Five Facets of Performance Testing

Transcription

1 Five Facets of Performance Testing What is Performance Testing Scope of testing Purposes Tools 1) Verification vs Validation 2) Simulation/Life Testing 3) Testing to Failure 4) Parameter/Feature Testing 5) How to synthesis a performance test Failure is good Sources of Damage

2 Scope and Purposes Performance - The way in which a product functions. Applies to all products that have an expected function and duration. Types of Performance: Function: the operation of a product Time: how fast or how long something functions Stress/noise factors: source of damage/interference to a product Accuracy: how close to the desired value the function is Precision: how repeatable the function is Information Goal: The key piece of information about the product that is needed to move the process forward.

3 Performance Testing-Tools Stress, Time and Probability

4 Infant Mortality: Production errors, material flaws Constant Failure Rate: Random Incident, abusive conditions Wear out mechanism: Fatigue, damage accumulation

5

6 Stress Probability 1 Life 2 Life Time Market Release Verification Life Test Development Concept Feasibility Service Conditions

7 Stress Market Release Verification Development Concept Feasibility Probability 1 Life 2 Life Time Stress Stress Life Test FSLT Stress Stress Stress Service Conditions Stress

8 Stress Market Release Verification Development Concept Feasibility Probability 1 Life 2 Life Step Stress Time Stress Stress Life Test FSLT Stress Stress Stress Service Conditions Stress

12 Environmental Testing Exposing materials, components, subsystems or full product to conditions that may be found in their end-use environments. Temperature (Hot, Cold, Ramp) Humidity, non-condensing Humidity, Condensing Humidity Radiated (UV or Heat Lamp) Sunlight (Carbon Arc and Xenon exposure) Salt mist, Salt Spray Dust Chemical Attack In order to test their ENDURANCE

13 Material Testing Measuring the Physical, Chemical or Mechanical properties of material Material can be raw, fabricated into a product, taken from field returns, etc. Physical Properties Color, density, thermal expansion, Glass Transition Point Chemical Properties Molecular make up Molecular structure (micro structure) Contaminants Flammability Melt Point Mechanical Properties Tensile strength, elongation, modulus, flex modulus, HDT, hardness, abrasion, compression, tear, peel, pull, impact

14 Mechanical/Durability Testing Exposing a product to cyclic mechanical loads in order to measure or demonstrate life. Measure or Demonstrate: Measuring life means running to failure Demonstrate life means running to a target with no failures (more common) This type of test is often done in conjunction with Environmental exposures (Temperature, Relative Humidity, Dust, Ultraviolet)

15 Vibration Testing Exposing a product to vibration energy in order to measure or demonstrate life. Measure or Demonstrate: Measuring life means running to failure Demonstrate life means running to a target with no failures (more common) This type of test is often done in conjunction with Environmental exposures (Temperature, Relative Humidity, Dust, Ultraviolet) and functional testing (while the product is functioning) Vibration can be: Single-axis (most common) sometimes called 3-axis but only one axis at a time Six Axis or 6 dof (degree of freedom). Often a Data Acquisition is conducted before the actual testing.

16 Electrical Testing Measure a product s performance at the system, subsystem or component level. Measurements can include Current, voltage and power draw Audio performance Product functionality Temperature rise in system component or location Resistance or Impedance changes This type of test is often done in conjunction with Environmental exposures, vibration and durability (Temperature, Relative Humidity, Dust, Ultraviolet)

17 MIL-STD 810

18 Lighting Testing Light quality, brightness, color, pattern and durability. Automotive, Consumer, Airport Only approved lab - Airport Lighting Equipment Certification Program Testing to FAA, ICAO, IEC, NATO, and military To ensure that airport lighting equipment meets the applicable FAA standards for safety, performance, quality and standardization Where: Cortland, Grand Rapids.

19 The Intertek Quality & Performance Mark

20 How do you show that you re the best choice? How do you translate your key differentiators to your customer as they make their purchase decision? How do you help customers navigate product features? How do you justify pricing for on-the-spot pricing comparisons? How do you show your product has integrity?

21 In a world of product recalls, feature creep and supply chain issues, quality is top of mind. Intertek s Quality & Performance Mark has been created to help our customers demonstrate their commitment to quality. To consumers the mark is third party, validated proof that a product meets or exceeds key purchasing criteria.

22 What Goes Into the Mark? Third party verified testing This line will read: Independently tested for Quality and Performance

23 What Goes Into the Mark? Baseline quality tests (1 to 5 tests are performed to expert specifications) Durability: Evaluates range of conditions product can handle and continue to function Functionality: Performance of product s functions & features under normal use Life Cycle: Evaluates how long product lasts in normal operation Usability: Ease of use for intended tasks Workmanship: Verifies product s physical characteristics for high quality fabrication Third party verified testing Independently tested for Quality and Performance

24 What Goes Into the Mark? Baseline quality tests (1 to 5 tests are performed to expert specifications) Durability: Evaluates range of conditions product can handle and continue to function Functionality: Performance of product s functions & features under normal use Life Cycle: Evaluates how long product lasts in normal operation Usability: Ease of use for intended tasks Workmanship: Verifies product s physical characteristics for high quality fabrication Third party verified testing Independently tested for Quality and Performance Above and Beyond tests Manufacturers Claims: (Optional 6 th test highlights manufacturer s differentiators. Test results on swing tags, POP, website)

25 What Goes Into the Mark? Baseline quality tests (1 to 5 tests are performed to expert specifications) Durability: Evaluates range of conditions product can handle and continue to function Functionality: Performance of product s functions & features under normal use Life Cycle: Evaluates how long product lasts in normal operation Usability: Ease of use for intended tasks Workmanship: Verifies product s physical characteristics for high quality fabrication Third party verified testing Above and Beyond tests Manufacturers Claims: (Optional 6 th test highlights manufacturer s differentiators. Test results on swing tags, POP, website) Independently tested for Quality and Performance Researchable results Model & certification # s Intertek website link

26 Verification Vs. Validation Verification: Proving that the out put of the design process achieved the desired parameters: Did we hit the target? Validation: Proving that the product is capable of meeting the requirements for the intended use. Do we have the right target? Example: Tightening Torque Parameters: Torque on a Fastener Verification Can the device achieve the correct torque? Does the production process provide the correct torque? Validation does the product perform as intended with the target torque: was it the right torque to begin with?

27 Simulation Life Testing Simulation- Goal is to simulate end use conditions precisly in the laboratory setting Requires: Knowing with a high degree of accuracy what the end use conditions are. Knowing what is ment by failure. Knowing what the end usage rate is. Life Testing Simulate the end use conditions Demonstrate or measure the life of the product.

28 End Use Conditions What are the end use conditions? What do you expect the product to see? Make sure to ask about conditions in four areas Electrical Mechanical Environmental Chemical Quantify: Value, range Duration, usage Modes: In Use Storage Shipping Maintenance Voltage Current Pressure Velocity Flow rate Force Duty Cycle Temperature Hot, Cold, Ramp RH% Sunlight Contaminants

29 Demonstrate Life Vs. Measure Life Demonstrate Beat a target value. Typically a truncated test. Shorter and easier Reliability and Confidence only. Measure Must go to End of life Measurable point Unknown time period Full reliability function.

30 MTBF Life Test Mean Time Between Failures MTBF = T / (ln ( 1-Nf/Ndut)) Delta T = Change in Time Nf = Number of failed units Ndut = Total number of units under test OR MTBF must be 2000 hrs or more Ndut = 20 samples available Test for 2000*(ln(1-1/20)) = 102 hrs with no more then 1 failure Test for 2000*(ln(1-2/20)) =211 hrs with nor more then 2 failures

31 Single Stress Model Determine stress to apply Determine service levels Estimate maximum levels Test at maximum levels until half fail Choose a lower stress level Test until half fail Spring Force 2 N 200 N

32 Single Stress Model Expected 95% R Life Life (Cycles) Life Test one Test two Test three Push Force

33 Acceleration and Shape Coefficients The rate at which life is shortened by the increase in stress is expressed by a coefficient in the math model. The shape of the distribution is expressed as a coefficient in the math model.

34 Example Math Models Arrhenius-Weibull Model F(t;T) = 1 -exp{-[t exp[-γ 0 -(γ 1 /T)]] β Power-Lognormal Model F(t,V)=Φ{[log(t)-µ (x)]/σ} Cox (Proporational Hazards) Model R 0 (t) = exp[- 0 t h 0 (t)dt] Capacitor dielectric or insulating tape Page 82 Metal fatigue Page 88 ASTM STP 744 Biomedical Page 104 Cox and Oakes (1984), Analysis of Survival Data All models from Accelerated Testing, Wayne Nelson, 1990 Wnconsult@aol.com

35 Testing to Failure Why? Find and fix the root cause of failure Faster and easier to get meaningful data How? Elevated sources of stress Multiple sources of stress

36 Typical Procedure in Failure Analysis Inspection Visual, Optical microscope, Electronic microscope. e.g. Fractography Material identification Atomic/Molecule, Chemical composition, Microstructure, Contamination, e.g. Infrared Spectroscopy Property evaluation Chemical, Physical, Mechanical, Thermal, Electrical, e.g Tensile Test Cognition and recommendation

37 Factors of Failures Metals Plastics Plating Glasses Adhesives Environmental Material Selection Design Manufacturing Frame Interior Components Electronics Structural Functional Decorative

38 Where is Failure Analysis Typically Utilized? Primary process problems: Material flows incorrectly through process Visual defects observed Performance parameters do not meet expectations (or specifications) Secondary process problems: Breakage or irregularities that interfere with assembly. Visual defects observed Adhesion problems with mating components (blocking, welding, or adhesion failures depending on desired assembly behavior) Failure due to contact with incompatible materials Transport related failures: Breakage Contamination from environment (dirt, transfer of materials from dunnage, moisture, etc.) Heat or vibration damage End-use failures: Incompatibilities with end-use environments Abuse Slow failures (repeated cycling, oxidation, fatigue, etc.) from processes or environments unanticipated in design Other failures observed in enduse but not detected in previous production or transport processes

39 If all failure modes were intuitive Tests would simulate what we expect. Tests would instrument for what we expect. Leads to warranty The human ability to ignore the unexpected can be profound.

40 Margin Discovery Process... Lower Destruct Limit Lower Operating Limit Product Specs Upper Operating Limit Upper Destruct Limit Operating Margin Operating Margin Destruct Margin Destruct Margin Stress

41 2. XXXXXXX Sample XXXXXXX 3. Table 4. Sample Hot Survey XXXXXXX Sample 1 XXXXXXX Sample 1 XXXXXXX Sample 1 XXXXXXX Sample 1 XXXXXXX Sample 1 XXXXXXX Sample 1 XXXXXXX Sample 1 XXXXXXX Sample 1 XXXXXXX Sample xiv sample reads ohms. Soft Failure Vpdiag function check. Boot Script error. Observation. TSDSP function check. Functioned properly Vpdiag function check. Boot Script error. Observation. TSDSP function check. Functioned properly Vpdiag function check. Boot Script error. Observation. TSDSP function check. Functioned properly Vpdiag function check. Boot Script error. Observation. TSDSP function check. Functioned properly Vpdiag function check. Boot Script error. Observation. TSDSP function check. Functioned properly Vpdiag function check. Boot Script error. Observation. TSDSP function check. Functioned properly Vpdiag function check. DSP error code 707. Observation. Boot Script error. Observation. TSDSP function check. Functioned properly Vpdiag function check. DSP error code 707. Observation. Boot Script error. Observation. TSDSP function check. Functioned properly Vpdiag function check. DSP error code 707. Observation. Boot Script error. Observation. TSDSP function check. Functioned properly Vpdiag function check. Boot Script error. Observation. TSDSP function check. Functioned properly Mounted Sample in chamber to start Step 12. Sample would not turn on. Removed sample from chamber and made several attempts to turn sample on. Sample never turned on again. Hard Failure.

42 SUMMARY OF THE HOT SURVEY After completing the function checks for Step 11, Sample 1 was placed back in the chamber for Step 12, and power was connected to the sample, but the sample would not turn on. Several attempts were made to turn on the sample before it was removed from testing and replaced with Sample 2.

43 Table 5. Thermal Cycle (Transition) Table 5. Thermal Cycle (Transition) Step Sample Time in minutes Temperature ( o C) 1A XXXXXXX Sample 2 1B A XXXXXXX B Sample A XXXXXXX B Sample A XXXXXXX B Sample Observations Vpdiag function check. DSP error code 707. Observation. Boot Script error. Observation. TSDSP function check. Functioned properly Vpdiag function check. Boot Script error. Observation. TSDSP function check. Functioned properly Vpdiag function check. Boot Script error. Observation. TSDSP function check. Functioned properly Vpdiag function check. Boot Script error. Observation. TSDSP function check. 7xiv sample reads ohms. Soft Failure

44 SUMMARY OF THE THERMAL TRANSITION SURVEY Sample 2 only exhibited one (1) Soft Failure during the Thermal Transition Survey After completing Step 4. During 7xiv of the TSDSP function checks, the sample was reading ohms.

45 Table 6. Vibration Step Samples XXXXXXX Sample 2 XXXXXXX Sample 2 XXXXXXX Sample 2 XXXXXXX Sample 2 XXXXXXX Sample 2 XXXXXXX Sample 2 Time in minutes Vibration (G s) Observations Vpdiag function check. Boot Script error. Observation. TSDSP function check. 7xiv sample reads ohms. Soft Failure Vpdiag function check. DSP error code 707. Observation. Boot Script error. Observation. TSDSP function check. 7xiv sample reads ohms. Soft Failure Vpdiag function check. DSP error code 707. Observation. Boot Script error. Observation. TSDSP function check. Functioned properly Vpdiag function check. Boot Script error. Observation. TSDSP function check. 7xiv sample reads ohms. Hard Failure Vpdiag function check. Boot Script error. Observation. TSDSP function check. 7xiv sample reads ohms. Hard Failure Vpdiag function check. Boot Script error. Observation. TSDSP function check. 7xiv sample reads ohms. Hard Failure Following step 7 component C904 was separated from the PCB. Hard Failure. Reference Appendix A Figure 3 for photograph. Table 6. Vibration 7. XXXXXXX Sample Vpdiag function check. DSP error code 705. Hard Failure Boot script error. Observation. TSDSP function check. 7xiv sample reads ohms. Hard Failure Vpdiag function check. DSP error code 705. Hard failure Boot Script error. Observation. 8. XXXXXXX Sample TSDSP function check. After selecting the TSDSP icon to launch the program a window popped up displaying DSP is not present. Hard Failure. 5iii through 5xxxi an error message is displayed that reads EEPROM Read Failure. Sample stopped responding. Reset sample and the display was solid blue. TSDSP function checks could not be finished. Hard Failure. Continued the vibration surveys.

46 Table 6. Vibration Cont.: Table 6. Vibration Cont.: Step Samples Time in minutes Vibration (G s) Observations After completing Step 9 both CF card were dislodged 9. XXXXXXX Sample Vpdiag function check DSP error code 705. Hard Failure Boot script error. Observation.. TSDSP function check. The display is solid blue could not perform function checks. After completing Step 10 both CF card were dislodged 10. XXXXXXX Sample Vpdiag function check DSP error code 705. Hard Failure Boot script error. Observation. CF2 error code 703. Hard Failure TSDSP function check. The display is solid blue could not perform function checks.

47 SUMMARY OF THE VIBRATION SURVEY During the Vibration Survey, sample 2 had compact flash cards installed in both Slot 1, and Slot 2 bays. Sample 2 exhibited the same Hard Failure multiple times during the TSDSP function check 7xiv. The sample was out of tolerance. Sample 2 exhibited a Hard Failure following Step 7 component C904 separated from the circuit board. Reference Appendix A Figure 3. Sample 2 exhibited a Hard Failure after completing Step 8. After selecting the TSDSP icon for the TSDSP function check a window popped up displaying an error message DSP is not present. The error window was closed by selecting ok and the functional checks were continued. During TSDSP 5iii, another window popped up displaying an error message EEPROM Read Failure. This message showed up every time the Select Show ADC Counts was selected. The Vibration Survey was continued and the sample was removed from testing after completing the Vibration Survey. Sample 2 exhibited a Hard Failure after completing Step 9 and Step 10. The LCD screen is solid blue and was unable to perform the TSDSP function check.

48 How to design an Hypothesis: A good design accumulates damage (wears out) uniformly throughout the product Screen Yellow Button stick Fatigue Button bounce Lance Electronics Software Batteries Interface

49 How to design an Hypothesis: A good design accumulates damage (wears out) uniformly throughout the product To test the hypothesis all of the sources of damage (stress sources) should be identified

50 How to design an What can break (wear out) the product? Operation Dust/Contaminant Turning on/off Voltage variations Hot temperature Cold temperature Dropping Pressure Changes Cleaning Temperature Ramp rates

51 How to design an Hypothesis: A good design accumulates damage (wears out) uniformly throughout the product To test the hypothesis all of the sources of damage (stress sources) should be identified Service conditions of each stress source Destruct limit of each stress source

52 Example: Test Profile (C, C) Stress Amplitude C (hot) C (cold) other(s) grms V Expected Maximum Service Conditions 1 10 Expected Maximum Test Conditions (maximum design or test equipment capability) (grms, V) Stress Amplitude Test Level

53 Example Test Plan Random Target Test Conditions: Environmental Chamber Temperature Relative Humidity Slam Inducing Random Vibration Door Assembly Slams Estimated Number of units = C C C/minute % grms Maximum Service = ,000 Maximum Test = ,000 Number of Steps = EVENT LOG TEST PLAN: Event Number Test Date Duration fixed level fixed dwell length length (minutes) Slam Slam Environmental Chamber Temperature Relative Inducing Inducing Humidity Random Random Minimum Maximum Ramp Rate Vibration Vibration C C C/minute % RH g g Op-0 n.a. n.a. n.a. n.a. n.a. n.a. n.a ,000 Op n.a. n.a. n.a. n.a. n.a. n.a ,000 Op n.a. n.a. n.a. n.a. n.a. n.a ,000 Op n.a. n.a. n.a. n.a. n.a. n.a ,000 Op n.a. n.a. n.a. n.a. n.a. n.a ,000 Op n.a. n.a. n.a. n.a. n.a. n.a ,000 Op n.a. n.a. n.a. n.a. n.a. n.a ,000 Op n.a. n.a. n.a. n.a. n.a. n.a ,000 Op n.a. n.a. n.a. n.a. n.a. n.a ,000 Op n.a. n.a. n.a. n.a. n.a. n.a ,000 Op n.a. n.a. n.a. n.a. n.a. n.a. 5/20/02 5/21/02 5/22/02 5/23/02 5/24/02

54 Example Test Plan

55 Parameter/Feature Testing Tests to check on particular parameters or features that are traecable to specific failure modes.

56 Design Failure Modes and Effects Analysis A disciplined approach for tracking all of the POTENTIAL failure modes in a design, their causes, effects prevention and detection.

57 DFMEA How Bad is it? What can be done? Design Changes What are the Functions, Features or Requirements? What can go wrong? What are the Effect's)? What are the Cause's)? How often does it happen? How good is this method at preventing and/or detecting Process Changes Special Controls Changes to Standards, Procedures or Guides No Function Partial/Over/ Degradation Function Unintended Function How can this be prevented and detected?

58 DFMEA How Bad is it? What can be done? Design Changes What are the Functions, Features or Requirements? What can go wrong? What are the Effect's)? What are the Cause's)? How often does it happen? How good is this method at preventing and/or detecting Process Changes Special Controls Changes to Standards, Procedures or Guides No Function Partial/Over/ Degradation Function Unintended Function How can this be prevented and detected?

59 DFMEA Function Item steam generator Potential Failure Mode plug Potential Effect(s) of failure diminished steam production Severity 10 Criticality 10 Potential Causes(s) / Mechanism(s) of Failure 8calium build up Occurrence Current Design Controls Prevention Detection Inspection periodicly during 7operation Detectability RPN 5600 Recommended Action n/a Responsibility Target Date With permission from: accompanying CD, Accelerated Testing and Validation Management, Alex Porter Elsevier

60 DFMEA Function Item Handle Potential Failure Mode split in grip insert area Potential Effect(s) of failure Severity Criticality Potential Causes(s) / Mechanism(s) of Failure Loss of rubber Impact resistant grip 3 3 impact 8 plastic Occurrence Current Design Controls Prevention Detection Detectability Recommended Action FEA model of impact from 3 likely directions RPN Responsibility Target Date 3 3 thermal cycle 8 thermal set plastic with stable material properties from -30 deg C to 100 deg C Thermal cycle testing chemically inert chemical attack/material plastic to mild incompatibility 8 alkali's and acids chemical exposures fatigue 8 FEA model of maximum loading: stress must be below 1/3 material load testing to yield. verify models Sharp radius 5 All design radius must be greater then 1 mm 2 90

61 Hypothesis Matrix from accompanying CD ACCELERATED TESTING AND VALIDATION with permission Mechanism of Failure Potential Failure Vibration High Temperature Cold Temperature Temperature Ramp Humidity Salt air Torque Vibration will not High Temperature will Cold Temperature will Temperature Ramp will Humidity will not Salt air will not cause Torque will not cause Filiment loss of continuity cause Filiment loss of continuity not cause Filiment loss of continuity not cause Filiment loss of continuity not cause Filiment loss of continuity cause Filiment loss of continuity Filiment loss of continuity Filiment loss of continuity CM Propritary life durability test CM Propritary life durability test CM Propritary life durability test CM Propritary life durability test CM Propritary life durability test N/A N/a Corrosion Vibration will not cause Corrosion High Temperature will not cause Corrosion Cold Temperature will not cause Corrosion Temperature Ramp will not cause Corrosion Humidity will not cause Corrosion Salt air will not cause Corrosion Torque will not cause Corrosion N/A Vibration will not cause Seal loss between glass and Seal loss between glass and base base ASTM cyclic Corrosion Propritary life durability test High Temperature will not cause Seal loss between glass and base ASTM cyclic Corrosion Propritary life durability test Cold Temperature will not cause Seal loss between glass and base ASTM cyclic Corrosion Propritary life durability test Temperature Ramp will not cause Seal loss between glass and base ASTM cyclic Corrosion Propritary life durability test Humidity will not cause Seal loss between glass and base ASTM cyclic Corrosion Propritary life durability test N/a Salt air will not cause Seal loss between glass and base Torque will not cause Seal loss between glass and base Base Thread does not match receptical CM Propritary life durability test Vibration will not cause Base Thread does not match receptical CM Propritary life durability test High Temperature will not cause Base Thread does not match receptical CM Propritary life durability test Cold Temperature will not cause Base Thread does not match receptical CM Propritary life durability test Temperature Ramp will not cause Base Thread does not match receptical CM Propritary life durability test Humidity will not cause Base Thread does not match receptical Propritary life durability test Salt air will not cause Base Thread does not match receptical CM Propritary life durability test Torque will not cause Base Thread does not match receptical Functional Test N/A N/A N/A N/A N/A N/A N/A Base di-electric allows current flow Vibration will not cause Base di-electric allows current flow Propritary life durability test High Temperature will not cause Base dielectric allows current flow Propritary life durability test Cold Temperature will not cause Base dielectric allows current flow Propritary life durability test Temperature Ramp will not cause Base dielectric allows current flow Propritary life durability test Humidity will not cause Base di-electric allows current flow Propritary life durability test Salt air will not cause Base di-electric allows current flow Propritary life durability test N/A Torque will not cause Base di-electric allows current flow

62 Function Item Potential Failure Mode Potential Effect(s) of failure Severity Criticality Potential Causes(s) / Mechanism(s) of Failure Occurrence Current Design Controls Prevention Detection Detectability RPN Recommended Action Responsibility Target Date Potential Effect(s) of failure: What are the results of the failure Potential on the Recommended Target Responsibility: Date: When function Causes: or Key behavior Action: Who will will Current Design Controls: of the Functional product. Item: The Often Potential Failure word the What the recommended Mode: here failure is action take responsibility mechanism. itself should action not be for What the visible current but functional feature the functional or effect will be apparent. For Key word is POTENTIAL. What taken be can to implementing completed. break improve the the the design feature example from the recommended design effort to prevent a sealed bearing may have excessive What failure modes could product. PRN. action. the design from failing, BOM (Bill wear, of Material) but the failure is not visible externally. The the feature experience. and how will the success effect of increased fiction is a slowing of the Source for this is be detected. motor or an increase in the power draw. The engineering experience, effects are key to designing instrumentation and warranty data and pure operational checks for tests to verify the imagination. existence of failure modes.

63 THE WHOLE KEY TO MAKING THIS VALUABLE!!!!

64 Function Item Potential Failure Mode Potential Effect(s) of failure Severity Criticality Potential Causes(s) / Mechanism(s) of Failure Occurrence Current Design Controls Prevention Detection Detectability RPN Recommended Action Responsibility Target Date Traceability: (Drop dead rule) Can a reasonably educated engineer, regardless of experience, read what is written and apply the knowledge?

65 Function Item Potential Failure Mode Potential Effect(s) of failure Severity Criticality Potential Causes(s) / Mechanism(s) of Failure Occurrence Current Design Controls Prevention Detection Detectability RPN Recommended Action Responsibility Target Date Criticality: Severity: Detectability: Occurrence: RPN: How Risk critical How bad are How Priority What to the well is the the function of the device consequences can Number the likelihood failure is the of failure. of the mode multiple be of is the detected all failure three mode. failure. if or it exists. four ratings

66 Effect Hazardous without warning Hazardous with warning Very High High Moderate Low Very Low Minor Very Minor None Example Severity Evaluation Criteria Criteria: Severity of Effect Very high severity ranking when a potential failure mode effects desired function and/or noncompliance with regulations without warning Very high severity ranking when a potential failure mode effects desired function and/or noncompliance with regulations without warning Loss of primary function Reduced level of performance Operational but convenience or ease of use is not functional. Operational but convenience or ease of use has reduced function Aesthetics, workmanship defect noticed by more then 75% of users. Aesthetics, workmanship defect noticed by more then 50% of users. Aesthetics, workmanship defect noticed by less then 25% of users. No discernible effect Ranking

67 Function Item Potential Failure Mode Potential Effect(s) of failure Severity Criticality Potential Causes(s) / Mechanism(s) of Failure Occurrence Current Design Controls Prevention Detection Detectability RPN Recommended Action Responsibility Target Date Classification: This column may be used to classify any special product characteristics: Examples: Regulated, Europe Only, CEO s Pet, Marketing Request, OEM Mandate

68 Examples DFMEA Occurrence Evaluation Criteria Probability of Failure Very High: Persistent Failures Likely Failure Rates over Design Life >100 per thousand 50 per thousand 10 9 Ranking High: Frequent Failures Moderate: Occasional Failures Low: Relatively Few Failures Remote: Failure is Unlikely 20 per Thousand 10 per Thousand 5 per Thousand 2 per Thousand 1 per Thousand 0.5 per Thousand 0.1 per Thousand <0.01 per Thousand

69 Detection Absolute Uncertainty Very Remote Remote Very Low Low Moderate Moderately High High Very High Almost Certain Example Detection Evaluation Criteria Criteria: Likelihood of Detection by Design Control or Detection Method Controls will not and/or can not detect a potential cause/mechanism and subsequent failure mode; or there is no control Very remote chance the control will detect a potential cause/mechanism and subsequent failure mode. Remote chance the control will detect a potential cause/mechanism and subsequent failure mode. Very low chance the control will detect a potential cause/mechanism and subsequent failure mode. Low chance the control will detect a potential cause/mechanism and subsequent failure mode. Moderate chance the control will detect a potential cause/mechanism and subsequent failure mode. Moderately High chance the control will detect a potential cause/mechanism and subsequent failure mode. High chance the control will detect a potential cause/mechanism and subsequent failure mode. Very High chance the control will detect a potential cause/mechanism and subsequent failure mode. Almost Certain chance the control will detect a potential cause/mechanism and subsequent failure mode Ranking

70 Synthesis a Performanc Test Plan Or Can you get to zero field failures?

71 DFMEA Function Item Handle Potential Failure Mode split in grip insert area Potential Effect(s) of failure Severity Criticality Potential Causes(s) / Mechanism(s) of Failure Loss of rubber Impact resistant grip 3 3 impact 8 plastic Occurrence Current Design Controls Prevention Detection Detectability Recommended Action FEA model of impact from 3 likely directions RPN Responsibility Target Date 3 3 thermal cycle 8 thermal set plastic with stable material properties from -30 deg C to 100 deg C Thermal cycle testing chemically inert chemical attack/material plastic to mild incompatibility 8 alkali's and acids chemical exposures fatigue 8 FEA model of maximum loading: stress must be below 1/3 material load testing to yield. verify models Sharp radius 5 All design radius must be greater then 1 mm 2 90

72 Hypothesis Matrix from ACCELERATED TESTING AND VALIDATION with permission Mechanism of Failure Potential Failure Vibration High Temperature Cold Temperature Temperature Ramp Humidity Salt air Torque Vibration will not High Temperature will Cold Temperature will Temperature Ramp will Humidity will not Salt air will not cause Torque will not cause Filiment loss of continuity cause Filiment loss of continuity not cause Filiment loss of continuity not cause Filiment loss of continuity not cause Filiment loss of continuity cause Filiment loss of continuity Filiment loss of continuity Filiment loss of continuity CM Propritary life durability test CM Propritary life durability test CM Propritary life durability test CM Propritary life durability test CM Propritary life durability test N/A N/a Corrosion Vibration will not cause Corrosion High Temperature will not cause Corrosion Cold Temperature will not cause Corrosion Temperature Ramp will not cause Corrosion Humidity will not cause Corrosion Salt air will not cause Corrosion Torque will not cause Corrosion N/A Vibration will not cause Seal loss between glass and Seal loss between glass and base base ASTM cyclic Corrosion Propritary life durability test High Temperature will not cause Seal loss between glass and base ASTM cyclic Corrosion Propritary life durability test Cold Temperature will not cause Seal loss between glass and base ASTM cyclic Corrosion Propritary life durability test Temperature Ramp will not cause Seal loss between glass and base ASTM cyclic Corrosion Propritary life durability test Humidity will not cause Seal loss between glass and base ASTM cyclic Corrosion Propritary life durability test N/a Salt air will not cause Seal loss between glass and base Torque will not cause Seal loss between glass and base Base Thread does not match receptical CM Propritary life durability test Vibration will not cause Base Thread does not match receptical CM Propritary life durability test High Temperature will not cause Base Thread does not match receptical CM Propritary life durability test Cold Temperature will not cause Base Thread does not match receptical CM Propritary life durability test Temperature Ramp will not cause Base Thread does not match receptical CM Propritary life durability test Humidity will not cause Base Thread does not match receptical Propritary life durability test Salt air will not cause Base Thread does not match receptical CM Propritary life durability test Torque will not cause Base Thread does not match receptical Functional Test N/A N/A N/A N/A N/A N/A N/A Base di-electric allows current flow High Temperature will Vibration will not not cause Base dielectric allows current cause Base di-electric allows current flow flow Cold Temperature will not cause Base dielectric allows current flow Temperature Ramp will not cause Base dielectric allows current flow Humidity will not cause Base di-electric allows current flow Salt air will not cause Base di-electric allows current flow Torque will not cause Base di-electric allows current flow

73 Information Timing vs Accuracy from ACCELERATED TESTING AND VALIDATION with permission Research Feasibility Developme nt/ design Design Material Sample Compatibility Test- Low Dectability Cost Risk validation ramp Production Production validation Production Service on Production intent with all stresses that could cause elctrolytic reaction - High Detectability Cost Risk Mitigate The Risk Sweet Spots Risk, Cost and Benefit 0 Research Feasibility Development/ design Design validation Production ramp Production validation Production Service Material Sample Compatibility Test- Low Dectability Risk on Production intent with all stresses that could cause elctrolytic reaction - High Detectability

74 Hypothesis Matrix Three Benefits of HM 1) Double-check on the brainstorming in the DFMEA DFMEA is a left-to-right thought process while the HM cross-references all potential mechanisms with all potential failures 2) Cross-check of current validation plan tests with the complete hypothesis exposing duplicate tests and holes 3) Provides for identification of the most concise set of tests that satisfies all of the hypothesis

75 Accelerated Validation valve stuck hot cold ramp cycle basket dust hardwater rh% hot will not cause valve stuck transportaion test FLST ASTM thermal exposure cold will not cause valve stuck ramp will not cause valve stuck cycle basket will not cause valve stuck dust will not cause valve stuck hardwater will rh% will not not cause valve cause valve stuck stuck hardwater test Tests transportation test cleaning solution coffe ground level cleaning coffe ground solution will not level will not cause valve cause valve stuck stuck forign in grounds forign in grounds wi not cause val stuck TCO Basket overflow rust circuit failure hot will not cause TCO hot will not cause Basket overflow hot will not cause rust cold will not cause TCO cold will not cause Basket overflow cold will not cause rust ramp will not cause TCO ramp will not cause Basket overflow ramp will not cause rust ASTM cyclic ASTM cyclic ASTM cyclic hot will not cause circuit failure cold will not cause circuit failure ramp will not cause circuit failure cycle basket will not cause TCO cycle basket will not cause Basket overflow cycle basket will not cause rust basket cycle - cycle basket will not cause circuit failure dust will not cause TCO dust will not cause Basket overflow dust will not cause rust dust will not cause circuit failure hardwater will not cause TCO hardwater test hardwater will not cause Basket overflow hardwater will not cause rust hardwater will not cause circuit failure rh% will not cause TCO transportation test rh% will not cause Basket overflow EMC ASTM cyclic rh% will not cause rust rh% will not cause circuit failure cleaning solution will not cause TCO coffe ground level will not cause TCO cleaning coffe ground solution will not level will not cause Basket cause Basket overflow overflow cleaning coffe ground solution will not level will not cause rust cause rust ASTM cyclic ASTM cyclic ASTM cyclic ASTM cyclic cleaning solution will not cause circuit basket cycle failure FSLT coffe ground level will not cause circuit failure forign in grounds wi not cause TC forign in grounds wi not cause Basket overflow forign in grounds wi not cause rus forign in grounds wi not cause circuit failure auto start failed hot will not cause auto start failed cold will not ramp will not cause auto cause auto start failed start failed hot will not cold will not ramp will not cycle basket will not cause auto start failed dust will not cause auto start failed cycle basket will not cause dust will not hardwater will not cause auto start failed hardwater will not cause no rh% will not cause auto start failed rh% will not cleaning solution will not cause auto start failed cleaning solution will not coffe ground level will not cause auto start failed coffe ground level will not forign in grounds wi not cause aut start failed forign in grounds wi not cause no

76 Typical Accelerated Development and Production Failure Progression from Development into Production Estimated Life Time to each unique failure (Minutes) Development Development Development Production Start Production 1 Production 2 Production 3 FSLT-one life estimate FLST-To Failrue FSLT Time (hrs)