Accelerated Life Testing (ALT) is an effective method of demonstrating and improving product reliability in applications where the products are expected to perform for a long period of time. Even though reliability professionals recognize the significance of high reliability, there are certain challenges which hinder an effective application of ALT principles in practical applications. This paper presents the six primary challenges that need to be considered during the planning and implementation of ALT and shows through means of a case study, how inadequate planning of ALT can result in expensive field failures. It also discusses the subsequent improvements that focus on the above principles to develop an improved plan. ALT plays a key role in the engineering development of products where high reliabilities are required. The case study discussed demonstrates the six challenges in effective implementation of such tests. The case study also showed the necessity for research in areas such as acceleration models for pressure and further investigation of aging effects of materials used.
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