No Trouble Found Issue

Abstract

Kirk and Fred delve into the crucial topic of managing returned parts and products, even those that are functioning perfectly.

Key Points

Join Kirk and Fred as they discuss why parts or products returned to the manufacturer seem to have no failure on their test bench.
Topics include:

• The cost of production loss can be significant for capital production equipment failures. A field service agent may replace many circuit boards or components, known as “shotgunning,” the system when only one of the replaced parts has caused the failure.
• Undoubtedly, there is a lot of noise when evaluating returned systems or parts identified as failed. Some failure mechanisms, such as fretting corrosion, are from poor contact plating or contamination in connectors, and re-seating or replacing the connector removes the cause of failure. Only through further analysis of the connector’s contact surfaces can it be diagnosed
• Companies that are dismissive and blame the customer for misuse, dismiss failures as expected “infant mortality,” and do not perform detailed failure analysis may perpetuate a costly hidden design or manufacturing defect.
• The value and concern companies have for the reliability of their products depend heavily on the industry’s expectations. Everyone expects high reliability in safety-related industries such as aircraft, where pinball machines’ unreliability has been historically accepted.

Enjoy an episode of Speaking of Reliability. Where you can join friends as they discuss reliability topics. Join us as we discuss topics ranging from design for reliability techniques to field data analysis approaches.

Show Notes

Please click on this link to access a relatively new analysis of traditional reliability prediction methods article from the US ARMY and CALCE titled  “Reliability Prediction – Continued Reliance on a Misleading Approach”. It is in the public domain, so please distribute freely. Trying to predict reliability for development is a misleading a costly approach.

You can now purchase the most recent recording of Kirk Gray’s Hobbs Engineering 8 (two 4 hour sessions) hour Webinar “Rapid and Robust Reliability Development 2022 HALT & HASS Methodologies Online Seminar” from this link.

For more information on the newest discovery testing methodology here is a link to the book “Next Generation HALT and HASS: Robust design of Electronics and Systems” written by Kirk Gray and John Paschkewitz.

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