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SYSTEM MANAGEMENT
RECOMMENDED PRACTICE
TAHB009™
REV. A
Issued 2013-05
Revised 2019-05
Superseding TAHB0009
(R) Reliability Program Handbook
RATIONALE
With the cancellation in 1998 of MIL-STD-785B, the government has not provided a suitable reliability standard that includes
reliability management practices and reliability design and testing Activities that its customers want developers to propose.
To restore and enhance the ability of government contracting authorities to contract for reliability, GEIASTD0009 was
developed by incorporating and aligning with best practices, without prescriptively defining the reliability tasks or Methods
to be performed. This orientation made developers equal partners in deciding which reliability Methods are applicable and
resulted in the release of GEIASTD0009 on November 13, 2008, and its subsequent adoption for voluntary use by the
Department of Defense on August 20, 2009.
NOTE: ANSI/GEIA-STD-0009 has become GEIASTD0009. Therefore, all further references will reflect this change. On
November 13, the government has not provided a suitable reliability standard that includes reliability management
practices and reliability design and testing Activities that its customers want developers to propose.
FOREWORD
This Reliability Handbook, TAHB0009, is the companion implementation guide for GEIASTD0009 and provides
comprehensive “how to” guidance to industry and government for the four Objectives of GEIASTD0009, which are:
• Understand customer/user requirements and constraints
• Design and redesign for reliability
• Produce reliable systems/products
• Monitor and assess user reliability
The second edition of TAHB0009 is substantially expanded and renewed on such topics as:
• Software Reliability
• Reliability Program
• FMEA
Besides support to GEIASTD0009 standard, the Handbook can be seen as a stand-alone e-publication that provides
comprehensive and modern methodology for reliability practitioners.
SAE INTERNATIONAL TAHB0009™A Page 2 of 428
ACKNOWLEDGMENTS (SECOND EDITION)
This Handbook could not have been developed without the skills and contributions of a team of subject matter experts from
industry, the Department of Defense, research institutes, and other government agencies.
TABLE OF CONTENTS
1. Scope ....................................................................................................................................................... 18
1.1
Scope ....................................................................................................................................................... 18
1.2 Handbook Approach ................................................................................................................................ 21
1.3 Definitions ................................................................................................................................................ 23
1.4 Handbook Activities .................................................................................................................................. 23
1.5 Handbook Methods .................................................................................................................................. 26
2. ACTIVITIES .............................................................................................................................................. 27
2.1
Engineering Process ................................................................................................................................ 27
2.1.1 Purpose .................................................................................................................................................... 27
2.1.2 Benefits, Enablers, and Constraints ......................................................................................................... 32
2.1.3 Timing....................................................................................................................................................... 33
2.1.4 Application Guidelines.............................................................................................................................. 34
2.1.5 Applicable Methods/Submethods ............................................................................................................ 38
2.2
System/Product-Level User and Environmental Life-Cycle Loads .......................................................... 40
2.2.1 Purpose .................................................................................................................................................... 40
2.2.2 Benefits, Enablers, and Constraints ......................................................................................................... 42
2.2.3 Timing....................................................................................................................................................... 43
2.2.4 Application Guidelines.............................................................................................................................. 43
2.2.5 Applicable Methods/Submethods ............................................................................................................ 44
2.3
Life-Cycle Loads on Assemblies, Subassemblies, Components ............................................................. 45
2.3.1 Purpose .................................................................................................................................................... 45
2.3.2 Benefits, Enablers, and Constraints ......................................................................................................... 48
2.3.3 Timing....................................................................................................................................................... 49
2.3.4 Application Guidelines.............................................................................................................................. 50
2.3.5 Applicable Methods/Submethods ............................................................................................................ 50
2.4
Closed-Loop Failure-Mode Mitigation Process ........................................................................................ 51
2.4.1 Purpose .................................................................................................................................................... 51
2.4.2 Benefits, Enablers, and Constraints ......................................................................................................... 56
2.4.3 Timing....................................................................................................................................................... 56
2.4.4 Application Guidelines.............................................................................................................................. 56
2.4.5 Applicable Methods/Submethods ............................................................................................................ 58
2.5
Identification of Failure Modes and Mechanisms ..................................................................................... 59
2.5.1 Purpose .................................................................................................................................................... 59
2.5.2 Benefits, Enablers, and Constraints ......................................................................................................... 62
2.5.3 Timing....................................................................................................................................................... 62
2.5.4 Application Guideline ............................................................................................................................... 63
2.5.5 Applicable Methods/Submethods ............................................................................................................ 64
2.6
Conceptual Reliability Model .................................................................................................................... 65
2.6.1 Purpose .................................................................................................................................................... 65
2.6.2 Constraints ............................................................................................................................................... 67
2.6.3 Timing
....................................................................................................................................................... 68
2.
6.4 Application Guidelines.............................................................................................................................. 68
2.6.5 Applicable Methods/Submethods ............................................................................................................ 68
2.7
System/Product Reliability Model ............................................................................................................ 70
2.7.1 Purpose .................................................................................................................................................... 70
2.7.2 Constraints ............................................................................................................................................... 74
2.7.3 Timing....................................................................................................................................................... 74
2.7.4 Application Guidelines.............................................................................................................................. 75
2.7.5 Applicable Methods/Submethods ............................................................................................................ 78
2.8
Reliability Assessment ............................................................................................................................. 78
2.8.1 Purpose .................................................................................................................................................... 78
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2.8.2 Benefits, Enablers, and Constraints ......................................................................................................... 82
2.8.3 Timing....................................................................................................................................................... 83
2.8.4 Application Guidelines.............................................................................................................................. 84
2.8.5 Applicable Methods/Submethods ............................................................................................................ 87
2.9
Failure Definition/Scoring Criteria ............................................................................................................ 88
2.9.1 Purpose .................................................................................................................................................... 88
2.9.2 Benefits, Enablers, Constraints ................................................................................................................ 92
2.9.3 Timing....................................................................................................................................................... 94
2.9.4 Application Guidelines.............................................................................................................................. 94
2.9.5 Applicable Methods/Submethods .......................................................................................................... 100
2.10
Reliability Program Plan ......................................................................................................................... 100
2.10.1 Purpose .................................................................................................................................................. 100
2.10.2 Benefits, Enablers, and Constraints ....................................................................................................... 107
2.10.3 Timing..................................................................................................................................................... 109
2.10.4 Application Guidelines............................................................................................................................ 109
2.10.5 Applicable Methods/Submethods .......................................................................................................... 110
2.10.6 Citations ................................................................................................................................................. 118
2.10.7 For More Information .............................................................................................................................. 118
2.11
Reliability Verification ............................................................................................................................. 119
2.11.1 Purpose .................................................................................................................................................. 119
2.11.2 Benefits, Enablers, and Constraints ....................................................................................................... 123
2.11.3 Timing..................................................................................................................................................... 123
2.11.4 Application Guidelines............................................................................................................................ 124
2.11.5 Applicable Methods/Submethods .......................................................................................................... 126
2.12
Technical Reviews ................................................................................................................................. 127
2.12.1 Purpose .................................................................................................................................................. 127
2.12.2 Benefits, Enablers, and Constraints ....................................................................................................... 130
2.12.3 Timing..................................................................................................................................................... 131
2.12.4 Application Guidelines............................................................................................................................ 131
2.12.5 Applicable Methods/Submethods .......................................................................................................... 132
3. METHODS ............................................................................................................................................. 133
3.1
Accelerated Testing Methods ................................................................................................................ 133
3.1.1 Purpose .................................................................................................................................................. 133
3.1.2 Benefits .................................................................................................................................................. 133
3.1.3 Constraints ............................................................................................................................................. 133
3.1.4 Timing..................................................................................................................................................... 134
3.1.5 Application Guidelines............................................................................................................................ 134
3.1.6 For More Information .............................................................................................................................. 137
3.2
Bayesian Techniques ............................................................................................................................. 138
3.2.1 Purpose .................................................................................................................................................. 138
3.2.2 Benefits .................................................................................................................................................. 138
3.2.3 Constraints ............................................................................................................................................. 138
3.2.4 Timing..................................................................................................................................................... 138
3.2.5 Application Guidelines............................................................................................................................ 139
3.2.6 For More Information .............................................................................................................................. 140
3.3
Benchmarking (Reliability Benchmarking) ............................................................................................. 140
3.3.1 Purpose .................................................................................................................................................. 140
3.3.2 Benefits .................................................................................................................................................. 140
3.3.3 Constraints ............................................................................................................................................. 140
3.3.4 Timing..................................................................................................................................................... 141
3.3.5 Application Guidelines............................................................................................................................ 141
3.
3.6 For More Information .............................................................................................................................. 144
3.4
Block Diagram Development ................................................................................................................. 144
3.4.1 Purpose .................................................................................................................................................. 144
3.4.2 Benefits .................................................................................................................................................. 145
3.4.3 Constraints ............................................................................................................................................. 145
3.4.4 Timing..................................................................................................................................................... 145
3.4.5 Application Guidelines............................................................................................................................ 145
3.4.6 For More Information .............................................................................................................................. 147
SAE INTERNATIONAL TAHB0009™A Page 4 of 428
3.5 Capability Maturity Model integration (CMMI
®
) ...................................................................................... 148
3.5.1 Purpose .................................................................................................................................................. 148
3.5.2 Benefits .................................................................................................................................................. 148
3.5.3 Constraints ............................................................................................................................................. 149
3.5.4 Timing..................................................................................................................................................... 149
3.5.5 Application Guidelines............................................................................................................................ 149
3.5.6 For More Information .............................................................................................................................. 151
3.6
Commercial Off-the-Shelf (COTS) Assessment .................................................................................... 151
3.6.1 Purpose .................................................................................................................................................. 151
3.6.2 Benefits .................................................................................................................................................. 151
3.6.3 Constraints ............................................................................................................................................. 151
3.6.4 Timing..................................................................................................................................................... 152
3.6.5 Application Guidelines............................................................................................................................ 152
3.6.6 For More Information .............................................................................................................................. 155
3.7
Component Testing ................................................................................................................................ 155
3.7.1 Purpose .................................................................................................................................................. 155
3.7.2 Benefits .................................................................................................................................................. 155
3.7.3 Constraints ............................................................................................................................................. 155
3.7.4 Timing..................................................................................................................................................... 156
3.7.5 Application Guidelines............................................................................................................................ 156
3.7.6 For More Information .............................................................................................................................. 158
3.8
Condition-Based Maintenance (CBM) ................................................................................................... 158
3.8.1 Purpose .................................................................................................................................................. 158
3.8.2 Benefits .................................................................................................................................................. 158
3.8.3 Constraints ............................................................................................................................................. 159
3.8.4 Timing..................................................................................................................................................... 159
3.8.5 Application Guidelines............................................................................................................................ 159
3.8.6 For More Information .............................................................................................................................. 160
3.9
Critical Items List .................................................................................................................................... 161
3.9.1 Purpose .................................................................................................................................................. 161
3.9.2 Benefits .................................................................................................................................................. 161
3.9.3 Constraints ............................................................................................................................................. 161
3.9.4 Timing..................................................................................................................................................... 161
3.9.5 Application Guidelines............................................................................................................................ 161
3.9.6 For More Information .............................................................................................................................. 164
3.10
Data Collection, Analysis, and Corrective Action System (DCACAS) ................................................... 164
3.10.1 Purpose .................................................................................................................................................. 164
3.10.2 Benefits .................................................................................................................................................. 164
3.10.3 Constraints ............................................................................................................................................. 164
3.10.4 Timing..................................................................................................................................................... 164
3.10.5 Application Guidelines............................................................................................................................ 164
3.10.6 For More Information .............................................................................................................................. 166
3.11
Data Management Technique (PREDICT) ............................................................................................ 166
3.11.1 Purpose .................................................................................................................................................. 166
3.11.2 Benefits .................................................................................................................................................. 166
3.11.3 Constraints ............................................................................................................................................. 167
3.11.4 Timing..................................................................................................................................................... 167
3.11.5 Application Guidelines............................................................................................................................ 167
3.11.6 For More Information .............................................................................................................................. 168
3.12
Design for Manufacturing and Design for Assembly .............................................................................. 168
3.12.1 Purpose .................................................................................................................................................. 168
3.12.2 Benefits .................................................................................................................................................. 169
3.12.3 C
onstraints ............................................................................................................................................. 169
3.12.4 Timing..................................................................................................................................................... 169
3.12.5 Application Guide ................................................................................................................................... 169
3.12.6 For More Information .............................................................................................................................. 170
3.13
Design of Experiments (DOE) - classical and Taguchi .......................................................................... 171
3.13.1 Purpose .................................................................................................................................................. 171
3.13.2 Benefits .................................................................................................................................................. 171
3.13.3 Constraints ............................................................................................................................................. 171
SAE INTERNATIONAL TAHB0009™A Page 5 of 428
3.13.4 Timing..................................................................................................................................................... 171
3.13.5 Application Guideline ............................................................................................................................. 171
3.13.6 For More Information .............................................................................................................................. 180
3.14
Design Guidelines for Reliable Surface Mount Technology Printed Board Assemblies ........................ 181
3.14.1 Purpose .................................................................................................................................................. 181
3.14.2 Benefits .................................................................................................................................................. 181
3.14.3 Constraints ............................................................................................................................................. 181
3.14.4 Timing..................................................................................................................................................... 181
3.14.5 Application Guidelines............................................................................................................................ 182
3.14.6 For More Information .............................................................................................................................. 183
3.15
Design Review ....................................................................................................................................... 184
3.15.1 Purpose .................................................................................................................................................. 184
3.15.2 Benefits .................................................................................................................................................. 184
3.15.3 Constraints ............................................................................................................................................. 184
3.15.4 Timing..................................................................................................................................................... 184
3.15.5 Application Guidelines............................................................................................................................ 184
3.15.6 For More Information .............................................................................................................................. 188
3.16
Durability Analysis .................................................................................................................................. 188
3.16.1 Purpose .................................................................................................................................................. 188
3.16.2 Benefits .................................................................................................................................................. 188
3.16.3 Constraints ............................................................................................................................................. 188
3.16.4 Timing..................................................................................................................................................... 189
3.16.5 Application Guidelines............................................................................................................................ 189
3.16.6 For More Information .............................................................................................................................. 191
3.17
Durability Verification Test ..................................................................................................................... 192
3.17.1 Purpose .................................................................................................................................................. 192
3.17.2 Benefits .................................................................................................................................................. 192
3.
17.3 Constraints ............................................................................................................................................. 192
3.17.4 Timing..................................................................................................................................................... 192
3.17.5 Application Guidelines............................................................................................................................ 192
3.17.6 For More Information .............................................................................................................................. 192
3.18
Environmental and Product Usage Profile/Mission Profile .................................................................... 193
3.18.1 Purpose .................................................................................................................................................. 193
3.18.2 Benefits .................................................................................................................................................. 193
3.18.3 Constraints ............................................................................................................................................. 193
3.18.4 Timing..................................................................................................................................................... 193
3.18.5 Application Guidelines............................................................................................................................ 194
3.18.6 For More Information .............................................................................................................................. 200
3.19
Environmental Qualification Test ........................................................................................................... 201
3.19.1 Purpose .................................................................................................................................................. 201
3.19.2 Benefits .................................................................................................................................................. 202
3.19.3 Constraints ............................................................................................................................................. 202
3.19.4 Timing..................................................................................................................................................... 202
3.19.5 Application Guidelines............................................................................................................................ 202
3.19.6 For More Information .............................................................................................................................. 203
3.20
Environmental Stress Screening/Highly Accelerated Stress Screening ................................................ 203
3.20.1 Purpose .................................................................................................................................................. 203
3.20.2 Benefits .................................................................................................................................................. 204
3.20.3 Constraints ............................................................................................................................................. 204
3.20.4 Timing..................................................................................................................................................... 205
3.20.5 Application Guidelines............................................................................................................................ 205
3.20.6 For More Information .............................................................................................................................. 211
3.21
Error/Mistake Proofing (Poka-Yoke) ...................................................................................................... 212
3.21.1 Purpose .................................................................................................................................................. 212
3.21.2 Benefits .................................................................................................................................................. 212
3.21.3 Constraints ............................................................................................................................................. 212
3.21.4 Timing..................................................................................................................................................... 212
3.21.5 Application Guidelines............................................................................................................................ 212
3.21.6 For More Information .............................................................................................................................. 214
3.22
Failure Mode and Effects Analysis/Failure Mode, Effects, and Criticality Analysis ............................... 215
