Strategic Failure Analysis in Resource-constrained Reliability Testing: Model Updates and Test Condition Selection

Uttara Chakraborty, Duane S. Boning, Carl V. Thompson

04-13-2026
 Flowchart for iterative update of model parameter estimates.

Abstract- This paper presents a new framework for optimizing, in the face of constraints on time and resources, selective failure analysis strategies for reliability modeling of systems where multiple failure mechanisms are present.We propose a new method to improve reliability parameter estimates for multiple failure mechanisms (under Weibull mixture and competingrisks models) via a dynamic, iterative strategy for selecting and determining the failure cause of a small number of failed units. Results are statistically validated for both uncensored and rightcensored data. Our approach yields, on average, a log-likelihood increase of up to two orders of magnitude. This paper also develops a procedure for optimal selection of accelerated life test conditions to enable accurate characterization of the parameters of physical failure mechanism models. This work provides a unified framework for strategic decision-making for reliability analysis, allowing the practitioner to maximize resource usage and minimize errors in the presence of experimental constraints.

            

Carl V. Thompson
Stavros Salapatas Professor of Materials Science and Engineering, MIT