HALT, HASS, and HASA Explained: Accelerated Reliability Techniques, Revised Edition

194 Pages·2009·1.94 MB·English

by  Harry W. McLean

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HALT, HASS,
AND HASA
EXPLAINED
FM_McLean_6X9_575019.qxd 4/6/09 4:01 PM Page ii
Also available from ASQ Quality Press:
The Certified Reliability Engineer Handbook
Donald W. Benbow and Hugh W. Broome
Concepts for R&R Studies, Second Edition
Larry B. Barrentine
The Certified Quality Engineer Handbook, Third Edition
Connie M. Borror, editor
Failure Mode and Effect Analysis: FMEA From Theory to Execution,
Second Edition
D.H. Stamatis
The Weibull Analysis Handbook, Second Edition
Bryan Dodson
The Quality Calibration Handbook: Developing and Managing a
Calibration Program
Jay L. Bucher
Reliability Statistics
Robert A. Dovich
Root Cause Analysis: Simplified Tools and Techniques, Second Edition
Bjørn Andersen and Tom Fagerhaug
The Metrology Handbook
Jay Bucher, editor
Product Liability Prevention: A Strategic Guide
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The Quality Toolbox, Second Edition
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To request a complimentary catalog of ASQ Quality Press publications, call
800-248-1946, or visit our Web site at http://www.asq.org/quality-press.
FM_McLean_6X9_575019.qxd 4/6/09 4:01 PM Page iii
HALT, HASS, and
HASA
EXPLAINED
Accelerated Reliability Techniques
Revised Edition
Harry W. McLean
ASQ Quality Press
Milwaukee, Wisconsin
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American Society for Quality, Quality Press, Milwaukee 53203
©2009 American Society for Quality
All rights reserved. Published 2009
Printed in the United States of America
13 12 11 10 09 5 4 3 2 1
Library of Congress Cataloging-in-Publication Data
McLean, Harry W., 1946–
HALT, HASS, and HASA explained : accelerated reliability techniques / Harry W. McLean.—
Rev. ed.
p. cm.
Includes bibliographical references and index.
ISBN 978-0-87389-766-2 (hardcover : alk. paper)
1. Reliability (Engineering) 2. Accelerated life testing. 3. Vibration—Testing.
4. Strains and stresses. I. Title.
TS173.M42 2009
620(cid:1).00452—dc22 2009005544
ISBN-13: 978-0-87389-766-2
No part of this book may be reproduced in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of the publisher.
Publisher: William A. Tony
Acquisitions Editor: Matt Meinholz
Project Editor: Paul O’Mara
Production Administrator: Randall Benson
ASQ Mission: The American Society for Quality advances individual, organizational, and
community excellence worldwide through learning, quality improvement, and knowledge
exchange.
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Printed on acid-free paper
FM_McLean_6X9_575019.qxd 4/6/09 4:01 PM Page v
Contents
Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xvii
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xix
Chapter 1 The Importance of High-Reliability Products
at Market Introduction—How and Why to Do
a HALT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
An Overview of HALT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Comparisons of Products with and without HALT . . . . . . . . . . . . 7
The HALT Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cold and Hot Step Stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rapid Thermal Transitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Vibration Step Stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Combined Stresses in HALT . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Other HALT Stresses and Special Situations . . . . . . . . . . . . . . 17
Verification HALT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
A Perspective on Implementing Corrective Action as a . . . . . . . . .
Result of HALT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
A Proposal for Managing HALT Limits and Issues . . . . . . . . . 19
Using the Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Comments Regarding the Various Vibration Tables . . . . . . . . . 24
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
HALT Summarized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Illustrating the Value of HALT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Some Thoughts Regarding Ruggedizing a Product Prior
to HALT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
The Recording of Failures and Corrective Action . . . . . . . . . . . . . 32
v
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vi Contents
Troubleshooting Products under Stress Conditions . . . . . . . . . . . . 33
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Chapter 2 Highly Accelerated Stress Screen—HASS . . . . . . . . 37
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
The ABCs of Building Robust Products . . . . . . . . . . . . . . . . . . . . 38
Production Product Stress Screen HASS . . . . . . . . . . . . . . . . . . . . 38
Why Does HASS Work? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Rate of Change of Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Acceleration Factor for Thermal Cycling . . . . . . . . . . . . . . . . . . . 42
Which Stress Levels Are Appropriate? . . . . . . . . . . . . . . . . . . . . . 43
Precipitation and Detection Screens . . . . . . . . . . . . . . . . . . . . . . . . 45
Precipitation Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Detection Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
A Comment on HASS Profiles or Screens . . . . . . . . . . . . . . . . . 48
Proof of Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fixture Characterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
The HASS Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Defect Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Life Determination in Proof of Screen . . . . . . . . . . . . . . . . . . . 52
Screen Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Cables for HASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
HASS Summarized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Some HASS Successes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
A Word of Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Chapter 3 Beyond the Paradigm of Environmental Stress
Screening—Using HASA . . . . . . . . . . . . . . . . . . . . . . 61
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Statistical Process Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Statistics—The System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Scenario 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Scenario 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
A Control Chart for the HASA Process . . . . . . . . . . . . . . . . . . . . 69
The Monitoring System Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Problems Uncovered through HASA . . . . . . . . . . . . . . . . . . . . . . . 71
An Observation on Using Equation 3.1 . . . . . . . . . . . . . . . . . . . . . 74
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Chapter 4 Refinements on Highly Accelerated Stress
Audit (HASA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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Contents vii
Background and Assumptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Application of the Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
A Graphical Tool for Detecting Defect Level Changes . . . . . . . . . 81
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Introduction to an Improved HASA Process . . . . . . . . . . . . . . . . . 85
HASA Process Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Typical Lot Acceptance Sampling Plan . . . . . . . . . . . . . . . . . . . . . 86
HASA Acceptance Sampling Plan . . . . . . . . . . . . . . . . . . . . . . . . . 87
Chapter 5 The Equipment Required to Perform
Efficient Accelerated Reliability Testing . . . . . . . . . 93
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
System Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Turbulence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
A Comparison of LN Systems and Compressor Systems
2
for HALT and HASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
The Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Product Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Ducting Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Work-Area Audible Noise Level . . . . . . . . . . . . . . . . . . . . . . . . 102
Serviceability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Maximum System Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . 103
Post-Sales Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Auxiliary Equipment, Operator Safety, and ESD . . . . . . . . . . . . . 103
Failure Analysis Lab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Why Develop an In-House Failure Analysis Capability? . . . . . 105
Initial Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Metallographic Sample Preparation . . . . . . . . . . . . . . . . . . . . . 108
Advanced Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Failure Analysis Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Chapter 6 How to Sell New Concepts to Management . . . . . . . 115
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
The Situation Today . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
The Proposed Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Addressing Potential Management Concerns . . . . . . . . . . . . . . . . 120
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viii Contents
The Savings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Chapter 7 Some Commonly Asked Questions and
Observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
How Would Someone Compare ESS and HASS? . . . . . . . . . . . . . 129
What Is HALT in a Few Words? . . . . . . . . . . . . . . . . . . . . . . . . . . 130
How Would One Compare Product Qualification Methods
and HALT? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Is HALT for Quality Improvement or Is It Intended to
Replace RGT and MTBF Tests? . . . . . . . . . . . . . . . . . . . . . . . 132
Is There Any Merit to Subjecting a Product to Stresses Far
Beyond Its Design Specifications? . . . . . . . . . . . . . . . . . . . . . . 132
What Are Product Specific and Generic Stresses? . . . . . . . . . . . . 133
If HALT and HASS Are So Great, Why Isn’t Everyone
Using HALT and HASS? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Is One HALT Enough? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
At What Product Level Should HALT Be Performed? . . . . . . . . . 135
Who Should Be Involved with the Accelerated Reliability
Program? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Physically, Where Should HALT Be Performed? . . . . . . . . . . . . . 137
How Many Units Are Required, and What Can Be Done
With Them Once We’re Finished with HALT? . . . . . . . . . . . . 138
Why a Cultural Change May Be Required in Order to
Perform a Successful HALT . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Can a Conventional Chamber and Vibration Table Be Used
to Perform a HALT? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Are All Six Degrees of Freedom Shakers the Same? . . . . . . . . . . 141
Are There Any Known Problems in Applying Product
Temperature Ramp Rates of (cid:2)60°C per Minute? . . . . . . . . . . 142
Are There Any Advantages to Performing Sequential
Rather Than Combined Stress Regimens? . . . . . . . . . . . . . . . . 142
Do HALT and HASS Just Uncover Electronic Defects? . . . . . . . 142
Can HASS Eliminate My Production Steady State,
Elevated Temperature Burn-in? . . . . . . . . . . . . . . . . . . . . . . . . 143
At What Levels of Temperature and Vibration Can I
Consider the Product Robust? . . . . . . . . . . . . . . . . . . . . . . . . . 143
How Can You Justify Doing HALT on Products with a
Very Short Field Life? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
What Are the Yearly Maintenance Costs for the HALT
Chambers? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Can the Results of HALT Be Used to Accurately Estimate
Field Life? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
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Contents ix
Appendix A The Derivation of Equation 3.1 . . . . . . . . . . . . . . . . . 147
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Trademarks and Service Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
About the Author . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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