Services
End-to-End Reliability Engineering for Modern Hardware Systems
ReliaNova delivers reliability across your entire product lifecycle — from the first sketch to field performance. We operate as an embedded partner within your engineering, quality, and supplier teams, helping you reduce risk, accelerate development, and launch with confidence.
Our team brings decades of global experience across consumer electronics, robotics, EV, datacenters, and industrial systems. A globally aligned, physics-driven, cradle-to-cradle approach ensures reliability is designed in, validated, monitored, and continuously improved.
- Concept to field reliability
- Cradle-to-cradle reliability philosophy
- Experience across consumer electronics, robotics, EV, datacenters
Our Service Pillars
From early design to global supply chains, our services cover the full reliability lifecycle.
Reliability must begin early. We apply Design for Reliability (DfR) and Physics of Failure (PoF) methods to identify and eliminate failure modes at the concept and design stages, long before they emerge — when they are cheapest and fastest to fix. Our work includes FMMEA, stress–strength analysis, PoF modeling, margin analysis, and defining Critical-to-Reliability (CTR) parameters.
More about this service
What we do
- FMMEA (Failure Mode, Mechanism & Effects Analysis)
- Stress–strength & safety-margin analysis
- Physics-of-failure modeling (fatigue, corrosion, creep, thermal-mechanical stress)
- Material and process risk assessments
- Critical-to-Reliability (CTR) parameter definition
Value
Prevents late-stage surprises and builds structural robustness into your design.
Mini Case Example
In an early EV phase investigation, one microphone in a four-element differential pressure array exhibited inconsistent mid-frequency measurements compared to the other three. Using PoF-based reasoning supported by FEA and laboratory failure analysis, the issue was traced to a tiny enclosure gap located precisely at the affected microphone’s position. This gap only opened under a specific structural-acoustic interference mode in that frequency band, allowing pressure leakage and producing destructive acoustic cancellation at the mic.
By introducing a visco-elastic support pad, the enclosure stiffness and damping characteristics were modified—shifting the resonance behavior, suppressing the structural-acoustic mode, and eliminating the gap opening. The fix fully resolved the measurement inconsistency in the next EV build.
We provide early predictive insights into your product’s weaknesses and reliability limits, using advanced modeling techniques. This includes FMMEA-based allocations, FEA for thermal/mechanical stress, Weibull and AFR modeling, Monte Carlo simulations, and structured Design of Experiments (DoE). These tools enable smarter design decisions and help avoid late-stage redesigns and guide robust engineering decisions.
More about this service …
What we do
- FMMEA-based reliability allocations
- Finite Element Analysis (FEA) for stress, thermal, vibration
- Reliability modeling (Weibull, AFR prediction, Monte Carlo)
- Design of Experiments (DoE) to isolate dominant stresses
- Forecasting for AFR, life expectancy, and warranty exposure
Value
Reduces uncertainty, prevents costly redesigns, and optimizes design trade-offs.
Mini Case Example
In past development cycles, early vibration simulations flagged potential fretting at a PCB–connector interface in a portable device. A structured DoE validated the mechanism and quantified sensitivity to mounting stiffness. Minor design enhancements to connector retention and solder-joint support reduced predicted AFR by more than 50% under expected field profiles.
Testing reveals what simulation alone cannot. We design and interpret reliability test programs such as HALT, HASS, ALT, RDT, ORT, and ESS. While third-party or client labs perform the tests, ReliaNova ensures correct stress profiles, sample plans, instrumentation, and analytics to validate design maturity and qualification readiness.
More about this service …
What we do
- Reliability Characterization Testing
- Drop/shock, vibration, thermal cycling
- Reliability Design of Experiment (DoE) Testing
- Accelerated Life Testing (ALT)
- Reliability Demonstration Testing (RDT)
- HALT, HASS
- Ongoing Reliability Testing (ORT)
- ESS and environmental screening
Value
Ensures the design matures as intended and meets customer and industrial standards.
Mini Case Example
In a previous qualification phase, EMI clips detached from the PCBA on a large number of tested DV build units. Unlike earlier builds—where the clips were hand-soldered after reflow—this revision required the clips to withstand two full reflow cycles. Failure analysis (EDX/FTIR) showed that a surface contaminant reduced solder wettability and that the Ni/Au–BeCu interface began to delaminate under the second reflow cycle. Additional process issues were identified, including insufficient solder paste height and uneven paste deposition across the panel.
Through reflow-profile optimization, stencil-cleanliness corrections, paste-height adjustments, and increased pick-and-place Z-force to drive solder flow through the clip’s center hole, the assembly process was stabilized. Subsequent DV runs showed robust clip attachment and consistent qualification yields.
We help clients turn raw returns, logs, and IoT data into actionable reliability insights. We integrate physics-of-failure (PoF) with AI-based prognostics to detect risks long before failures occur. Our work includes AFR analysis, warranty modeling, Prognostics & Health Management (PHM), condition-based monitoring, Remaining Useful Life (RUL) estimation, and AI-driven risk prediction.
More about this service …
What we do
- AFR / warranty data mining
- IoT data ingestion & sensor-driven diagnostics
- PHM (Prognostics & Health Management)
- Remaining Useful Life (RUL) estimation
- Prognostics Distance (PD) forecasting
- Condition-based maintenance strategy
Value
Shifts teams from reactive to predictive — lowering downtime, warranty exposure, and lifecycle costs.
Mini Case Example
In earlier field-operations work, a conveyor system suffered unexpected motor failures without sufficient lead time. By integrating IR-based thermal patterns with PHM algorithms to estimate degradation and Prognostics Distance (PD), the team enabled scheduled maintenance interventions weeks before end-of-life signatures appeared.
Suppliers play a central role in hardware reliability. We help ensure suppliers deliver consistent, predictable quality across global manufacturing ecosystems.We conduct reliability-focused supplier audits, evaluate test labs, create AVL and derating rules, develop supplier reliability scorecards, and close gaps through corrective actions. Our expertise spans AMER/EMEA/APAC supply chain bridging.
More about this service …
What we do
- Supplier reliability audits and capability assessments
- Reliability and Failure Analysis lab evaluation & process-quality reviews
- AVL creation & component derating analysis
- Reliability scorecards & maturity ranking
- Corrective Action (8D/RCA) support
- Ongoing supplier reliability programs
Value
Reduces variability, improves part quality, and bridges cultural/technical gaps between international customers and suppliers.
Mini Case Example
In a previous program, reliability testing at our side revealed that a batch of board-to-board connectors consistently failed customer bend-test requirements and showed insufficient terminal extraction force. Deeper investigation traced the issue upstream to a Tier-3 supplier, where material properties and tolerance stack-up were driving weakened mechanical retention. Statistical analysis indicated that nearly 20% of units in the lot would fall below the 1 kgf extraction-force threshold, with about 0.5% dropping below 0.6 kgf—well outside specification.
The findings highlighted the critical importance of structured supplier-reliability management. By coordinating with cross-functional teams—reliability engineering, SQE, supplier engineering, and manufacturing—we implemented corrective recommendations to stabilize production while initiating longer-term material and dimensional improvements with the Tier-3 supplier.
Reliability is not a toolset — it is an operating model. Our Reliability Strategy & Roadmapping service helps organizations build structured, scalable reliability programs aligned with business goals, product complexity, and organizational maturity. We translate high-level objectives into actionable reliability plans, complete with governance models, KPIs, reliability budgets, and capability-building pathways.
More about this service …
What we do
- Reliability maturity assessments and gap analysis (process, skill, infrastructure)
- Define reliability strategy and budget, AFR targets, and CTR-based prioritization
- Develop multi-year reliability roadmaps aligned with cost, schedule, and risk
- Build scalable reliability programs across prototype, DV, and production phases
- Align cross-functional teams around reliability goals and decision-making
Value
Creates a unified reliability direction, ensuring teams are aligned, funded, and working toward measurable long-term objectives instead of reacting to failures.
Mini Case Example
In a prior role, our team supported a global hardware organization that lacked a unified reliability strategy across its engineering, manufacturing, and supplier groups. By mapping maturity gaps and aligning cross-functional priorities, the team delivered a multi-year reliability roadmap that clarified targets, structured investment, and created a cohesive reliability function. The same structured approach now guides how ReliaNova supports early-stage partners establishing their first reliability programs.
Reliability is strongest when internal teams understand the “why” behind the engineering. ReliaNova provides training and capability-building grounded in decades of hands-on experience across product development, failure analysis, supplier engineering, and field reliability. Our approach blends fundamentals with practical, real-world examples that resonate with engineers, technicians, and leaders.
More about this service …
What we do
- Customized reliability workshops covering DfR, PoF, FMMEA, RCA, PHM, and test planning
- Supplier reliability and audit training for procurement, SQE, and supplier engineering teams
- Field reliability analytics training (AFR, RUL, sensor data interpretation, trend analysis)
- Human-factors-driven reliability practices for operations, service, and manufacturing teams
- Leadership coaching on reliability culture and decision-making
- Hands-on case-study exercises and mentoring for new reliability engineers and emerging leaders
Value
Transforms reliability from a dependency on external experts into a durable, scalable internal capability that grows with your organization.
Mini Case Example
Members of the ReliaNova team have previously led hands-on reliability coaching for robotics, consumer electronics, and datacenter organizations. In one engagement, training technicians on PoF failure signatures dramatically improved troubleshooting accuracy and cut unscheduled downtime by more than a third. These experiences directly shape the practical, application-focused training programs ReliaNova now offers to clients.
Academic institutions are increasingly expected to equip students with industry-ready reliability engineering skills. We partner with universities to design, modernize, and scale reliability programs — integrating Physics of Failure, FMMEA, accelerated testing, data analytics, and industry-aligned lab capabilities into their curriculum and research ecosystem.
More about this service …
What we do
- Design and modernization of undergraduate and graduate reliability curricula
- Creation of course and lab modules (PoF, PHM, FMMEA, DfR, accelerated testing, reliability analytics)
- Hands-on reliability lab development including equipment selection and test-capability roadmaps
- Support for capstone projects and applied research collaborations
- Faculty training workshops and guest lecture support
- Academic–industry partnership frameworks (internships, joint research, and shared lab initiatives)
Value
Bridges academic foundations with industry needs, helping institutions graduate students who are ready for real-world reliability roles.
Mini Case Example
Before founding ReliaNova, members of our team contributed to university reliability courses, supervised graduate research, and collaborated with internationally recognized programs in PoF, PHM, and system reliability. These experiences now inform ReliaNova’s academic partnerships, helping universities modernize reliability curricula and connect students with practical engineering pathways.
- Early Design
- Virtual Insight
- Prove & Qualify
- Predict & Prevent
- Supply Chain
- Strategic Reliability
- Capability Building
- Academic Partnership
EARLY DESIGN
Design for Reliability (DfR) & Physics of Failure (PoF)
Reliability must begin early. We apply Design for Reliability (DfR) and Physics of Failure (PoF) methods to identify and eliminate failure modes at the concept and design stages, long before they emerge — when they are cheapest and fastest to fix. Our work includes FMMEA, stress–strength analysis, PoF modeling, margin analysis, and defining Critical-to-Reliability (CTR) parameters.
More about this service
What we do
- FMMEA (Failure Mode, Mechanism & Effects Analysis)
- Stress–strength & safety-margin analysis
- Physics-of-failure modeling (fatigue, corrosion, creep, thermal-mechanical stress)
- Material and process risk assessments
- Critical-to-Reliability (CTR) parameter definition
Value
Prevents late-stage surprises and builds structural robustness into your design.
Mini Case Example
In an early EV phase investigation, one microphone in a four-element differential pressure array exhibited inconsistent mid-frequency measurements compared to the other three. Using PoF-based reasoning supported by FEA and laboratory failure analysis, the issue was traced to a tiny enclosure gap located precisely at the affected microphone’s position. This gap only opened under a specific structural-acoustic interference mode in that frequency band, allowing pressure leakage and producing destructive acoustic cancellation at the mic.
By introducing a visco-elastic support pad, the enclosure stiffness and damping characteristics were modified—shifting the resonance behavior, suppressing the structural-acoustic mode, and eliminating the gap opening. The fix fully resolved the measurement inconsistency in the next EV build.
VIRTUAL INSIGHT
Modeling & Simulation
We provide early predictive insights into your product’s weaknesses and reliability limits, using advanced modeling techniques. This includes FMMEA-based allocations, FEA for thermal/mechanical stress, Weibull and AFR modeling, Monte Carlo simulations, and structured Design of Experiments (DoE). These tools enable smarter design decisions and help avoid late-stage redesigns and guide robust engineering decisions.
More about this service …
What we do
- FMMEA-based reliability allocations
- Finite Element Analysis (FEA) for stress, thermal, vibration
- Reliability modeling (Weibull, AFR prediction, Monte Carlo)
- Design of Experiments (DoE) to isolate dominant stresses
- Forecasting for AFR, life expectancy, and warranty exposure
Value
Reduces uncertainty, prevents costly redesigns, and optimizes design trade-offs.
Mini Case Example
In past development cycles, early vibration simulations flagged potential fretting at a PCB–connector interface in a portable device. A structured DoE validated the mechanism and quantified sensitivity to mounting stiffness. Minor design enhancements to connector retention and solder-joint support reduced predicted AFR by more than 50% under expected field profiles.
PROVE & QUALIFY
Testing & Qualification
Testing reveals what simulation alone cannot. We design and interpret reliability test programs such as HALT, HASS, ALT, RDT, ORT, and ESS. While third-party or client labs perform the tests, ReliaNova ensures correct stress profiles, sample plans, instrumentation, and analytics to validate design maturity and qualification readiness.
More about this service …
What we do
- Reliability Characterization Testing
- Drop/shock, vibration, thermal cycling
- Reliability Design of Experiment (DoE) Testing
- Accelerated Life Testing (ALT)
- Reliability Demonstration Testing (RDT)
- HALT, HASS
- Ongoing Reliability Testing (ORT)
- ESS and environmental screening
Value
Ensures the design matures as intended and meets customer and industrial standards.
Mini Case Example
In a previous qualification phase, EMI clips detached from the PCBA on a large number of tested DV build units. Unlike earlier builds—where the clips were hand-soldered after reflow—this revision required the clips to withstand two full reflow cycles. Failure analysis (EDX/FTIR) showed that a surface contaminant reduced solder wettability and that the Ni/Au–BeCu interface began to delaminate under the second reflow cycle. Additional process issues were identified, including insufficient solder paste height and uneven paste deposition across the panel.
Through reflow-profile optimization, stencil-cleanliness corrections, paste-height adjustments, and increased pick-and-place Z-force to drive solder flow through the clip’s center hole, the assembly process was stabilized. Subsequent DV runs showed robust clip attachment and consistent qualification yields.
PREDICT & PREVENT
Field Reliability, Data Analytics & PHM (AI-Driven)
We help clients turn raw returns, logs, and IoT data into actionable reliability insights. We integrate physics-of-failure (PoF) with AI-based prognostics to detect risks long before failures occur. Our work includes AFR analysis, warranty modeling, Prognostics & Health Management (PHM), condition-based monitoring, Remaining Useful Life (RUL) estimation, and AI-driven risk prediction.
More about this service …
What we do
- AFR / warranty data mining
- IoT data ingestion & sensor-driven diagnostics
- PHM (Prognostics & Health Management)
- Remaining Useful Life (RUL) estimation
- Prognostics Distance (PD) forecasting
- Condition-based maintenance strategy
Value
Shifts teams from reactive to predictive — lowering downtime, warranty exposure, and lifecycle costs.
Mini Case Example
In earlier field-operations work, a conveyor system suffered unexpected motor failures without sufficient lead time. By integrating IR-based thermal patterns with PHM algorithms to estimate degradation and Prognostics Distance (PD), the team enabled scheduled maintenance interventions weeks before end-of-life signatures appeared.
SUPPLY CHAIN
Supplier Reliability & Global Supply Chain Assurance
Suppliers play a central role in hardware reliability. We help ensure suppliers deliver consistent, predictable quality across global manufacturing ecosystems.We conduct reliability-focused supplier audits, evaluate test labs, create AVL and derating rules, develop supplier reliability scorecards, and close gaps through corrective actions. Our expertise spans AMER/EMEA/APAC supply chain bridging.
More about this service …
What we do
- Supplier reliability audits and capability assessments
- Reliability and Failure Analysis lab evaluation & process-quality reviews
- AVL creation & component derating analysis
- Reliability scorecards & maturity ranking
- Corrective Action (8D/RCA) support
- Ongoing supplier reliability programs
Value
Reduces variability, improves part quality, and bridges cultural/technical gaps between international customers and suppliers.
Mini Case Example
In a previous program, reliability testing at our side revealed that a batch of board-to-board connectors consistently failed customer bend-test requirements and showed insufficient terminal extraction force. Deeper investigation traced the issue upstream to a Tier-3 supplier, where material properties and tolerance stack-up were driving weakened mechanical retention. Statistical analysis indicated that nearly 20% of units in the lot would fall below the 1 kgf extraction-force threshold, with about 0.5% dropping below 0.6 kgf—well outside specification.
The findings highlighted the critical importance of structured supplier-reliability management. By coordinating with cross-functional teams—reliability engineering, SQE, supplier engineering, and manufacturing—we implemented corrective recommendations to stabilize production while initiating longer-term material and dimensional improvements with the Tier-3 supplier.
STRATEGIC RELIABILITY
Reliability Strategy & Roadmapping
Reliability is not a toolset — it is an operating model. Our Reliability Strategy & Roadmapping service helps organizations build structured, scalable reliability programs aligned with business goals, product complexity, and organizational maturity. We translate high-level objectives into actionable reliability plans, complete with governance models, KPIs, reliability budgets, and capability-building pathways.
More about this service …
What we do
- Reliability maturity assessments and gap analysis (process, skill, infrastructure)
- Define reliability strategy and budget, AFR targets, and CTR-based prioritization
- Develop multi-year reliability roadmaps aligned with cost, schedule, and risk
- Build scalable reliability programs across prototype, DV, and production phases
- Align cross-functional teams around reliability goals and decision-making
Value
Creates a unified reliability direction, ensuring teams are aligned, funded, and working toward measurable long-term objectives instead of reacting to failures.
Mini Case Example
In a prior role, our team supported a global hardware organization that lacked a unified reliability strategy across its engineering, manufacturing, and supplier groups. By mapping maturity gaps and aligning cross-functional priorities, the team delivered a multi-year reliability roadmap that clarified targets, structured investment, and created a cohesive reliability function. The same structured approach now guides how ReliaNova supports early-stage partners establishing their first reliability programs.
CAPABILITY BUILDING
Training & Capability Building
Reliability is strongest when internal teams understand the “why” behind the engineering. ReliaNova provides training and capability-building grounded in decades of hands-on experience across product development, failure analysis, supplier engineering, and field reliability. Our approach blends fundamentals with practical, real-world examples that resonate with engineers, technicians, and leaders.
More about this service …
What we do
- Customized reliability workshops covering DfR, PoF, FMMEA, RCA, PHM, and test planning
- Supplier reliability and audit training for procurement, SQE, and supplier engineering teams
- Field reliability analytics training (AFR, RUL, sensor data interpretation, trend analysis)
- Human-factors-driven reliability practices for operations, service, and manufacturing teams
- Leadership coaching on reliability culture and decision-making
- Hands-on case-study exercises and mentoring for new reliability engineers and emerging leaders
Value
Transforms reliability from a dependency on external experts into a durable, scalable internal capability that grows with your organization.
Mini Case Example
Members of the ReliaNova team have previously led hands-on reliability coaching for robotics, consumer electronics, and datacenter organizations. In one engagement, training technicians on PoF failure signatures dramatically improved troubleshooting accuracy and cut unscheduled downtime by more than a third. These experiences directly shape the practical, application-focused training programs ReliaNova now offers to clients.
ACADEMIC PARTNERSHIP
University Reliability Program Support
Academic institutions are increasingly expected to equip students with industry-ready reliability engineering skills. We partner with universities to design, modernize, and scale reliability programs — integrating Physics of Failure, FMMEA, accelerated testing, data analytics, and industry-aligned lab capabilities into their curriculum and research ecosystem.
More about this service …
What we do
- Design and modernization of undergraduate and graduate reliability curricula
- Creation of course and lab modules (PoF, PHM, FMMEA, DfR, accelerated testing, reliability analytics)
- Hands-on reliability lab development including equipment selection and test-capability roadmaps
- Support for capstone projects and applied research collaborations
- Faculty training workshops and guest lecture support
- Academic–industry partnership frameworks (internships, joint research, and shared lab initiatives)
Value
Bridges academic foundations with industry needs, helping institutions graduate students who are ready for real-world reliability roles.
Mini Case Example
Before founding ReliaNova, members of our team contributed to university reliability courses, supervised graduate research, and collaborated with internationally recognized programs in PoF, PHM, and system reliability. These experiences now inform ReliaNova’s academic partnerships, helping universities modernize reliability curricula and connect students with practical engineering pathways.
Ready to Strengthen Your Product’s Reliability?
Whether you’re building your first prototype or scaling a global supply chain, ReliaNova provides a cradle-to-cradle reliability partnership grounded in science, analytics, and decades of experience. We will help you launch reliable, safed6ddeb, and durable products.