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VINOD KUMAR
RCMA Korwa
vinodkorwa@gmail.com
What is ESS?
ESS is a Product Development Process which involves
the precipitation and detection of latent defects by
applying accelerated stressed.
Constant Failure
Rate Region
0 Time t
Latent Defect
Latent defects are flaws that are not readily apparent-
not identifiable through conventional testing- but with
time it can precipitate product failure. Latent defects
generally leads to failure early in the products life.
DEFECTIVE COMPONENTS
WORKMANSHIP ERROR
PROCESS STRESS
When to do ESS
TRANSFER OF
TECHNOLOGY
REPEAT TYPE
TESTING
FAI
ESS DELIVERY
Benefit of doing ESS before QT.
Provides design technology edge over competition in
world markets
PARAMETER DRIFTS
PCB SHORTS AND OPEN
INCORRECT PART INSTALLATION
WRONG PART INSTALLATION
CONTAMINATED PART
HERMETIC SEAL FAILURE
FOREIGN MATERIAL CONTAMINATION
COLD SOLDER JOINTS
DEFECTIVE PARTS.
ESS Screens
Random Vibration Altitude
Electrical Stress
ESS Thermal Shock
STRESS
SCREEN
Low Temperature Sine Vibration
Humidity Acceleration
Which is the most effective Screen for ESS
Which is the most effective Screen for ESS
FINDING DEFECTS
THERMAL VIBRATION
SCREEN SCREEN
Wrong Component
Improperly installed Mixed Assembly
component Defects
Wire insulation Two Components
Shortings
Defective Harness
Termination Loose Contact
Component Mechanical Flaws
Parameter Drift Poorly bonded
Hermetic Seal components
failure Loose hardware
Conformal Coating Chafed, Pinched wire
Weak Components Loose connectors
No solder joints in Weak Switches
IC through Hole
MOST PREFERRED METHODS OF ESS
BURN IN
THERMAL CYCLING
RANDOM VIBRATION
BURN-IN
DWELL TIME
MULTIPLE CYCLES
TEMPERATURE EXTREMES
RANDOM VIBRATION
ESS EFFECTIVENESS
MIL 2164 ESS PROFILE
THERMAL CYCLING
(10 CYCLES, 02 DEFECT FREE CYCLE)
CHAMBER INSTRUMENTATIO
N
FIXTURE COMPUTER
CONTROL
HASS
Product #1 - Product #2 -
HALT Process Traditional Methods
3-5 days to complete 7 months to complete
HASS
Highly Accelerated Stress Screen
A process used in
HALT Knowledge manufacturing, to allow
discovery of process
changes and prevent
products with latent defects
from getting into the field.
HASS Goal