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Reliability reporting guide
Microelectronics and Reliability,
Vol. 17, pp. 365 to 366. PergamonPress. 1978.Printedin Great Britain
BOOK
R ELIABILITY (A R e l i a b i l i t y G u i d e to F a i l u r e
REVIEWS
R EPOR TING GUIDE
Reporting,
Analysis,
and Corrective
Action Systems)
Produced by the American Society for Quality Control, 161 W e s t W i s c o n s i n A v e n u e , M i l w a u k e e , W i s c o n s i n , 53203 1977 1. Design Phase. Documented reliability functions include mathematical modeling (reliability predictions, apportionments, growth models, assessments, e t c . , ), t r a d e off s t u d i e s , s t a t i s t i c a l t e s t p l a n n i n g , d e s i g n reviews, parts studies and reviews, evalu a t i o n of t e s t d a t a , f a i l u r e m o d e a n d e f f e c t s analysis, fault tree studies, and others. W h e t h e r a n y o r a l l of t h e s e f u n c t i o n s , o r p o r t i o n s of e a c h , a r e r e q u i r e d w o u l d d e p e n d on m a n y f a c t o r s i n c l u d i n g t y p e of i n d u s t r y , c o n t r a c t , p r o d u c t o r s i z e of c o m p a n y , e t c . The Reliability Failure Reporting, Analysis and Corrective Action System, should commence during the design phase as a p a r t of t h e o v e r a l l d o c u m e n t a t i o n e f f o r t .
This small booklet was prepared by the A S Q C C o m m i t t e e on R e l i a b i l i t y R e p o r t i n g and is intended as a specialised reliability assurance procedure for industry. The objectives and general comments are outlined below: A.
Objectives
T h e p r i m a r y o b j e c t i v e of t h i s d o c u m e n t i s to p r o v i d e b a s i c m e t h o d o l o g y a n d i d e a s for developing a Failure Reporting, Analysis a n d C o r r e c t i v e A c t i o n S y s t e m ~ s p a r t of a reliability program within an industrial firm. This guide provides an introduction upon which further study and planning efforts may be based.
2. Manufacturing Phase. S o m e of t h e above functions or techniques extend into the manufacturing phase which also involves additional reliability functions such as test monitoring, screening methods, special functional test process controls, and review of d e s i g n c h a n g e s . S o m e l e v e l of f o r m a l reliability failure reporting analysis and corrective action should be performed throughout the manufacturing phase.
The guide may be useful for a company of a n y s i z e , a l t h o u g h i t s h o u l d b e of m a x i m u m i n t e r e s t t o n e w o r g a n i z a t i o n s w h i c h do n o t have a Failure Reporting, Analysis and Corrective Action System, or have one which is not well developed. The guide may also serve as a Training Manual or a source book for larger organizations. ]3.
Distinction Between Quality and Reliability Reporting.
Quality reporting records nonconforma n c e s to p u r c h a s e r e q u i r e m e n t s , manufactu r i n g s p e c i f i c a t i o n s a n d to w o r k m a n s h i p standards during a productls fabrication and assembly. These data are collected individually and in aggregate. Statistics a r e i n t e r m s of d e f e c t s p e r u n i t , p e r b a t c h or per lot and/or by process or assembly station.
3. Field Use Phase. Failure reporting, a n a l y s i s a n d c o r r e c t i v e a c t i o n i s o n e of ~" t h e f e w f u n c t i o n s to c a r r y o v e r i n t o t h e field use phase. T o a l a r g e e x t e n t , a l l of the other reliability functions and techniques may be monitored for effectiveness in this crucial phase. T h e o b j e c t i v e s of a R e l i a b i l i t y D o c u mentation System are summarized in Chart 1 where it becomes apparent that failure reporting, analysis and corrective action is an important function. The system for assuring proper accomplishm e n t of t h i s f u n c t i o n w i l l b e d e s c r i b e d i n t h e r e m a i n d e r of t h i s g u i d e .
Reliability reporting records r~onconf o r m a n c e s to p e r f o r m a n c e specifications of e n t i t i e s w h i c h a r e of a c c e p t a b l e q u a l i t y . These can include piece-parts, components, assemblies and/or the end product. Reliability reports can be prepared by a part or component supplier, during inhouse performance testing, during field performance testing and during operational use. Nonconformances can be collected individua)ly and in aggregate. Statistics a r e i n t d r m s of d e f e c t s p e r u n i t p e r operating time (and/or cycles) and defects per unit per calendar period. C.
The R eli-ability Documentation
Objectives System. A. B. C.
System
D.
Complete Reliability Documentation should appropriately cover three phases: (3)
Manufacturing Field Use 365
M.R. 17/3-- C
CHAR T 1 of a R e l i a b i l i t y
Documentation
Assess historical reliability performance. D e v e l o p p a t t e r n of d e f i c i e n c i e s . Provide engineering data for corrective action. Develop statistical data for 1) p a r t f a i l u r e r a t e s a n d d o w n t i m e 2) p a r t s e l e c t i o n s u i t a b i l i t y c r i t e r i a 3) p a r t a p p l i c a t i o n r e v i e w s 4) f u t u r e d e s i g n s a n d d e s i g n r e v i e w s 5) p r o d u c t i m p r o v e m e n t p r o g r a m s
366
Book Reviews
6) s p a r e s p r o v i s i o n i n g 7) l i f e c y c l e c o s t i n g E. F. G.
H.
Develop contractual conformance data Provide warranty information F u r n i s h s a f e t y and r e g u l a t o r y compliance data.
MACKINTOSH
YEABBOOK
OF
and
Assess
liability-claim
This is an extremely summarises a great
information.
useful booklet deal of experience.
G. W.A.D.
WEST
EUROPEAN
ELECTRONICS
DATA
1978 { P u b l i s h e d by M a c k i n t o s h P u b l i c a t i o n s L i m i t e d , T h e r e i s an i n c r e a s i n g d e m a n d f o r d a t a on e l e c t r o n i c s a n d , in p a r t i c u l a r , on microelectronics, a n d t h e F i f t h E d i t i o n of t h e M a c k i n t o s h Y e a r b o o k i s i n t e n d e d to present data summarising the electronics m a r k e t s a n d p r o d u c t i o n f i g u r e s in W e s t Europe. T h i s it d o e s e x t r e m e l y w e l l a n d the information contained has been gleaned b y a p a i n s t a k i n g s t u d y of E u r o p e a n p u b l i c a t i o n s and a l s o f r o m the M a c k i n t o s h c o n t a c t s in t h e i r " R e p o r t s for I n d u s t r y " . The e l e c t r o n i c s f i e l d c o v e r e d is wide and i n c l u d e s data p r o c e s s i n g , c o n t r o l and instrumentation, communications, telec o m m u n i c a t i o n s , c o n s u m e r e l e c t r o n i c s and active, passive and audio components. T h e b o o k c o n t a i n s 133 p a g e s , m a i n l y of s t a t i s t i c s , w h i c h c o v e r m a r k e t s a n d p r o d u c t i o n of e l e c t r o n i c s in 13 W e s t E u r o p e a n countries. The market estimates represent t h e t o t a l v o l u m e of p r o d u c t s c o n s u m e d in the country during a particular year,whether s h i p p e d by l o c a l s u p p l i e r s o r i m p o r t e d , a n d t h e s e f i g u r e s c a n b e u s e d to d e t e r m i n e t h e s t r e n g t h of d e m a n d f o r a p a r t i c u l a r p r o d u c t in the c o u n t r y c o n c e r n e d . The production statistics measure t h e l e v e l of a c t i v i t y of l o c a l m a n u f a c t u r e r s only, w h e t h e r s h i p p e d f o r h o m e c o n s u m p tion or exported and these figures represent t h e l e v e l of p o t o n t i a l f o r m a r k e t s a l e s of c o m p o n e n t s and can be u s e d as a b a s i s f o r i n p u t - o u t p u t a n a l y s i s.
L u t o n at £ 6 0 - 0 0 ) .
The countries covered are:AUSTRIA, BELGIUM, DENMARK, FINLAND, FRANCE, ITALY, NETHERLANDS, NORWAY, SPAIN, SWEDEN, SWITZERLAND, UNITED KINGDOM AND W E S T GER M A N Y . T h e d a t a on m a r k e t s a n d on p r o d u c t i o n o c c u p y s o m e 100 p a g e s . T h e r e i s a l s o s o m e u s e f u l i n f o r m a t i o n on t h e p r o d u c t i o n of c a r s and c o m m e r c i a l v e h i c l e s in W e s t E u r o p e a n d a l s o on w a t c h e s and clocks. Some general economic i n d i c a t o r s a r e g i v e n in A p p e n d i c e s , t o g e t h e r w i t h e m p l o y m e n t f i g u r e s in t h e electronics industries. A u s e f u l t r a n s l a t i o n of p r o d u c t h e a d i n g s i s a l s o g i v e n in E n g l i s h , F r e n c h G e r m a n and I t a l i a n . T h e m a i n p r o b l e m s of u n r e l i a b i l i t y of s t a t i s t i c s , l a c k of c o n t i n u i t y , c o m p r e h e n s i v e n e s s a n d c o m p a r a b i l i t y in t h e d a t a a v a i l a b l e h a v e b e e n d e a l t with by d i r e c t c o n t a c t with the c o u n t r i e s c o n c e r n e d and t h e r e is no doubt that the f i g u r e s p r o v i d e d a r e as r e a s o n a b l y a c c u r a t e as can be obtained. It i s t h e r e f o r e a m o s t v a l u a b l e s u r v e y of t h e e l e c t r o n i c s p r o d u c t i o n position and market survey which is a v a i l a b l e at t h e p r e s e n t t i m e .
G.W.A.D.
Vol. 17, pp. 365 to 366. PergamonPress. 1978.Printedin Great Britain
BOOK
R ELIABILITY (A R e l i a b i l i t y G u i d e to F a i l u r e
REVIEWS
R EPOR TING GUIDE
Reporting,
Analysis,
and Corrective
Action Systems)
Produced by the American Society for Quality Control, 161 W e s t W i s c o n s i n A v e n u e , M i l w a u k e e , W i s c o n s i n , 53203 1977 1. Design Phase. Documented reliability functions include mathematical modeling (reliability predictions, apportionments, growth models, assessments, e t c . , ), t r a d e off s t u d i e s , s t a t i s t i c a l t e s t p l a n n i n g , d e s i g n reviews, parts studies and reviews, evalu a t i o n of t e s t d a t a , f a i l u r e m o d e a n d e f f e c t s analysis, fault tree studies, and others. W h e t h e r a n y o r a l l of t h e s e f u n c t i o n s , o r p o r t i o n s of e a c h , a r e r e q u i r e d w o u l d d e p e n d on m a n y f a c t o r s i n c l u d i n g t y p e of i n d u s t r y , c o n t r a c t , p r o d u c t o r s i z e of c o m p a n y , e t c . The Reliability Failure Reporting, Analysis and Corrective Action System, should commence during the design phase as a p a r t of t h e o v e r a l l d o c u m e n t a t i o n e f f o r t .
This small booklet was prepared by the A S Q C C o m m i t t e e on R e l i a b i l i t y R e p o r t i n g and is intended as a specialised reliability assurance procedure for industry. The objectives and general comments are outlined below: A.
Objectives
T h e p r i m a r y o b j e c t i v e of t h i s d o c u m e n t i s to p r o v i d e b a s i c m e t h o d o l o g y a n d i d e a s for developing a Failure Reporting, Analysis a n d C o r r e c t i v e A c t i o n S y s t e m ~ s p a r t of a reliability program within an industrial firm. This guide provides an introduction upon which further study and planning efforts may be based.
2. Manufacturing Phase. S o m e of t h e above functions or techniques extend into the manufacturing phase which also involves additional reliability functions such as test monitoring, screening methods, special functional test process controls, and review of d e s i g n c h a n g e s . S o m e l e v e l of f o r m a l reliability failure reporting analysis and corrective action should be performed throughout the manufacturing phase.
The guide may be useful for a company of a n y s i z e , a l t h o u g h i t s h o u l d b e of m a x i m u m i n t e r e s t t o n e w o r g a n i z a t i o n s w h i c h do n o t have a Failure Reporting, Analysis and Corrective Action System, or have one which is not well developed. The guide may also serve as a Training Manual or a source book for larger organizations. ]3.
Distinction Between Quality and Reliability Reporting.
Quality reporting records nonconforma n c e s to p u r c h a s e r e q u i r e m e n t s , manufactu r i n g s p e c i f i c a t i o n s a n d to w o r k m a n s h i p standards during a productls fabrication and assembly. These data are collected individually and in aggregate. Statistics a r e i n t e r m s of d e f e c t s p e r u n i t , p e r b a t c h or per lot and/or by process or assembly station.
3. Field Use Phase. Failure reporting, a n a l y s i s a n d c o r r e c t i v e a c t i o n i s o n e of ~" t h e f e w f u n c t i o n s to c a r r y o v e r i n t o t h e field use phase. T o a l a r g e e x t e n t , a l l of the other reliability functions and techniques may be monitored for effectiveness in this crucial phase. T h e o b j e c t i v e s of a R e l i a b i l i t y D o c u mentation System are summarized in Chart 1 where it becomes apparent that failure reporting, analysis and corrective action is an important function. The system for assuring proper accomplishm e n t of t h i s f u n c t i o n w i l l b e d e s c r i b e d i n t h e r e m a i n d e r of t h i s g u i d e .
Reliability reporting records r~onconf o r m a n c e s to p e r f o r m a n c e specifications of e n t i t i e s w h i c h a r e of a c c e p t a b l e q u a l i t y . These can include piece-parts, components, assemblies and/or the end product. Reliability reports can be prepared by a part or component supplier, during inhouse performance testing, during field performance testing and during operational use. Nonconformances can be collected individua)ly and in aggregate. Statistics a r e i n t d r m s of d e f e c t s p e r u n i t p e r operating time (and/or cycles) and defects per unit per calendar period. C.
The R eli-ability Documentation
Objectives System. A. B. C.
System
D.
Complete Reliability Documentation should appropriately cover three phases: (3)
Manufacturing Field Use 365
M.R. 17/3-- C
CHAR T 1 of a R e l i a b i l i t y
Documentation
Assess historical reliability performance. D e v e l o p p a t t e r n of d e f i c i e n c i e s . Provide engineering data for corrective action. Develop statistical data for 1) p a r t f a i l u r e r a t e s a n d d o w n t i m e 2) p a r t s e l e c t i o n s u i t a b i l i t y c r i t e r i a 3) p a r t a p p l i c a t i o n r e v i e w s 4) f u t u r e d e s i g n s a n d d e s i g n r e v i e w s 5) p r o d u c t i m p r o v e m e n t p r o g r a m s
366
Book Reviews
6) s p a r e s p r o v i s i o n i n g 7) l i f e c y c l e c o s t i n g E. F. G.
H.
Develop contractual conformance data Provide warranty information F u r n i s h s a f e t y and r e g u l a t o r y compliance data.
MACKINTOSH
YEABBOOK
OF
and
Assess
liability-claim
This is an extremely summarises a great
information.
useful booklet deal of experience.
G. W.A.D.
WEST
EUROPEAN
ELECTRONICS
DATA
1978 { P u b l i s h e d by M a c k i n t o s h P u b l i c a t i o n s L i m i t e d , T h e r e i s an i n c r e a s i n g d e m a n d f o r d a t a on e l e c t r o n i c s a n d , in p a r t i c u l a r , on microelectronics, a n d t h e F i f t h E d i t i o n of t h e M a c k i n t o s h Y e a r b o o k i s i n t e n d e d to present data summarising the electronics m a r k e t s a n d p r o d u c t i o n f i g u r e s in W e s t Europe. T h i s it d o e s e x t r e m e l y w e l l a n d the information contained has been gleaned b y a p a i n s t a k i n g s t u d y of E u r o p e a n p u b l i c a t i o n s and a l s o f r o m the M a c k i n t o s h c o n t a c t s in t h e i r " R e p o r t s for I n d u s t r y " . The e l e c t r o n i c s f i e l d c o v e r e d is wide and i n c l u d e s data p r o c e s s i n g , c o n t r o l and instrumentation, communications, telec o m m u n i c a t i o n s , c o n s u m e r e l e c t r o n i c s and active, passive and audio components. T h e b o o k c o n t a i n s 133 p a g e s , m a i n l y of s t a t i s t i c s , w h i c h c o v e r m a r k e t s a n d p r o d u c t i o n of e l e c t r o n i c s in 13 W e s t E u r o p e a n countries. The market estimates represent t h e t o t a l v o l u m e of p r o d u c t s c o n s u m e d in the country during a particular year,whether s h i p p e d by l o c a l s u p p l i e r s o r i m p o r t e d , a n d t h e s e f i g u r e s c a n b e u s e d to d e t e r m i n e t h e s t r e n g t h of d e m a n d f o r a p a r t i c u l a r p r o d u c t in the c o u n t r y c o n c e r n e d . The production statistics measure t h e l e v e l of a c t i v i t y of l o c a l m a n u f a c t u r e r s only, w h e t h e r s h i p p e d f o r h o m e c o n s u m p tion or exported and these figures represent t h e l e v e l of p o t o n t i a l f o r m a r k e t s a l e s of c o m p o n e n t s and can be u s e d as a b a s i s f o r i n p u t - o u t p u t a n a l y s i s.
L u t o n at £ 6 0 - 0 0 ) .
The countries covered are:AUSTRIA, BELGIUM, DENMARK, FINLAND, FRANCE, ITALY, NETHERLANDS, NORWAY, SPAIN, SWEDEN, SWITZERLAND, UNITED KINGDOM AND W E S T GER M A N Y . T h e d a t a on m a r k e t s a n d on p r o d u c t i o n o c c u p y s o m e 100 p a g e s . T h e r e i s a l s o s o m e u s e f u l i n f o r m a t i o n on t h e p r o d u c t i o n of c a r s and c o m m e r c i a l v e h i c l e s in W e s t E u r o p e a n d a l s o on w a t c h e s and clocks. Some general economic i n d i c a t o r s a r e g i v e n in A p p e n d i c e s , t o g e t h e r w i t h e m p l o y m e n t f i g u r e s in t h e electronics industries. A u s e f u l t r a n s l a t i o n of p r o d u c t h e a d i n g s i s a l s o g i v e n in E n g l i s h , F r e n c h G e r m a n and I t a l i a n . T h e m a i n p r o b l e m s of u n r e l i a b i l i t y of s t a t i s t i c s , l a c k of c o n t i n u i t y , c o m p r e h e n s i v e n e s s a n d c o m p a r a b i l i t y in t h e d a t a a v a i l a b l e h a v e b e e n d e a l t with by d i r e c t c o n t a c t with the c o u n t r i e s c o n c e r n e d and t h e r e is no doubt that the f i g u r e s p r o v i d e d a r e as r e a s o n a b l y a c c u r a t e as can be obtained. It i s t h e r e f o r e a m o s t v a l u a b l e s u r v e y of t h e e l e c t r o n i c s p r o d u c t i o n position and market survey which is a v a i l a b l e at t h e p r e s e n t t i m e .
G.W.A.D.