Accelerated Stress Testing and Reliability Conference

HASS Rapid Change Out Process

Derik Clayton & Julie Stuckey

Honeywell Federal Manufacturing & Technologies, LLC

The Department of Energy’s National Security Campus is operated and managed by Honeywell Federal Manufacturing & Technologies, LLC under contract number DE-NA00002839.

www.ieee-astr.org September 28- 30 2016, Pensacola Beach, Florida

Accelerated Stress Testing and Reliability Conference

Overview

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Common Solution for all Products

• Significant Increase in HASS Testing Requirements

• Chamber Capacity Constraints

• Floor Space Constraints

• Needed Common Solution for Diverse Products

• Areas of Opportunityo Tester

o Fixturing

o Change-Over

o Mistake Proofing

o Ergonomics

o Storage

Accelerated Stress Testing and Reliability Conference

Current State

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Current Practices Will Not Support Future Demand

• One part currently undergoes HASS testingo Dedicated Chamber and 3 Bay Tester

o 4 products tested at once

o Fixtures “permanently” installed in chamber parts loaded into fixtures

o Multiple electrical connections made in the fixture

o Complex product – extensive test times to allow for electrical coverage during HASS testing

o Significant Floor Space required to support a single product.

Accelerated Stress Testing and Reliability Conference

Problem Statement

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How do we optimize throughput while minimizing capital expenditure and assuring quality?

• 5 distinctly shaped products require testing• What are the common elements we can leverage?• What will change-over look like?• What is the maximum number of products

that can he tested at one time?• Smallest footprint possible with easy

product flow• What do the operators think?

Accelerated Stress Testing and Reliability Conference

Common Tester for all ProductsCustomized with Adapters

Tester Challenges

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Accelerated Stress Testing and Reliability Conference

• Fixtures/product orientation

• Ducting configuration differences

• Cable organization and change out

• Unnecessary related weight on the chamber

• Operator tooling access

• Storage

• Common procedures

Chamber Challenges

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Accelerated Stress Testing and Reliability Conference

• Reducing variations and eliminating wasteo Reducing change out time

o Universal designs and setups

o 5S standards

• Concept design development and selectiono Modified Pugh

• Implementation and Controlo Sustain the gain.

Six Sigma – Problem Solving Tools

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Accelerated Stress Testing and Reliability Conference

• Develop goals and define weighted factor of importance.

• Analyzed concepts against established goals

• Recognize strengths and weaknesses in each proposed design or concept.

• Converge on a hybrid design to maximize strengths

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Six Sigma – Modified Pugh

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Accelerated Stress Testing and Reliability Conference

• Minimize the process step variationsoGeneric procedures written as base templates for all products to

be tested

oProduct specific steps highlighted to more easily identify procedure differences

• Assembly outside of chamberoModified current process to assembly as much of the product,

fixture, and cabling as possible outside the chamber

oMistake Proofing

Common Processes / Procedures

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• www.ieee-astr.org September 28- 30 2016, Pensacola Beach, Florida 9

Accelerated Stress Testing and Reliability Conference

•Repeatable and consistent UUT placement inside the chamber

o Labeling on the product fixture

o Modify the standoffs

o Color Coding

o Resistor IDs

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Modified Standoffs

Keyed

Rapid Change Over - Fixturing

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Accelerated Stress Testing and Reliability Conference

Rapid Change Over - Ducting

• Redirecting air by means of plenumso Customized plenums for use across

numerous productso Optimizing product placement

• Quick connect pinso Allows for quick removalo Collet on end of ducts

• Universal connection pointso Six Sigma design – standardizeo Unique designed plenums

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Accelerated Stress Testing and Reliability Conference

Rapid Change Over - Cabling

• Cable fixturingo Mistake proofing built into the fixture

• Cable tray in chambero Keeps cables organized and out of the wayo Isolated from vibrationo No added weight on the vibration table

• Break out boxo Product specifico Universal Connectors

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• www.ieee-astr.org September 28- 30 2016, Pensacola Beach, Florida 12

Accelerated Stress Testing and Reliability Conference

• Design Engineeringo Separate design facility with dedicated chambers for running HALT testing

• Production Facility o Separate production facility with dedicated chambers for running HASS

• Collaborationo Early development design fixturing and cabling input

Collaborating with HALT

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Accelerated Stress Testing and Reliability Conference

• Implementing a “5S” workplace organizational and housekeeping methodology for lean manufacturing processo Sort, set in order, shine, standardize, sustain

• Why is it important?o Space, time, money, energy saving

o Enhances productivity

o Reduces waste

Storage

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Accelerated Stress Testing and Reliability Conference

• Reduced each change over time by 1.2 hrso From current process: 121 total steps, 110 during “change over”

o To current process: 89 total steps, 38 during “change over”

• Design Engineering and Production Engineering collaborationo Reduced duplicated efforts and rework

o Production Engineering leading the fixture design efforts and decisions

• Improved Ergonomics

• Reduced risk of making mistake

• Adaptable to future products

The Impact

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Accelerated Stress Testing and Reliability Conference

•Reducing HASS change-over times allows greater utilization of capital equipment

•Areas to considero Common Test Equipment

o Flexible Fixturing

o Mistake-Proofing

o Ergonomics

o Storage

Summary

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Rapid Change-Over is Key for Increased Production Output

• www.ieee-astr.org September 28- 30 2016, Pensacola Beach, Florida 16

Accelerated Stress Testing and Reliability Conference

• References–G. Hobbs, “HALT and HASS: Accelerated Reliability Engineering”:

Westminster, CO: Hobbs Engineering Corporation, 2005–H. McLean, “HALT, HASS & HASA Explained: Accelerated

Reliability Techniques”: Milwaukee, WI; ASQ Quality Press, 2000 –T. Pyzdek and P. Keller, “Six Sigma Handbook: A Complete Guide

for Green Belts, Black Belts, and Managers at All Levels”, New York, NY: McGraw-Hill Education, 2014

–S. Pugh, “Total Design: Integrated Methods for Successful Product Engineering” First Printed 1990. Reprinted 1991.. ed. Wokingham, England ; Reading, Mass.: Addison-Wesley Pub., 1991

–D. Mc Dermott, “Decision Making Confidence: How to use the Pugh Matrix” [http://www.decision-making-confidence.com/pugh-matrix.html]

– Institute of Environmental Sciences and Technology, “IEST-RP-PR003.1 HALT and HASS”: Arlington Heights, IL, September 2012

–M. Imai, “Gemba Kaizen: a Commonsense, Low-Cost Approach to Management”, New York, NY: McGraw-Hill 1997

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