About The Authors Series Foreword Second Edition Preface Second Edition Series Foreword First Edition Foreword First Edition Preface First Edition List Of Acronyms 1 The Need For A New Paradigm For Hardware Reliability And Software Quality 36 1.1 Gaining Competitive Advantage 4 1.2 Competing In The Next Decade - Winners Will Compete On Reliability 4 1.3 Concurrent Engineering 5 1.4 Reducing The Number Of Engineering Change Orders (ECOS) At Product Release 7 1.5 Time-To-Market Advantage 7 1.6 Accelerating Product Development 9 1.7 Identifying And Managing Risks 10 1.

8 ICM, A Process To Mitigate Risk 10 1.9 Software Quality Overview 11 1.9.1 Software Glossary 13 2 Barriers To Implementing Hardware Reliability And Software Quality 14 2.1 Lack Of Understanding 14 2.2 Internal Barriers 15 2.3 Implementing Change And Change Agents 16 2.4 Building Credibility 18 2.

5 Perceived External Barriers 19 2.6 It Takes Time To Gain Acceptance 20 2.7 External Barrier 21 2.8 Barriers To Software Process Improvement 22 3 Understanding Why Products Fail 24 3.1 Why Things Fail 24 3.2 Parts Have Improved, Everyone Can Build Quality Products 26 3.3 Hardware Reliability And Software Quality - The New Paradigm 27 3.4 Reliability VS Quality Escapes 28 3.

5 Why Software Quality Improvement Programs Are Unsuccessful 28 4 Alternative Approaches To Implementing Reliability 31 4.1 Hiring Consultants For HALT Testing 31 4.2 Outsourcing Reliability Testing 31 4.3 Using Consultants To Develop And Implement A Reliability Program 32 4.4 Hiring Reliability Engineers 32 5 The Product Life Cycle 35 5.1 Six Phases Of The Product Life Cycle 35 5.1.1 Mitigate Risk 36 5.

2 The ICM Process For A Small Company 42 5.2.1 DFX - Design For Manufacturability (DFM), Design For Test (DFT), Design For Serviceability (DFS) And Maintainability, And Design For Reliability (DFR) 43 5.2.2 Warranty 43 6 Reliability Concepts 46 6.1 The Bathtub Curve 47 6.2 Mean Time Between Failure 48 6.2.

1 Mean Time Between Repair 49 6.2.2 Mean Time Between Maintenances (MTBM) 49 6.2.3 Mean Time Between Incident (MTBI) 49 6.2.4 Mean Time To Failure (MTTF) 49 6.2.

5 Mean Time To Repair (MTTR) 49 6.2.6 Mean Time To Restore System (MTTRS) 49 6.3 Warranty Costs 50 6.4 Availability 51 6.4.1 On-Site Manufacturer Service Personnel 53 6.4.

2 Customer Trained Service Personnel 53 6.4.3 Manufacturer Training For Customer Service Personnel 53 6.4.4 Easy-To-Use Service Manuals 53 6.4.5 Rapid Diagnosis Capability 53 6.4.

6 Repair And Spare Parts Availability 53 6.4.7 Rapid Response To Customer Requests For Service 54 6.4.8 Failure Data Tracking 54 6.5 Reliability Growth 55 6.6 Reliability Demonstration Testing 56 6.7 Maintenance And Availability 59 6.

7.1 Preventative Maintenance 60 6.7.2 Predictive Maintenance 61 6.7.3 Prognostic And Health Management (PHM) 62 6.8 Component Derating 66 6.9 Component Uprating 68 7 FMEA 71 7.

1 The FMEA Process 71 7.1.1 The Functional Block Diagram (FBD) 72 7.1.2 The Fault Tree Analysis 76 7.1.3 Failure Modes And Effects Analysis Spreadsheet 79 7.1.

4 Preparing For The FMEA 83 7.1.5 Barriers To The FMEA Process 85 7.1.6 FMEA Ground Rules 88 7.1.7 Ways To Improve FMEA Efficiency And Effectiveness 90 7.1.

8 Software FMEA 92 7.1.9 Software Fault Tree Analysis (SFTA) 96 7.1.10 Process FMEA 97 7.1.11 FMMEA 98 8 The Reliability Toolbox 100 8.1 The HALT Process 100 8.

1.1 Types Of Stresses Applied In HALT 103 8.1.2 The Theory Behind The HALT Process 104 8.1.3 HALT Testing Liquid Cooled Products 107 8.1.4 HALT Testing 108 8.

2 Highly Accelerated Stress Screening (HASS) 120 8.2.1 Proof Of Screen (POS) 122 8.2.2 Burn-In 123 8.2.3 Environmental Stress Screening (ESS) 124 8.2.

4 Economic Impact Of Hass 125 7.3.5 The HASA Process 125 8.3 Summary Of HALT, HASS, HASA And POS Benefits 126 8.4 HALT And Hass Test Chambers 126 8.5 Accelerated Reliability Growth (ARG) 127 8.6 Accelerated Early Life Test (ELT) 131 8.7 Spc Tool 131 8.

8 Fifo Tool 132 9 Software Quality Goals And Metrics 137 9.1 Software Metrics 139 9.2 Lines of Code (LOC) 140 9.3 Defect Density 141 9.4 Defect Models 143 9.5 Defect Run Chart 144 9.6 Escaped Defect Rate 146 9.7 Code Coverage 147 10 Software Quality Analysis Techniques 149 10.

1 Root Cause Analysis 149 10.2 The 5 Whys 149 10.3 Cause And Effect Diagrams 150 10.4 Pareto Charts 151 10.5 Defect Prevention, Defect Detection And Defensive Programming 153 10.6 Effort Estimation 156 11 Software Lifecycles 158 11.1 Waterfall 158 11.2 Agile 160 11.

3 CMMI 163 11.4 How To Choose A Software Lifecycle 166 12 Software Procedures And Techniques 168 12.1 Gathering Requirements 168 12.2 Documenting Requirements 170 12.3 Documentation 173 12.4 Code Comments 175 12.5 Reviews And Inspections 178 12.6 Traceability 182 12.

7 Software And Hardware Integration 182 13 Why Hardware Reliability And Software Quality Improvement Efforts Fail 185 13.1 Lack Of Commitment To The Reliability Process 185 13.2 Inability To Embrace And Mitigate Technologies Risk Issues 187 13.3 Choosing The Wrong People For The Job 188 13.4 Inadequate Funding 188 13.5 Inadequate Resources 193 13.6 Mil-Std 217 - Why They Are Obsolete 194 13.7 Finding But Not Fixing Problems 197 13.

8 Nondynamic Testing 198 13.9 Vibration Testing Too Difficult To Implement 198 13.10 The Impact Of Late Hardware Or Late Software Delivery 198 13.11 Supplier Reliability 198 14 Supplier Management 200 14.1 Purchasing Interface 200 14.2 Identifying Your Critical Suppliers 201 14.3 Develop A Thorough Supplier Audit Process 201 14.4 Develop Rapid Nonconformance Feedback 202 14.

5 Develop A Materials Review Board (MRB) 203 14.6 Counterfeit Parts And Materials 203 15 Establishing A Reliability Lab 207 15.1 Staffing For Reliability 207 15.2 The Reliability Lab 208 15.3 Facility Requirements 209 15.4 Liquid Nitrogen Requirements 209 15.5 Air Compressor Requirements 211 15.6 Selecting A Reliability Lab Location 211 15.

7 Selecting A HALT Test Chamber 212 15.7.1 Chamber Size 213 15.7.2 Machine Overall Height 214 15.7.3 Power Required And Consumption 216 15.7.

4 Acceptable Operational Noise Levels 216 15.7.5 Door Swing 216 15.7.6 Ease Of Operation 216 15.7.7 Profile Creation, Editing, And Storage 216 15.7.

8 Temperature Rates Of Change 217 15.7.9 Built-In Test Instrumentation 217 15.7.10 Safety 217 15.7.11 Time From Order To Delivery 217 15.7.

12 Warranty 217 15.7.13 Technical/Service Support 217 15.7.14 Compressed Air Requirements 222 15.7.15 Lighting 222 15.7.

16 Customization 222 16 Hiring And Staffing The Right People 223 16.1 Staffing For Reliability 223 16.2 Staffing For Software Engineers 227 16.3 Choosing The Wrong People For The Job 228 17 Implementing The Reliability Process 230 17.1 Reliability is Everyone''s Job 230 17.2 Formalizing The Reliability Process 231 17.3 Implementing The Reliability Process 232 17.4 Rolling Out The Reliability Process 232 17.

5 Developing A Reliability Culture 236 17.6 Setting Reliability Goals 237 17.7 Training 238 17.8 Product Life Cycle Defined 239 17.9 Concept Phase 240 17.10 Design Phase 241 17.11 Production Phase 242 17.12 End-Of-Life And Obsolesence Phase 242 17.

13 Proactive And Reactive Reliability Activities 242 18 Product Concept Phase 249 18.1 Establish The Reliability Organization 251 18.2 Define The Reliability Process 251 18.3 Define The System Reliability Requirement 251 18.4 Capture And Apply Lessons Learned 252 18.5 Risk Mitigation 254 18.5.1 Filling Out The Risk Mitigation Form 255 18.

5.2 Risk Mitigation Meeting 257 19 Design Concept Phase 258 19.1 Setting Reliability Requirements And Budgets 259 19.2 Define Reliability Design Guidelines 263 19.3 Risk Mitigation In The Design Concept Phase 264 19.3.1 Identifying Risk Issues 264 19.3.

2 Reflecting Back (Capturing Internal Lessons Learned) 265 19.3.3 Looking Forward (Capturing New Risk Issues) 266 19.4 Reliability Capital Budget And Activity Scheduling 268 19.5 Risk Mitigation Meeting 270 19.6 Reflection 270 20 Product Design Phase 271 20.1 Product Design Phase 271 20.2 Reliability Estimates 273 20.

3 Implementing Risk Mitigation Plans 273 20.3.1 Mitigating Risk Issues Captured Reflecting Back 274 20.3.2 Mitigating Risk Issues Captured Looking Forward 276 20.4.