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Comprehensive Stress Testing for Product Reliability: Ensuring Quality and Performance

This document outlines a robust testing framework designed to evaluate product performance under various conditions, focusing on validation against specifications and consumer misuse scenarios. Key aspects include assessing performance limits in challenging environments—like extreme temperatures, moisture exposure, and physical impact—alongside environmental testing and compliance with EMI standards. The testing approach includes event and life reliability assessments, ensuring products not only comply with claims but can sustain real-world usage over time.

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Comprehensive Stress Testing for Product Reliability: Ensuring Quality and Performance

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Presentation Transcript

  1. System Testing "You make it, I’ll break it"

  2. Purpose: • Does the product as a whole perform up to specifications? (validation?) • Does it perform under normal, upper, and lower limits wrt the environment? • Does it meet or exceed all claims?

  3. Stressors:

  4. Customer Misuse: • Coffee spillage • Drop in toilet • Use as a seat • Cross-connecting • Reverse polarity • Dirty hands • Unplugging via jerk on cable

  5. Testing requires that you define failure! • Intended application? • Anticipated environment? • Lifetime? • Value vs. time • Sunken ships make good coral reefs in time …

  6. Types of testing: • Event testing – cycling, time to failure • Environmental – operating & storage • Altitude • Threshold (door, elevator, bricks… ) • Vibration • ISTA shipping test • EMI (standards!, see next slide: )

  7. EN 1000 series standards • Radiated electric field immunity • Fast transients • Surge, line, magnetic • Dips, variations, V, F variation • On/off, ESU • Walkie-talkie, cell phone • ESU, etc.

  8. Types of testing, continued • Life test/reliability • Customer misuse • Fluid spillage • Weight test • Keyed connections • Time related • Failure related (MTBF)

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