Design an effective reliability demonstration test plan using Six Sigma approach

Reliability Demonstration Test (RDT) is a stress testing to determine whether the product will meet a specified reliability goal and time. Often being discussed is the method in performing the RDT, but the detailed steps in developing RDT is seldom being shared, especially on new product development with no correlation to field data. RDT is a hypothesis testing, failure in using the effective RDT plan will cause disputed confidence in the integrity of the testing result. One of the ways to ensure the effectiveness of the RDT plan is by implementing the Six Sigma strategy. In this paper, the planning of developing RDT by using a structured Design for Six Sigma method, DMADV - Define, Measure, Analyze, Design and Verify is discussed. The DMADV steps will guide and outline the process from early stage until the end stage of developing the RDT plan. The plan will consider every process that is involved in the product design life cycle, including market or customer needs, reliability requirements, cumulative effects of use environment, life analysis distribution and tests equipment capabilities. The analysis tools used are translated from Critical-To-Quality (CTQ) to Critical-To-Reliability (CTR) requirements.