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Track 2 Session 10
9:10 to 10:10 a.m. Thursday June 19, 2008
Design for Reliability in High Volume
Spindle Motor Applications
The Design for Reliability (DFR) approach
was used for an early detection of the critical failure modes in
a stage gate spindle motor product development process. Initially, the
product reliability was assessed using Failure Mode and Effects
Analysis (FMEA). Once the requirements were defined, the prototype
of the product was exposed to physics-based reliability tests
designed to assess design robustness and identify critical
reliability flaws in order to provide an early stage feedback to the design
engineers. The early reliability tests were developed using the
understanding of the product operation and accelerated through custom-developed, physics-based stressors. The results of the
early reliability tests were then compared to the results of the
physics predictive reliability modeling and used in re-evaluation of
the prototype build. This approach has resulted in a significant
decrease in the product integration Defect Part Per Million (DPPM)
and Annual Failure Rate (AFR) as well as significant design and
manufacturing cost reduction.
Key Words: Design for Reliability, Reliability Physics,
Design for Six Sigma, Accelerated Reliability Testing, Predictive
Reliability Modeling, Reliability Management
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