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Failure analysis (FA) and accelerated testing are essential tools used in mobility electronics. Yet, FA’s role is underestimated and underutilized. Its administration lacks standardization and support, esp., during multi-stress accelerated reliability testing (ART). Proposed three-stage systemic early FA (SEFA) methodology provides feedback using conventional and original systematic hierarchical complementary multidisciplinary comparative tools and methods focusing on prevalent early failures (EF). Subject matter result-oriented technical root-cause FA (RCFA) is a vital past of SEFA. This paper outlines three-phase RCFA methodology along with specific methods, tools, and examples related to ART. Presented EF classifications interpret EFs’ symptoms, mechanisms, and causes and propose corrective actions. Suitable RCFA-SEFA improve products and ART by precluding-resolving prevalent EF.

Failure analysis (FA) management is insufficiently described by current standards and literature. Previously proposed three-step systemic FA methodology provides effective and efficient alternative to sporadic FA. Organization, methods and results of the first step of the systemic FA, failure mode analysis (FMA), during product/project life cycle, is described. FMA promptly address ∼80% of all problems and justify/supports further actions using conventional ready techniques and resources. Original subject matter tools (three FMA levels, joint FMA-FMECA-F5 technique, and P5 failure classification) substantiate, facilitate and illustrate FMA. Multiple examples demonstrate FMA strengths and limitations with uniquely broad range of products and applications. Particular attention is paid to rare combination of high quality, reliability and profitability.

A three-stage systematic hierarchical complementary failure analysis (SHCFA) methodology is proposed. It addresses all types of failures occurred during different phases of reliability stress tests (RST) and product life cycles in a flexible, but consistent manner. The SHCFA provides a result-effective and cost-efficient approach leading to significant sustainable growth of quality, reliability and customer satisfaction, improvement of RST, and concurrent reduction of losses. Practical failure classifications and RST-related examples substantiate and illustrate the proposed approach.

This paper demonstrates the results of the analysis of current situation in prediction of reliability, durability, quality, and maintainability; as well as results of development methodology and equipment for accelerated reliability testing which is a key factor in improving the current situation in the above areas. The implementation of 10 basic new concepts of this development decreases recalls, complaints, and total life-cycle cost of the product by at least 33% to 47%. This paper compares basic principles of new concepts with current ones. Practical accelerated reliability assurance for complex mobile systems and components based on multipurpose accelerated reliability testing (ART) is presented and illustrated. ART optimization and enhancement based on early reliability physics, systemic failure analysis and customized applied statistics covering various stages of R&D, manufacturing, and field service is justified and detailed.