Maximizing the Benefits of HASS Testing: Tips for Successful Implementation

Friday, June 28 2024

Highly Accelerated Stress Screening (HASS) is a production screening tool using stresses based on HALT results. It subjects products to extreme thermal and repetitive shock stress to reveal defects that typical Environmental Stress Screening (ESS) can miss.

The goal of HASS is to catch and fix defects due to factory or supplier shifts before the product reaches consumers. This process boosts product reliability, reduces time to test, cuts costs, reduces risks, and promotes continuous improvement. To make the most of it, manufacturers and production facility workers must understand how it works. With that in mind, here are a few tips for optimizing the process at every stage:

10 Ways to Maximize the Benefits of HASS Testing

1. Design Effective Fixtures

Create custom fixtures tailored to the product to ensure uniform stress application. A correctly designed fixture will:

  • Efficiently transmit vibration energy into the product

  • Uniformly excite products across a fixture and across a table

  • Reduce chances of cosmetic damage to the product during testing

  • Allow for quick and easy loading and unloading of the product to improve throughput

  • Integrates connections to functional test equipment

2. Validate Stress Levels

Refer to HALT data to determine appropriate stress levels that reveal defects without causing unnecessary damage. The limits found in HALT are guard-banded then tested to demonstrate that the stress levels are effective and safe. Regularly review and adjust these profiles based on new data and production changes.

3. Implement ESD Protection

Use anti-static materials and grounding techniques—and train staff in ESD prevention—to protect sensitive components from electrostatic discharge during testing.

4. Maintain Detailed Reporting

Keep comprehensive records of testing procedures, conditions, and results. Analyze data to identify trends and inform improvements in the product or the HASS process. Ensure reports are clear and accessible to all relevant stakeholders.

5. Develop Corrective Actions

Investigate root causes of defects found during HASS, implement corrective actions, and use insights to continuously improve product design, manufacturing processes, and testing protocols.

6. Conduct Functional Tests

Perform functional testing while the product is under stress in HASS to allow for capturing of soft failures. These soft failures are a key contributor to “No Defect Found” (NDF) problems in the field.

7. Provide Staff Training

Offer ongoing training on HASS procedures, equipment use, and safety protocols. Update training regularly to incorporate advancements and ensure staff understand the goal and methodology of HASS testing. To learn more about training your staff, reach out to [email protected].

8. Customize and Adapt Protocols

Adjust HASS protocols to accommodate changes in product design or manufacturing processes. Customize stress profiles for different product types to ensure relevant and effective testing.

9. Encourage Feedback and Collaboration

Foster collaboration between engineering, manufacturing, and quality assurance teams. Incorporate customer feedback to address real-world performance issues and enhance product reliability.

10. Track Performance Metrics

Establish KPIs to measure HASS effectiveness, such as defect detection rates and field failure metrics. Regularly review this data to identify improvement areas and refine testing protocols for better product reliability and manufacturing test efficiency.

Enhance Product Reliability with ESPEC's HASS Testing Chambers

HASS testing is an excellent method for identifying production issues before they reach your customers. It helps reduce costs, build customer trust, and improve continuous product refinement. Understanding and utilizing this effective stress-testing method is valuable for your business.

Looking for top-notch HASS testing solutions? ESPEC provides a wide range of HASS testing chambers designed to ensure product reliability and quality. Contact us today to learn how we can help streamline your testing process and enhance product performance.