Delta Resistance Measurement Impact On Thin (Metal) Film Resistors (original) (raw)

Failure of passive component gives the most delicate and severe Impact in an application field. The cost of the individual failed component is quite low, however, the impact of consequential losses and liability-related costs could be extremely high. The impact of defects could go for complete failure for vehicles in automotive or aerospace applications, even worse, in safety-relevant equipment. Long term study for the failure of passive component in field was done. The major defects were due to specific pulse load application. Specified failure levels of 0. 05 ppm (parts per million) for thin-film resistors are quite common in quality assurance contracts between component supplier and customer today. That sounds quite low. But in practice that still means accepting a thousand more or less severe field defects amongst approx. 20 billion produced, sold, and used metal-film resistors world-wide per year. Several improvements by reengineering on product and manufacturing process were developed. The effects will be discussed in detail. As a result of this basic long-term process the failure rate of thin film resistor has been dramatically reduced by three times of magnitude. Furthermore through this study new process knowledge has been gained on control loops of process changes affecting field defect minimization. Paper will show follow of time. Impact of resistor delta measurement Methodology in process. Effectiveness of a Corrective action will become obvious in field data, and the introduction of an optimized process before significant effects on failure rates in field become measurable.