Product Reliability Techniques

Course Length:



$2090 per person


In this 3 day course you will learn how to use the appropriate statistical tools to enhance the reliability performance of your design. Complex product design requires an understanding of the variation present in modern components, supplied modules, assembly processes, and use conditions. Each set of variation may lead to a change in the expected reliability performance. Mastering and applying the right tools, from process capability to tolerance analysis, from stress / strength analysis to reliability testing and analysis permits you to employ powerful statistical tools as you design systems that are robust and reliable. Starting with the fundamentals of reliability engineering we will build an understanding of the interconnected and reinforcing nature of design, manufacturing, assembly, and use on product reliability performance. Through lectures, discussions, case studies, and practical examples, we will build a solid foundation for your useful mastery of product reliability techniques.

What you will learn:

  • How to identify and quantify variability that impacts your design’s reliability performance.
  • How to structure a reliability plan to achieve the desired results for your customers
  • How to identify and verify critical assumptions avoiding costly mistakes
  • How to use capability studies in tolerance analysis during the early design phase
  • How to identify and efficiently monitor critical to reliability aspects of your product
  • How to design and execute reliability testing even with small sample sizes
  • How to engage your critical suppliers to understand and achieved the desired reliability performance of supplied items

Course Outline:

  1. Reliability Statistics Fundamentals. Dealing with time to failure datasets, understanding comparisons, statistical thinking, data summary, and exploring, characterizing and understanding variability.
  2. Product Design and Statistics. Reliability goals and models and the impact of variability on design decisions. Connecting your design tolerances to process capability and stability. Using the data you have available to the best advantage when creating a reliable product.
  3. The Basic Reliability Plan. Start with a goal, understand the risks, characterize capabilities, identify the critical decisions and the necessary information necessary to make the right decision. The best use of reliability testing to learn the most from each test item.
  4. Challenging Statistical Assumptions. Understand the impact of your ability to select the best option when the underlying assumptions are invalid. Identify the important assumptions behind common statistical techniques and how to check those assumptions.
  5. Identify Critical to Reliability Design Elements. Find the critical few aspects of your design that risk resulting in poor field reliability performance. Establish enhanced focus on the key elements of the design and assembly process that permit either the improvement of reliability performance or the early warning of potential problems.
  6. Effective Reliability Testing. HALT, ALT, Environmental Testing each provide a means to learn. Connecting every test to specific decisions permits the design of testing that yield the right information to inform and guide the development of a reliability product. Learn the limitations of test to pass approaches and how to design cost effective and valuable reliability testing.
  7. Suppliers, Vendors, and Reliability. You vendor supplied components, modules and assemblies can make or break your system’s reliability performance. Learn how to establish positive and reinforcing relationships that avoids disappointing field reliability problems.


If this course is not on the current schedule of open enrollment courses and you are interested in attending this or another course as an open enrollment, please contact us at (410)956-8805 or Please indicate the course name, number of students who wish to participate. and a preferred time frame. ATI typically schedules open enrollment courses with a 3-5 month lead time. For on-site pricing, you can use the request an on-site quote form, call us at (410)956-8805, or email us at


  • Fred Schenkelbergs an international authority on reliability engineering. He is the reliability expert at FMS Reliability, a reliability engineering and management consulting firm he founded in 2004. Fred left Hewlett Packard (HP)’s Reliability Team where he helped create a culture of reliability across the corporation to assist other organizations. His passion is working with teams to improve product reliability, customer satisfaction, and efficiencies in product development; and to reduce product risk and warranty costs. Fred has a Bachelor of Science in Physics from the United States Military Academy and a Master of Science in Statistics from Stanford University.

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