presented by
Ted Kalal

June 17-19, 2008
(8am - 4pm)

at
Cincinnati Sub-Zero Products, Inc.
12011 Mosteller Rd.
Cincinnati, OH 45241-1528

Course Description
The Highly Accelerated Life Test (HALT) 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.

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.

Objectives
The 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.

For whom intended
The 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.

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

Text Material
Soft copies of all materials provided at the end of the sessions.

Click here to register!

Location
Cincinnati Sub-Zero Products, Inc. (CSZ)
12011 Mosteller Rd.
Cincinnati, OH 45241-1528 USA
ph: 513.772.8810
tf: 800.989.7373

Directions to Cincinnati Sub-Zero.

Suggestion for Accommodation
Holiday Inn Express - Sharonville
11160 Dowlin Drive
Sharonville, OH 45241
Hotel Front Desk: 1-513-7719080
1 888 HOLIDAY (888 465 4329)

Mention CSZ to get a discounted room rate.

Hours
8am - 4pm

Fee
Fee is US$2,395 per student. Payment in advance via check, VISA or Mastercard preferred credit cards or bank transfer (ask for transfer details).

For registration and payment received one month prior to course, deduct $100. For three or more participants from an organization and payment received one month prior to course, deduct $200 each.

Contact Information
Tel: (805) 564-1260
FAX: (805) 966-7875
E-mail: tustin@equipment-reliability.com

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