Modeling and maximizing burn-in effectiveness

System burn-in can get rid of many residual defects left from component and subsystem burn-in since incompatibility exists not only among components but also among different subsystems and at the system level. Even if system, subsystem, and component burn-in are performed, the system reliability often does not achieve the requirement. In this case, redundancy is a good way to increase system reliability when improving component reliability is expensive. This paper proposes a nonlinear model to: estimate the optimal burn-in times for all levels, and determine the optimal amount of redundancy for each subsystem. For illustration, a bridge system configuration is considered; however, the model can be easily applied to other system configurations. Since there are few studies on system, subsystem, and component incompatibility, reasonable values are assigned for the compatibility factors at each level