Quality: Optimum Ive Reliability

Optimum Quality
Quantative Reliability
HIGH RELIABILITY - is achieved by
adh erence to the following policy
mission line s required.

Reduction in s ize and number of Interface cards by use of a serial data system
utilising MSI components.
Stri ct Quality Control of wire jointing

processes.
Choice of High Quality Components underrun with spec ial attention to their thermal
and mechanical environment.
Advanced Electrostatic and Electromagnetic s hielding to improve Noise

Immunity, fully isolated s ub-chassis to
improve Comm.on Mode Rejection.
Use of Medium Scale Integration (MS I)

gi vin g improvement in overall reliability
for a given functional complexity and
improvernent in packaging techniques.
QUALITY IMPROVEME NTS BROUGHT

ABOUT BY:
Controlled soldering techniques.

Use of tywrapping to secure cable forms.
Full printed wiring boards and modular

sub-assemblie s.
Production personnel working to fully

documented process instructions .
Advance bonding techniques u sed in

chassis design gi ving hi gh strength/weight
ratio, clo se tolerance and simplified
construction.
Cross flow cooling provides fresh air

cooling to all chassis.
Maximum use of cable forming on chassis

and cabinet wiring.
Use of Kynar shrink sleeves to give

added support to conductors soldered to
terminal po s ts of edge connectors ,
Maximum use made of plated through holes

to improve packaging.
Use of s older sleeves fo r terminating

conductors and screen tails.
Use of Computer Aided Design for artwork

generation giving high accuracy - uniform
layout.
Use of standard white jacket cables ,

colour coded to assist Maintainability.
Use of durable, low mating force, low

contact wear connectors.
The QUANTATIVE RELIABILITY
parameters of t he equipment are:
Reduction in number of display tubes

required by utilisin g an advanced AlphaN umeric Display integrated into a single
Plasma Display Matrix .
Mean Tim e Between Failures

(MTBF)
312 hour s
Mean Time to Repair (MTTR)
60 mins.
Equipm.ent Availability A =
1
High Reliability Power Supply Modules as

integral part of unit.
1 + MTTR
U se of Ground Plane techniques to improve

noise immunity.
MTBF
O' 996
Use of High Noise Immunity Data Highway

g i ving a reduction in number of trans-
99 ' 6%
Reduction in Hardware by:Use of MSI

U se of Sampling Techniques
Multi Purpose Stimulus De vice s
Advance Bonding Techniques for
c h assis construction
F ull Printed Wired Boards with plated
through holes
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On Demand Availability
Individual UUT Check
A vailab ility i s D e pend e n t upon Maintenance Procedures
Maintainability Targets
Maintenance Simplicity
Adequate identification , vi s ibility and

acce ss ibility of part s .
Inte rchangeability of identical s uba ssemblie s .
Limitation in numb er and variety of

tools , acce ss ories and support e quipment.
Infrequent Maintenance
(a )
..
OPERATOR
DECISION
(b)
UUT FAULTY
DIAGNOSE
FAULT IN LSU
Quick remo val achi eving ease of fault

correction s .
LSU
SELF TEST
~
:0
'"'"
MAINTENAN CE PHILOSOPHY
SELF TEST
Rapid and po s itive detection of unit

failures .
Rapid and po siti ve adj u strnent calibration

a nd verification of correction.
UUT
SATIS FACTORY
Adequate tolera n ces pro vid ed which

allow for u se and wear throughout life.
Minimum Downtime
SELF CHECK
P a rt s s elected that require little or no

prev entive maintenance.
Corros ion pre ve ntion or control fe atures.
Fails safe and Fault limitation features

in the de s ign.
Connect UUT to ATE - Select Program Test UUT

2 A ll Tests Pass - UUT Satisfactory Remove UUT
3 UUT Tests Fail - Program Proceeds to
Self Check Routines
4 Self Check Tests Pass - Stimuli and Measurement Units Satisfactory - Remove UUT
Operator Decides (a) A TE Previously in Operation - No Similar
UUT Failure Confidence in ATE Performance - UUT Faulty
(b) ATE Not Previou sly in Operation - Recent
Similar UUT Failure - Suspected ATE
Relay Fault
5 Carry Out Rapid 5 Minute Check of LSU by
Selecting Program from Store
6 Line Switch Unit (LSU) Tests Pass - UUT
F aulty - Repair Action
7 Self Check Tests Fail - Program Indicate s
Selection of Self Test Routeings - Diagnosis
to FTU Board , Module or Sub-assembly
8 LSU Tests Fail - Immediate Diagnosis to
Relay Module and Relay Failure
1
UUT TESTS
Check calibration program carried out at

180 day interval s .
Maximun1 u se will be l11.ade of automatic

d i agnostic self test routines to locate
malfunction s quickly in order to re duce
repair times, s kill l evel a nd special
s upport e quipm e nt.
CORRECT IVE MAINTENANCE

Dia gno sis is accomplished by self check
and/ or self test diagnostic routines.
The de s i gn of t he ATE w ill be s uch as to

a llow a u tomatic dia gno sis to board or
module le vel.
The self test diagnostic program will

i solat e malfunctions to board, module,
or a s ub-a ssembly. Where an
indi vidual board or module cannot be
indicated groupings with a maximum of
four boards will be specified in the most
probable order of failure.
Repair of the ATE will be to replaceable

board or module.
Self te st routines can be store d and
accessed quickly by selected keyboard
operations with disc option fitted or
direct from the self check program.
Diagnosi s to a lower level in these

additional area s will require secondary
ll1aintenance action.
Limited amount of manual diagnosis

required.
The secondary action takes the form of

manual diagnosis by the technician aided
by circuit diagrams and information
contained in the ATE maintenanc e manual.
PREVENTIVE MAINTENANCE
No preventive maintenanc e w ill be required
on th e A TE other than routine servicing
on e lectro mechanical peripherals of the
control cOlnplex s uch as the tape reader,
disc, printer, punch and air filters
fitte d.
Areas that will require some manual

diagnosis are:
Power Supply Units
Chassis/ Cabinet Wirin g
-36-
ATE Checkout
FA ILURES WITHIN THE ATE RAPIDLY
IDENTIFIED BY:
SELF CHECK
These routines arrange for stimuli to be
routed back via the appropriate measurement
system on detection of a fai l ure by the test
program.
Detection of any fault by the program

1110nitor causes the Master Program to
reset the ATE and provide a fault
indication.
POWER SUPPLY FAILURE MONITORS
Failures of the system power s upplie s are
detected and indicated by:
Failures in Self Check will produce an

indication of a sel ected entry into the
Self Test Program.
Power Fail Indication on the Main

Control Panel
A specific supply failure indication on
the system power supplies front panel
PROGRAM MON ITORS

These are written within the Interpretive
Master Program and include : Continuous checks of a ll dat a transfers to
ve rify that information received and stored
by an IFU i s the same as that transmitted
from the control system.
A logic signal will inform the computer of

a supply failure in order to bring about
a program and hardware reset condition.
Failures of the measuring system power
supplies are indicated separately on the
unit front panel.
- 37 -
Rapid and complete checkout of the LineSwitch Unit using a Self Test Adaptor
designed only to test the relays . Indication
of Relay Module and Relay Failure will
be displayed .
SELF TEST
TEIT ATE
CONTRO L
COMPLEX
DIAGNOIE
PERIRH ERAL
FAILURE
INC I CllTES
BOARD OR
SUB ASSY.
FAILURE WITHIN
CON TROL &
DISPLAY UNIT
A comparison check of all FTUs one

against another using an FTU routeing
adaptor will provide a checkout of all
parameters to fulfil an ATE operational
test while using second opinions as
necessary to isolate any malfunction
first to the failing unit and then to
indicate the faulty board, module or
s ub-a ssem bly within that unit.
TEST
LSU
SELF
CHECK
ENTRY
D IAGNOSE
FAULT IN
L SU
TEST ATE
ATE
SAT I SF ACTORY
IN DICATES
RELAY MODULE
AND RELAY
FAILURE
DIAGNOSE BOARD
MOD ULE OR SUB'
ASSEMeLY FAILURE
WITHIN UNIT
The program is constructed such that

selected entry into the program is allowed
to provide a direct link from Self Check
failure s .
After Sales Support
Routines can be contained on the disc

backing store and selected quickly when
required.
INDICATE CHECK
CAll BRAT ION
ROUTINE FOR
ADJUSTMENT
Failure information will be indicated by

the Display or Printer with references to
the Maintenance Manual as necessary
for detailed repair action.
CONTROL COMPLEX SELF TEST

The Control Complex Self Test routines
establish the integrity of, and perform
fault diagnosis on the units of the Complex.
CHECK CA LIB RA TION
The program is stored and is designed

to be accessed quickly via a selected
operation of the keyboard .
Diagnostic routines will isolate faults to a
unit of the Complex with further diagnosis
to board level for the serial data transfer
system.
Tests on all control functions to and from
computer are checked and information on
any failure showing type of error and data
bit malfunction will be indicated.
Calibration will be carried out at 180 day

intervals using a check calibration program.
INSTRUMENTATION COMPLEX SELF TEST
A limited amount of external equipment

will be used to calibrate selected units
which are then considered as standards.
Tests on the ATE instrumentation provide

for the adequate checking of all Functional
Test Unit parameters identifying any
faulty unit and diagnosing the malfunction
to board or su b- assembl y l evel.
These are then used to calibrate the

remaining units.
All units are calibrated via the UUT
Interface to take into account any
inaccuracies due to cabinet wiring.
The program consists of three main

features:
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Optimum Quality

mission line s required.

Stri ct Quality Control of wire jointing

Advanced Electrostatic and Electromagnetic s hielding to improve Noise

Use of Medium Scale Integration (MS I)

QUALITY IMPROVEME NTS BROUGHT

Controlled soldering techniques.

Full printed wiring boards and modular

Production personnel working to fully

Advance bonding techniques u sed in

Cross flow cooling provides fresh air

Maximum use of cable forming on chassis

Use of Kynar shrink sleeves to give

Maximum use made of plated through holes

Use of s older sleeves fo r terminating

Use of Computer Aided Design for artwork

Use of standard white jacket cables ,

Use of durable, low mating force, low

Reduction in number of display tubes

Mean Tim e Between Failures

High Reliability Power Supply Modules as

U se of Ground Plane techniques to improve

Use of High Noise Immunity Data Highway

Reduction in Hardware by:Use of MSI

CO;1YIIQhl rJllf,1 1 Brnlhl!I.-. (Lljrtd;'nt

Individual UUT Check

A vailab ility i s D e pend e n t upon Maintenance Procedures

Adequate identification , vi s ibility and

Inte rchangeability of identical s uba ssemblie s .

Limitation in numb er and variety of

Quick remo val achi eving ease of fault

Rapid and po s itive detection of unit

Rapid and po siti ve adj u strnent calibration

Adequate tolera n ces pro vid ed which

P a rt s s elected that require little or no

Corros ion pre ve ntion or control fe atures.

Fails safe and Fault limitation features

Connect UUT to ATE - Select Program Test UUT

Check calibration program carried out at

Maximun1 u se will be l11.ade of automatic

CORRECT IVE MAINTENANCE

The de s i gn of t he ATE w ill be s uch as to

The self test diagnostic program will

Repair of the ATE will be to replaceable

Diagnosi s to a lower level in these

Limited amount of manual diagnosis

The secondary action takes the form of

Areas that will require some manual

Detection of any fault by the program

Failures in Self Check will produce an

Power Fail Indication on the Main

PROGRAM MON ITORS

A logic signal will inform the computer of

A comparison check of all FTUs one

The program is constructed such that

After Sales Support

Routines can be contained on the disc

Failure information will be indicated by