Library of Recorded Qualmark Webinars

Category: 2014 Webinars

Cheryl Tulkoff and Greg Caswell, DfR Solutions

Root-Cause of HALT Failures -- Part I: Qualmark / DfR Solutions Webinar Series

Presented by Cheryl Tulkoff and Greg Caswell, DfR Solutions

HALT can be an important step in best practice reliability activities but its use is extremely limited without root-cause analysis. In HALT, failures are frequently treated in either a "fix and move on" or "ignore as not relevant" fashion. As a result, organizations experience significant losses from unreliable equipment and processes as they repeatedly correct rather than prevent problems. This is a reactive rather than a proactive method of solving, managing an eliminating undesirable events.

Root Cause Analysis (RCA) is a structured, systematic, analytical approach that, when used correctly, can prevent and alleviate chronic failures. When further enhanced with knowledge of common failure mechanisms, RCA can dramatically accelerate the problem solving process.

This webinar covers a case study of a classic Highly Accelerated Life Testing (HALT) activity. The HALT consisted of
• Cold Step Stress
• Hot Step Stress
• Rapid Thermal Transition
• Vibration Step Stress
• Combined Thermal and Vibration
DfR reviews each failure mode, when the failure occurred during the HALT process, and the root-cause of the failure. They also provide an assessment as to relevancy of the failure mode for the field environment and possible corrective actions.

Category: 2013 Webinars

Qualmark's Ask the Experts

An Effective Method for Detecting Counterfeit and Marginal Components in the Supply Chain

Ask The Experts Webinar

Counterfeit and marginal components have become an increasingly insidious and pervasive risk in the electronics supply chain. This leaves manufacturers at an extreme peril for system failures in the field, rising warranty costs, ongoing design challenges, and a potential PR nightmare. However, Qualmark’s HALT systems offer a solution that will help mitigate these hideous risks. In this webinar, the Expert presents a quick and effective qualification process using HALT; a high level technical discussion of HALT and how it is used to qualify vendor components/ assemblies with data not available by other means (margin and robustness); a specific case study stemming from Japan and Thailand; and wraps up with recommendations on establishing processes for rapid vendor and assembly qualification.

The series is aimed to help Qualmark customers achieve maximum return on investment in Qualmark technology that provide effective solutions for driving down warranty costs. Qualmark’s senior application engineers will present along with experienced HALT/HASS practitioners to teach best practices for achieving corporate reliability goals.

Qualmark's Ask the Experts

The complexity of Reliability Engineering is manifest during the design and development of a new product. The challenge to deliver on reliability requirements, enhanced life-cycle maintainability, and risk mitigation relies on a program designed to deliver accurate analysis and prediction. Yet, accurate Life Cycle models and Reliability Predictions are expected before the first testable samples are produced and Accelerated Life Testing (ALT) and Reliability Growth Testing (RGT) must frequently commence with preliminary product designs that will change as a result of issues that may be found during verification testing. These factors increase the risk of inaccurate predictions and poor outcomes from life testing.

HALT results from early subassembly testing or previous generation testing can provide qualitative data that will minimize the variance in predictions and decrease the time necessary to realize accurate information from ALT and RGT — data that helps to effectively meet and overcome the increasing challenges faced in Reliability Engineering.

This webinar describes how to collect and apply key data points gained from HALT to streamline and enhance prediction and demonstration of life expectancy in a reliability program.

Category: 2012 HALT/HASS Effectiveness Series

Qualmark Director of Professional Services, Tom Peters and Senior Applications Engineer, Neill Doertenbach
This presentation walks through the facility requirements for implementing an effective HALT program. It provides an overview of the layout and equipment needed for performing HALT, facility infrastructure requirements and discusses product and testing equipment and material considerations for customizing the process to meet specific product needs. Examples are shown from Qualmark’s own Center of Excellence facility and are presented by Qualmark’s Director of Professional Services, Tom Peters and Senior Applications Engineer, Neill Doertenbach.
Qualmark Center of Excellence Director Tom Peters
A key element that makes Qualmark technology so effective for testing today’s complex products and components is the way in which LN2 (liquid nitrogen) is used to drive the rapid thermal cycling necessary for HALT. Understanding LN2 and how it should be supplied to the system will assist the test facility in achieving maximum efficiencies and performance consistency.

In part 2 of this series on HALT/HASS Effectiveness to Achieve Warranty Cost Reduction Goals, Tom Peters, your host and Qualmark’s Center of Excellence director will discuss with Paul Trcka, President of Midwest Cryogenics, strategic considerations that go into designing an effective LN2 infrastructure.
Qualmark Director of Professional Services Tom Peters
In this webinar, Dave Rahe, Vice-President of Austin Reliability Labs, joins host Tom Peters, Qualmark’s Director of Professional Services, to explain the steps for achieving optimum HALT results that will inform you about your product design reliability. Dave will share his in-depth testing expertise on power supplies to achieve high reliability and discuss the application of IPC9592A in power supply reliability development processes.

This part 3 in the series focuses on the HALT process — pre-HALT planning, the HALT process, documentation (best practices), post-HALT activities — to provide fundamental insights into performing effective HALT and why Qualmark patented technology and processes are the right tools for companies who want to significantly reduce warranty costs.
John Hansen, the Reliability Director for Varian Medical Systems
Part 4 of this special series on performing effective HALT and HASS focuses on HASS – Highly Accelerated Stress Screening. While Qualmark HALT technology is applied primarily during the design stage to provide insights for improving design robustness, our HASS technology is applied during the manufacturing stage to quickly detect flaws that can be introduced during the production process. HASS is especially effective at reducing infant mortalities, a key outcome for proactive warranty cost containment.

Introducing a new product, especially in the medical industry, can be particularly exacting in today’s market. Now new, rapidly evolving technologies and manufacturing advances challenge the efficacy of traditional approaches to process monitoring. Qualmark technology helps companies rise up to the challenge.

Today’s session on effective HASS features John Hansen, the Reliability Director for Varian Medical Systems, who will share with you lessons learned and the results of their accelerated reliability program:

Varian was one of the earliest adopters of Qualmark’s latest offering, the QFusion® HASS system. Hansen will reveal how QFusion’s unique design enabled rapid implementation of Varian's accelerated reliability test program.
Neill Doertenbach, Qualmark Senior Applications Engineer

This presentation discusses why HALT testing is a critical step before implementing a HASS program. It provides an overview of HASS fixturing considerations, developing an effective HASS screen with proof of screen, and overall HASS implementation. Examples are shown from Qualmark’s own Center of Excellence facility and are presented by Qualmark’s Senior Applications Engineer, Neill Doertenbach.

Qualmark HALT/HASS Experts

To maximize the value of HALT, it is critical to get the vibration and shock stresses coupled well into the product under test. Understanding the nature of Repetitive Shock (RS) vibration used in HALT and HASS and how it differs from the more familiar Electrodynamic (ED) system is a key consideration in developing fixture design. Today’s webinar covers basic theory and guidelines for HALT fixturing, reviews the differences between RS and ED shaker vibration, and provides examples of how to apply this knowledge to varied products.

Category: 2011 Webinars

Qualmark's Ask the Experts
In Qualmark's 20 year history of leading the HALT (Highly Accelerated Life Test) and HASS (Highly Accelerated Stress Screen) industry, we are frequently asked these 3 questions:

  • Why test beyond spec?
  • If it fails beyond spec, why should I care?
  • Can HALT find software defects as well as hardware defects?


If you've found yourself wondering the same thing or tried to answer these questions for colleagues, you should listen in as Kirk Gray, a 32-year industry veteran and an early adopter of HALT and HASS, explains why stressing beyond specs is meaningful, the reliability relevancy of failures found outside of specs, and why HALT can find software defects that might otherwise go undiscovered until they become warranty issues.
Qualmark's Ask the Experts
Power Supplies are one of the highest failure rate assemblies in systems entering today’s marketplace. Ranging from the telecommunications industry to handhelds, military, and medical products, a wide range of systems are dependent on the reliability of power supplies.

Given that power supplies are such a critical component in systems design, ensuring power supply reliability is paramount to reducing field failures, building customer satisfaction, and lowering warranty costs. Applying HALT and HASS to power supplies provides the opportunity to determine weak links in design and manufacture and correct them before they are fielded. In this presentation, Qualmark partner, Reliant Labs, discusses case studies and tests to validate design, thermal characteristics, and common issues found in Power Supplies.
Qualmark's Ask the Experts
This year’s earthquake and subsequent tsunami in Japan provides a good example of how suddenly supply chains can be disrupted. Whether the disruption is caused by natural disaster, political forces, economic upheaval, or simply part obsolescence, any change in supply chain is fraught with uncertainty and risk. This risk is magnified when the change is unplanned and lengthy production floor downtime or severe product liability excursions loom.

HALT and HASS (Highly Accelerated Life Testing and Highly Accelerated Stress Screening) are excellent for providing the first line of defense in deflecting inferior substitutions and maintaining product quality during Supply Chain disruptions. With a HALT-established baseline, new products/vendors can be evaluated for reliability and robustness. Components can be compared side by side and measured against established quality parameters. Relying on spec sheet or MTBF data alone is misplaced when it comes to knowing whether the substitute part will become a raging headache for warranty and repair or perhaps the key element for securing product dominance against competitors.

This webinar details how HALT and HASS are effective risk management tools for reducing uncertainty, monitoring substitute vendor process quality, and preparing your business for the fastest possible response to Supply Chain disruptions.
Qualmark's Ask the Experts
Although the specification of HALT and HASS in DOD RFQs is increasing, many DOD projects still fall back on the traditional, time-worn reliability and screening protocols developed in the 1950’s and 60’s. Larry Choate, is the Vice President of Ensign Power Systems, Inc., an established DOD vendor. In this presentation he describes Ensign’s decision to use HASS on their products whenever possible, in lieu of the ESS protocols such as NAVMAT P-4855-1 that are typically specified by their DOD customers. The data and logic used to move the customer from their familiar ESS specification and its NAVMAT vibration profile to HASS and 6 Degree of Freedom, Repetitive Shock vibration will be reviewed, including the reliability and production throughput improvements HASS provides.

Using HALT and HASS will make your DOD products more reliable and more likely to be delivered on time and under budget. This webinar demonstrates how to have your HALT and HASS processes accepted by your DOD customer and written into their specification, making your proposal the compelling choice.
Qualmark's Ask the Experts
Qualmark's Ask the Experts webinar reviews: IPC — the Association Connecting Electronics Industries® recently released the A revision of IPC-9592, Requirements for Power Conversion Devices for the Computer and Telecommunications Industries.

First released in 2008, IPC-9592 sets the requirements for power conversion devices (PCDs) in the computer and telecommunications industries, including design for reliability, design and qualification testing, quality processes and manufacturing conformance testing.

The new A revision of the document provides suppliers and end-users of PCDs with much greater guidance and definition for design qualification testing including product classification and product categories.

IPC-9592A significantly expanded its description of Highly Accelerated Life Testing (HALT) and the application of HALT to PCDs.

This presentation focuses on the how and why of Section 5 Design and Qualification Testing Section subsection 5.2.3 Highly Accelerated Life Test and Section 7 Manufacturing Conformance Testing subsection 7.3.2 Stress Tests (Short Term Reliability Tests – BI/HASS)

Category: 2010 Webinars

Qualmark's Ask the Experts
Thales Aerospace Division - a global leader in supplying electronic avionic equipment, subsystems and systems for flight control, navigation, communication and surveillance for commercial and military aircrafts – has introduced the use of Highly Accelerated Tests (HAT) in order to reach product maturity more quickly. Thales has successfully met this goal with accelerated reliability testing:

• During development phase to discover product weaknesses
• During production, as a replacement of classical ESS (Environmental Stress Screening) to effectively eliminate early failures (infant defects)

An overview of the application of Highly Accelerated Tests during design and production phases will be explained. Associated results and common human errors made during HAT testing are revealed.
Qualmark's Ask the Experts
In the history of electrical engineering, failure prediction methodology based on Military Handbook 217 gained widespread acceptance as the basis for reliability engineering and design rules to insure reliability of electronic components. For a reference point in history, we call this ‘Reliability Test Plan A’. MIL-HDBK-217 is based mainly on the Arrhenius Equation which is misapplied as a dominant factor for most failure mechanisms.

This webinar presents a summary of what might be proposed as the “new school” of electronics reliability development based on operational boundaries or limits, the physics involved, and materials engineering, or collectively considered “Reliability Test Plan B“. This new school of reliability is not based on the theoretical “calculated” life of electronic components, but instead on empirical stress limits using HALT - mapping limits of stress combinations, the physical causes of those limits, and comparative analysis of the variable data from those limits to enable rapid reliability development.
Qualmark's Ask the Experts
Are you currently performing burn-in and wondering if you should be performing Highly Accelerated Stress Audits (HASA) of your product before it ships? This webinar explores the financial considerations of traditional burn-in vs. HASA by following a hypothetical corporation that seeks to determine the cost effectiveness of each approach. The costs involved in both types of product testing are evaluated and outcomes that impact return on investment are valued to compare the financial implications of the test choices made.

Category: 2009 Webinars

Qualmark Corporation

From Qualmark's Ask the Experts Series

This webinar provides best practices and strategies for companies that are in the early stages of planning HASS implementation. It includes guidelines for pre-HASS HALT work, information on key facilities considerations for multiple chambers, and a step by step project plan for HASS implementation. It also outlines the role that Qualmark’s Professional Services team can play in ensuring a successful HASS launch.

Qualmark - Ask the Experts Series (Special French Edition)
Thales Division Aérospace – leader dans la fourniture d'équipements électroniques, sous systèmes et systèmes pour applications civiles et militaires – a introduit l'utilisation des Essais Aggravés (HAT) dans le but d'aboutir plus rapidement à la Maturité des produits. Thales a atteint son but par la mise en oeuvre des Essais Aggravés :
  • Durant la phase développement des produits pour découvrir les faiblesse
  • Durant la production, en remplacement du déverminage pour éliminer efficacement les défauts de jeunesse
Le principe de l'application des Essais Aggravés dans les phases de développement et de Production sera présenté. Résultats obtenus et erreurs les plus fréquemment commises seront révélées.
Qualmark Corporation

From Qualmark's Ask the Experts Series

The goal of an Accelerated Testing program is to make cost effective improvements in the field reliability of the hardware being tested by selective use of stresses beyond the design limit stress of the product. Dr. Ed Kyser shows you how to evaluate the ROI of your HALT/HASS program.

Design for Excellence
Qualmark Corporation

From Qualmark's Ask the Experts Series

Design for Excellence (DfX) is based upon the premise that getting product design right the first time is far less expensive than finding failure during use. This webinar will summarize how utilizing DfX concepts will not only reduce research and development costs, but will also decrease time to market, and allow companies to confidently issue warranty coverage.

Qualmark Corporation

From Qualmark's Ask the Experts Series

Creating an effective vibration fixture for HALT is critical to test success. However, it can be a counter intuitive task for a designer that is not familiar with HALT goals and the unique vibration system used in HALT chambers. This webinar provides a basic working knowledge of how to design an effective HALT vibration fixture. Qualmark's Senior Applications Engineer, Neill Doertenbach, reviews the HALT test method and why fixture characteristics must be designed to accommodate the output of the table and HALT test goals.

Qualmark Corporation

From Qualmark's Ask the Experts Series

Over the last decade the use of surface mount PCBs in all types of electronic assemblies has increased dramatically. The different responses of surface mount vs. through hole boards to both vibration and thermal stresses have changed the ratios and types of failures under the different stresses used in HALT as this change has taken place. HALT results across a wide variety of products conducted at Qualmark labs in the mid-1990's and in our new study show that current technology devices are more likely to require a HALT unique stress, such as a combined vibration and thermal or rapid thermal ramp stress, to drive out a failure mode. Comparisons include the fraction of failures found under each stress, the types of failures found, the operating and destruct limits of the products, as well as the industries that use HALT and the types of products that are tested. These results, as well as the causes of some of the interesting and significant differences between the failure data from the two time periods are discussed.

Qualmark Corporation

From Qualmark's Ask the Experts Series

The goal of an Accelerated Testing program is to make cost effective improvements in the field reliability of the hardware being tested by selective use of stresses beyond the design limit stress of the product. Dr. Ed Kyser shows you how to evaluate the ROI of your HALT/HASS program.

Qualmark Corporation

From Qualmark's Ask the Experts Series

The development and propagation of HALT throughout the electronics industry has provided engineering teams a powerful tool to assess robustness early in the design process. However, to take full advantage of HALT testing, failure analysis is necessary to identify root cause. Without root cause analysis, the investment in HALT testing is not being maximized. This presentation will review the HALT root-cause analysis and provide insightful case studies on how to make sure you and your teams close the loop on design improvement.