted Samples (a discussion) - PoS in Manufacturing - Pos Determined During HALT - PoS Specifications required in HALT Report
Highly Accelerated Stress Audit (HASA):
Determining Sample Size - Customer Requirements - Queuing Space (before Shipment) Corrective Action(s) - Stop Order (in manufacturing)
Open Discussion on Class Subjects and Concern |
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Text Materials
Soft copies of all materials provided at the end of the sessions. |
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About the Lecturer |
 Ted Kalal
Ted is a practicing reliability engineer who has gained much of his understanding of reliability from hands-on experience and from many great mentors. He is a graduate of the University of Wisconsin (1981). He has authored several papers on electronic circuitry, HALT, and holds a patent in the field of power electronics. He has been a practicing reliability engineer for 25+ years specializing in HALT, FMEA and the full reliability process.
Mark Levin & Ted Kalal collaborated at Teradyne, Inc. in Agoura Hills, CA where together they coauthored "Improving Product Reliability". The work is intended for engineering managers and company owners who see a need to:
- Lower Warranty Costs
- Increase Customer Satisfaction
- Speed Time to Market
- Promote Re-Orders
- Add Reliability as a "Competitive Advantage" as part of their product mix
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Registration
- On line
Course registration can be completed, including secure payment via a credit card, by clicking on the email link immediately below.
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- Off line
To register with any other form of payment simply click on the "CLICK HERE to pay without using a Credit Card " below left and follow the instructions.
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Willow House, Greenrig Road, Hawksland, Lanark, ML11 9QA, UK
