HALT and HASS – Why they work 5 min. ○ Benefits of ... P acific 2012. ○ The
HALT Process. 10 min. HASS th d. 5 i p osium, Asia P ...... HALT/HASS/HASA.
2012 ARS, AsiaAsia-Pacific: Jakarta Session 11 Replacement
Current Time:
Begins at 2:40 PM PM,, Wednesday, October 17th
11:32 AM
Is Your Reliability Testing Program K Keeping i P Pace with ith M Manufacturing f t i and Design Advancements? Ken Ryan, Qualmark & Oh Chong Ch H Hoe, LSP-Technology Pte Ltd
Agenda g
Applied Re eliability Symp posium, Asia P Pacific 2012
Introduction 5 min Introduction to HALT 5 min HALT and d HASS – Why Wh they th work k 5 min i Benefits of HALT and HASS 10 min The HALT Process 10 min HASS theory th and d process 5 min i HALT/HASS / SS equipment equ p e t 5 min Summary 5 min Questions 10 min Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 2
ACRONYMS
Applied Re eliability Symp posium, Asia P Pacific 2012
HALT – Highly g y Accelerated Life Test HASS – Highly Accelerated Stress Screen POS – Proof P f off Screen S RS – Repetitive p Shock ((vibration))
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 3
Applied Re eliability Symp posium, Asia P Pacific 2012
Qualmark Support pp in Indonesia
LSP- Technology Pte Ltd Competencies :. •Environmental Test Chamber Repair, Start-up, Maintenance and Calibration •Mechanical Test Repair, Start-up and Maintenance •Sale and lease of Environmental Test Equipment and Mechanical Tester •Pre-owned P d Ch Chambers b •Test System integration
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 4
Applied Re eliability Symp posium, Asia P Pacific 2012
Improve p Product Reliability y and Profitability with HALT and HASS
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 5
Applied Re eliability Symp posium, Asia P Pacific 2012
Reliabilityy Pressures
Modern technology gy applied pp during g design g and manufacturing can introduce failure modes undetectable by conventional tests tests.
Consumer demand, corporate mandates, shorter design cycles, litigation exposure, and escalating warranty costs create pressures to extend product reliability.
HALT and HASS are rapidly being adopted as a solution to these challenges. g Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 6
Applied Re eliability Symp posium, Asia P Pacific 2012
The Goal of HALT
The g goal of HALT is to rapidly p y fatigue g a product, quickly forcing the weakest parts of the design to fail so the failure modes can be detected and corrected.
This rapid fatigue is accomplished by applying thermal and vibration stresses of types and levels that are not normally seen in the field field.
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 7
HALT Fundamentals
Applied Re eliability Symp posium, Asia P Pacific 2012
HALT is not a test with a p pass or fail result, it is a process tool for the development team. team There are no pre-established limits - the product d t determines d t i th the lilimits. it Stress to failure. It is critical to monitor the product during stressing. stressing
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 8
Applied Re eliability Symp posium, Asia P Pacific 2012
Different Purpose, p , Different Stresses
Extreme Temperatures
Extreme Temperature change rates
6 DOF RS vibration (6 Degree of Freedom, Repetitive Shock)
Stimulate, Not Simulate
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 9
Applied Re eliability Symp posium, Asia P Pacific 2012
Slow Motion Video Example p
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 10
How HALT Works
Applied Re eliability Symp posium, Asia P Pacific 2012
Startt low St l and d step t up the th stress, testing the product during the stressing
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 11
Applied Re eliability Symp posium, Asia P Pacific 2012
How HALT Works
Gradually increase stress level until a failure occurs
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 12
Applied Re eliability Symp posium, Asia P Pacific 2012
How HALT Works
Analyze the failure
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 13
Applied Re eliability Symp posium, Asia P Pacific 2012
How HALT Works
Make temporary improvements
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 14
How HALT Works
Applied Re eliability Symp posium, Asia P Pacific 2012
Increase stress and start process over
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 15
Applied Re eliability Symp posium, Asia P Pacific 2012
How HALT Works
FUNDAMENTAL LIMIT OF TECHNOLOGY
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 16
Whyy HALT Works – S vs N
Applied Re eliability Symp posium, Asia P Pacific 2012
The p power of HALT is derived from a simple basic principle – if you wish to fatigue a component component, you can stress it with lower levels of stress (S) for a lot of cycles (N), (N) or use a higher level of stress for a fewer number of cycles.
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 17
Level of Stress vs. Cycles to Failure – th Heart the H t off HALT
Applied Re eliability Symp posium, Asia P Pacific 2012
High stress/Low cycle
Low stress/High cycle
Effectiveness ff i and d Economics i – Yardsticks d i k for f ESS Decisions, i i Smithson, ih Stephen h A., Proceedings – Institute of Environmental Sciences, 1990 Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 18
Applied Re eliability Symp posium, Asia P Pacific 2012
PRODUCT STRENGTH
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 19
PRODUCT STRENGTH Nominal Product Strength
Applied Re eliability Symp posium, Asia P Pacific 2012
Lower Limit of Strength Distribution
Lower Strength
Upper Limit of Strength Distribution
Higher Strength
Strength g may y be tolerance of temperature, p , vibration,, humidity, y, time, etc., or a composite of all of the above
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 20
FIELD STRESSES
Applied Re eliability Symp posium, Asia P Pacific 2012
Nominal Field Stresses
Lower Stresses
Higher Stresses
Field stresses can include temperature, p vibration, humidity, y time, dust, shock, etc.
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 21
Product Strength Versus Field Stresses
Applied Re eliability Symp posium, Asia P Pacific 2012
Field Stress
Product Strength
W k units Weaker it fail f il under d higher hi h field fi ld stresses t
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 22
Product Strength Versus Field Stresses Field Stress
Product Strength
Applied Re eliability Symp posium, Asia P Pacific 2012
Product strength may deteriorate over time
W k units Weaker it fail f il under d hi higher h fi field ld stresses t Product strength deteriorates over time causing even more failures
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 23
Effect of Halt on Product Strength g
Product strength g curve narrower due to improving low margins
Applied Re eliability Symp posium, Asia P Pacific 2012
Before HALT
After HALT
Increase product strength
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 24
HALT – Different from DVT
Applied Re eliability Symp posium, Asia P Pacific 2012
Different Purpose, Purpose Different Results DVT
HALT
Verifies that product meets specification
Stresses product beyond specification
Verifies that product will function in its intended environment
Stresses product until weak points fail
Determines functional and destruct limits
Is successful when failure modes are found and eliminated
Is successful when product shows no failures
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 25
A KEY Difference...
Applied Re eliability Symp posium, Asia P Pacific 2012
PASS FAIL
DVT is a “Pass/Fail” Pass/Fail test
Ken Ryan, Qualmark Corporation
HALT is not - you can never “PASS” a HALT. There are no prep established limits.
Session 5
Slide Number: 26
Failure Relationship Between Environmental Factors and Failure at Hughes Electronics Sand & Brine, 4% Dust, 6%
Other, 4%
Temperature, 40%
Applied Re eliability Symp posium, Asia P Pacific 2012
Humidity, 18%
Vibration, Vibration 28%
Source: ESPEC Technology Report, 1996
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 27
Should I Design g to HALT Limits?
Applied Re eliability Symp posium, Asia P Pacific 2012
Absolutely Not!
Design for normal limits limits. Let HALT tell you where the weak links are. Use information found in HALT to eliminate the weak links ahead of time. Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 28
The Goal of HASS
Applied Re eliability Symp posium, Asia P Pacific 2012
The g goal of HASS is to rapidly p y fatigue g all production units, using stresses based on the limits found in HALT HALT. This forces any new weaknesses in the product to become detectable so that the defective units will not be shipped. These new weaknesses can be due to process, design, or supplier changes.
The Proof of Screen (POS) process ensures that HASS will not reduce life of the product in the field and will find the desired failure modes modes. Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 29
HASS - Different From Burn Burn--In
Applied Re eliability Symp posium, Asia P Pacific 2012
Different Purpose, Purpose Different Results Burn-In
HASS
Weed out infant mortality
Verify function at elevated temp.
Verify that HALT limits haven’t changed
No new “weak links” due to process or component variability, including upstream suppliers
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 30
Proof of Screen ((POS)) - A Critical Step p
Serves two keyy purposes p p
Applied Re eliability Symp posium, Asia P Pacific 2012
Verify that the screen is not taking excessive lif outt off the life th product d t Verify that the screen is effectively finding defective units
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 31
Applied Re eliability Symp posium, Asia P Pacific 2012
Th Equipment The E i tN Needed d dF For HALT and HASS
Ken Ryan, Qualmark Corporation
Session 5
Slide Number: 32
HALT and HASS Equipment q p
Liquid nitrogen cooled Rapid thermal transitions, greater than 60°C/min -100°C to +200°C (250°C) operating range
Applied Re eliability Symp posium, Asia P Pacific 2012
R Repetitive i i shock h k vibration ib i 6 degrees of freedom 3 axis i & 3 rotations, t ti simultaneously Broad frequency band (10-5,000Hz)
Combined environment Thermal and vibration
Low ambient noise
