Improving Product Reliability and Software Quality

433 Pages·2019·10.286 MB·English

by  Ted Kalal, Mark Levin, Jonathan Rodin;

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ImprovingProductReliabilityandSoftwareQuality
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WileySeriesinQuality&ReliabilityEngineering
DrAndreKleyner
SeriesEditor
TheWileyseriesinQuality&ReliabilityEngineeringaimstoprovideasolid
educationalfoundationforbothpractitionersandresearchersinQ&Rfieldandto
expandthereader’sknowledgebasetoincludethelatestdevelopmentsinthisfield.
Theserieswillprovidealastingandpositivecontributiontotheteachingandpractice
ofengineering.
Theseriescoveragewillcontain,butisnotexclusiveto,
• statisticalmethods;
• physicsoffailure;
• reliabilitymodeling;
• functionalsafety;
• six-sigmamethods;
• lead-freeelectronics;
• warrantyanalysis/management;and
• riskandsafetyanalysis.
WileySeriesinQuality&ReliabilityEngineering
(cid:2) ImprovingProductReliabilityandSoftwareQuality (cid:2)
byMarkA.Levin,TedT.Kalal,JonathanRodin
April2019
DesignforSafety
ByLouisJGullo,JackDixon
February2018
NextGenerationHALTandHASS:RobustDesignofElectronicsandSystems
byKirkA.Gray,JohnJ.Paschkewitz
May2016
ReliabilityandRiskModels:SettingReliabilityRequirements,2ndEdition
byMichaelTodinov
September2015
AppliedReliabilityEngineeringandRiskAnalysis:ProbabilisticModelsand
StatisticalInference
byIliaB.Frenkel,AlexKaragrigoriou,AnatolyLisnianski,AndreV.Kleyner
September2013
DesignforReliability
byDevG.Raheja(Editor),LouisJ.Gullo(Editor)
July2012
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(cid:2)
Effective FMEAs: Achieving Safe, Reliable, and Economical Products and Processes
usingFailureModeandEffectsAnalysis
byCarlCarlson
April2012
FailureAnalyis:APracticalGuideforManufacturersofElectronicComponents
andSystems
byMariusBazu,TituBajenescu
April2011
ReliabilityTechnology:PrinciplesandPracticeofFailurePreventionin
ElectronicSystems
byNormanPascoe
April2011
ImprovingProductReliability:StrategiesandImplementation
byMarkA.Levin,TedT.Kalal
March2003
TestEngineering:AConciseGuidetoCost-effectiveDeign,Developmentand
Manufacture
byPatrickO’Connor
April2001
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IntegratedCircuitFailureAnalysis:AGuidetoPreparationTechniques
byFriedrichBeck
January1998
MeasurementandCalibrationRequirementsforQualityAssurancetoISO9000
byAlanS.Morris
October1997
ElectronicComponentReliability:Fundamentals,Modelling,Evaluation,andAssurance
byFinnJensen
November1995
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Improving Product Reliability and Software
Quality
Strategies,Tools,ProcessandImplementation
SecondEdition
MarkA.Levin
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Teradyne,Inc.
California,USA
TedT.Kalal
Retired
Texas,USA
JonathanRodin
Teradyne,Inc.
California,USA
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Thiseditionfirstpublished2019
©2019JohnWiley&SonsLtd
EditionHistory
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LibraryofCongressCataloging-in-PublicationData
Names:Levin,MarkA.,1959-author.|Kalal,TedT.,author.|Rodin,Jonathan,
1957-author.
Title:Improvingproductreliabilityandsoftwarequality:strategies,
tools,processandimplementation/MarkA.Levin,Teradyne,Inc.,
California,USA,TedT.Kalal(Retired),Texas,USA,JonathanRodin,
Teradyne,Inc.,California,USA.
Othertitles:Improvingproductreliability
Description:2ndedition.|Hoboken,NJ:JohnWiley&Sons,Inc.,[2019]|
Revisededitionof:Improvingproductreliability:strategiesand
implementation/MarkA.LevinandTedT.Kalal.c2003.|Includes
bibliographicalreferencesandindex.|
Identifiers:LCCN2018061430(print)|LCCN2019000421(ebook)|ISBN
9781119179412(AdobePDF)|ISBN9781119179436(ePub)|ISBN9781119179399
(hardcover)
Subjects:LCSH:Reliability(Engineering)|Manufacturingprocesses–Data
processing.|Computersoftware–Evaluation.
Classification:LCCTS173(ebook)|LCCTS173.L472019(print)|DDC
620/.00452–dc23
LCrecordavailableathttps://lccn.loc.gov/2018061430
CoverDesign:Wiley
CoverImages:(toptobottom):©teekid/GettyImages,©ez_thug/GettyImages,©AK2/GettyImages,
CourtesyofUniversalRobots/TeradyneInc.
Setin10/12ptWarnockProbySPiGlobal,Chennai,India
PrintedinGreatBritainbyTJInternationalLtd,Padstow,Cornwall
10 9 8 7 6 5 4 3 2 1
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CaryandDarrenKalal
Tomybeautifulwife,DanaMischelLevin,forherendlesslove,support,andpatience,
andtooursons,SpencerNathanLevinandAndrewDylanLevin.
ToBrigid,Sam,andMollyRodinfortheirsupportandencouragement.
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ix
Contents
AbouttheAuthors xix
ListofFigures xxi
ListofTables xxv
SeriesEditor'sForeword xxvii
SeriesForewordSecondEdition xxix
SeriesForewordFirstEdition xxxi
ForewordFirstEdition xxxiii
PrefaceSecondEdition xxxv
PrefaceFirstEdition xxxvii
Acknowledgments xli
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Glossary xliii
PartI ReliabilityandSoftwareQuality–It’saMatterofSurvival 1
1 TheNeedforaNewParadigmforHardwareReliabilityandSoftware
Quality 3
1.1 RapidlyShiftingChallengesforHardwareReliabilityandSoftwareQuality 3
1.2 GainingCompetitiveAdvantage 5
1.3 CompetingintheNextDecade–WinnersWillCompeteonReliability 5
1.4 ConcurrentEngineering 6
1.5 ReducingtheNumberofEngineeringChangeOrdersatProductRelease 8
1.6 Time-to-MarketAdvantage 9
1.7 AcceleratingProductDevelopment 10
1.8 IdentifyingandManagingRisks 11
1.9 ICM,aProcesstoMitigateRisk 11
1.10 SoftwareQualityOverview 12
References 13
FurtherReading 13
2 BarrierstoImplementingHardwareReliabilityandSoftware
Quality 15
2.1 LackofUnderstanding 15
2.2 InternalBarriers 16
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x Contents
2.3 ImplementingChangeandChangeAgents 17
2.4 BuildingCredibility 19
2.5 PerceivedExternalBarriers 20
2.6 TimetoGainAcceptance 21
2.7 ExternalBarrier 22
2.8 BarrierstoSoftwareProcessImprovement 23
3 UnderstandingWhyProductsFail 25
3.1 WhyThingsFail 25
3.2 PartsHaveImproved,EveryoneCanBuildQualityProducts 28
3.3 HardwareReliabilityandSoftwareQuality–TheNewParadigm 28
3.4 Reliabilityvs.QualityEscapes 29
3.5 WhySoftwareQualityImprovementProgramsAreUnsuccessful 30
FurtherReading 31
4 AlternativeApproachestoImplementingReliability 33
4.1 HiringConsultantsforHALTTesting 33
4.2 OutsourcingReliabilityTesting 33
4.3 UsingConsultantstoDevelopandImplementaReliability
Program 34
4.4 HiringReliabilityEngineers 34
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PartII UnravelingtheMystery 37
5 TheProductLifeCycle 39
5.1 SixPhasesoftheProductLifeCycle 39
5.2 RiskMitigation 41
5.2.1 InvestigatetheRisk 41
5.2.2 CommunicatetheRisk 41
5.2.3 MitigatetheRisk 44
5.3 TheICMProcessforaSmallCompany 45
5.4 DesignGuidelines 46
5.5 Warranty 46
FurtherReading 47
ReliabilityProcess 47
DFM 48
6 ReliabilityConcepts 49
6.1 TheBathtubCurve 50
6.2 MeanTimebetweenFailure 51
6.2.1 MeanTimebetweenRepair 52
6.2.2 MeanTimebetweenMaintenance(MTBM) 52
6.2.3 MeanTimebetweenIncidents(MTBI) 52
6.2.4 MeanTimetoFailure(MTTF) 52
6.2.5 MeanTimetoRepair(MTTR) 52
6.2.6 MeanTimetoRestoreSystem(MTTRS) 52
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Contents xi
6.3 WarrantyCosts 53
6.4 Availability 55
6.4.1 On-siteManufacturerServicePersonnel 56
6.4.2 TrainedCustomerServicePersonnel 56
6.4.3 ManufacturerTrainingforCustomerServicePersonnel 56
6.4.4 Easy-to-UseServiceManuals 56
6.4.5 RapidDiagnosisCapability 56
6.4.6 RepairandSparePartsAvailability 57
6.4.7 RapidResponsetoCustomerRequestsforService 57
6.4.8 FailureDataTracking 57
6.5 ReliabilityGrowth 57
6.6 ReliabilityDemonstrationTesting 59
6.7 MaintenanceandAvailability 62
6.7.1 PreventativeMaintenance 63
6.7.2 PredictiveMaintenance 64
6.7.3 PrognosticsandHealthManagement(PHM) 64
6.8 ComponentDerating 69
6.9 ComponentUprating 70
Reference 71
FurtherReading 72
ReliabilityGrowth 72
ReliabilityDemonstration 72
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7 FMEA 73
7.1 BenefitsofFMEA 73
7.2 ComponentsofFMEA 74
7.2.1 TheFunctionalBlockDiagram(FBD) 74
7.2.1.1 GeneratingtheFunctionalBlockDiagram 75
7.2.1.2 FillingintheFunctionalBlockDiagram 76
7.2.2 TheFaultTreeAnalysis 78
7.2.2.1 BuildingtheFaultTree 78
7.2.2.2 Brainstorming 79
7.2.3 FailureModesandEffectsAnalysisSpreadsheet 80
7.3 PreparingfortheFMEA 86
7.4 BarrierstotheFMEAProcess 89
7.5 FMEAGroundRules 91
7.6 UsingMacrostoImproveFMEAEfficiencyandEffectiveness 92
7.7 SoftwareFMEA 94
7.8 SoftwareFaultTreeAnalysis(SFTA) 97
7.9 ProcessFMEAs 97
7.10 FMMEA 99
8 TheReliabilityToolbox 101
8.1 TheHALTProcess 101
8.1.1 TypesofStressesAppliedinHALT 104
8.1.2 TheTheorybehindtheHALTProcess 105
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xii Contents
8.1.3 HALTTestingLiquidCooledProducts 109
8.1.4 PlanningforHALTTesting 110
8.2 HighlyAcceleratedStressScreening(HASS) 121
8.2.1 ProofofScreen(POS) 122
8.2.2 Burn-In 123
8.2.3 EnvironmentalStressScreening(ESS) 124
8.2.4 EconomicImpactofHASS 125
8.2.5 TheHASAProcess 126
8.3 HALTandHASSTestChambers 127
8.4 AcceleratedReliabilityGrowth(ARG) 128
8.5 AcceleratedEarlyLifeTest(ELT) 131
8.6 SPCTool 132
8.7 FIFOTool 132
References 134
FurtherReading 134
FMEA 134
HALT 135
HASS 136
Quality 136
Burn-in 136
ESS 137
UpRating 137
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9 SoftwareQualityGoalsandMetrics 139
9.1 SettingSoftwareQualityGoals 139
9.2 SoftwareMetrics 140
9.3 LinesofCode(LOC) 142
9.4 DefectDensity 142
9.5 DefectModels 144
9.6 DefectRunChart 145
9.7 EscapedDefectRate 147
9.8 CodeCoverage 148
References 149
FurtherReading 150
10 SoftwareQualityAnalysisTechniques 151
10.1 RootCauseAnalysis 151
10.2 The5Whys 151
10.3 CauseandEffectDiagrams 152
10.4 ParetoCharts 153
10.5 DefectPrevention,DefectDetection,andDefensiveProgramming 154
10.6 EffortEstimation 157
Reference 158
FurtherReading 158
11 SoftwareLifeCycles 159
11.1 Waterfall 159
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