Recently I saw an unsupported statement saying that the industry average for DOA (Dead on Arrival) rates were 2% in the electronics.

Does anyone have any information/links on this figure as I would like a comparison figure for my employers DOA rates.

:thanx:

Recently I saw an unsupported statement saying that the industry average for DOA (Dead on Arrival) rates were 2% in the electronics.

Does anyone have any information/links on this figure as I would like a comparison figure for my employers DOA rates.

:thanx:Is this for finished product or components?

Is this for finished product or components?

And what "industry"?

It's for finished products. My company is professional broadcast products such as multiplexers, encoders etc. It basically a load of components mounted on a PCB so looking for something similar.

Recently I saw an unsupported statement saying that the industry average for DOA (Dead on Arrival) rates were 2% in the electronics.

Does anyone have any information/links on this figure as I would like a comparison figure for my employers DOA rates.We build power inverters for mobile applications. Translation: 100s of electronics components in a metal box that convert 12VDC to 120VAC in a moving vehicle. First off, our TS customers would bury us in paperwork if we had a 2% lineside failure rate!!! Then they would dig us out and fire what was left. That's a 20,000 PPM rate. :mg:
We warrant our products for 2 years from the date of installation. Our overall warranty return rate for COMPLETE ASSEMBLIES is a lot closer to 1% than it is to 2%. Example product: 400 components, surface mount and through-hole mixed, single PCB, mounted in an aluminum casting and ultimately located in the battery compartment of transit authority buses: 99.63% operative after 2 years. Add in a daughter PCB (200 components SMT) for monitoring, with microprocessor and cabling connection to the bus brain, and we have 99.37% operative after 2 years.

We are a similar electronics supplier, providing surface mount and thru hole products, along with machining and cable work, and recently added ruggidized displays to the aerospace and defense industries. Our corporate goals break down as follows:

Defense - 1,500 ppm failure at customer
Aerospace - 5,000 ppm failure at customer

And we exceed our goals more often then not.

Definitely not 2% coming from us! I would probably be out of a job if we were :o)

But I also have heard that basic consumer goods (not are customer base) has a much higher failure rate.

Rebecca

Manufacturing entites are now taking their products to 2 to 3 digit ppm for catastropic failures. I know of some of customers in Japan demanding 0.5 ppm for their audio video manfacturing. 4 digit ppm goes 20 years backward.

Thanks for the info folks very helpful :)

After doing a little more digging around what my company considers to be a DOA device I found out it included things like missing manuals, wrongly configured software, licence keys etc :mad:

This would explain why our DOA figure is so high, higher even than the 2% reference figure quoted. First job for me is to now have a good hard look at how we categorize these calls.

In my future I suddenly see a lot more meetings :(

Anybody have any idea what will happen to these DOA rates with all devices complying with the new Reduction of Hazardous Substances requirements?

I assume you mean Restriction of the Use of Certain Hazardous Substances(RoHS). All our products are now RoHS compliant and we have certainly not had any noticeable jump in either DOA or ELF's (Early Life Failures).

We spent a lot of time identifying replacement components and then a lot more time with our manufacturing subcontractors getting the new processes sorted out (lead free soldering etc.). The result has been very good and we have not seen any increase in failures due to RoHS, and I would put this down to the amount of resource we expended on these activities.