The Conformability Analysis technique was developed as a tool for the analysis of mechanical designs and manufacturing processes. It combines process capability indices and Failure Modes and Effects Analysis (FMEA) with a cost mapping to allow the quality costs associated with a design and manufacturing process to be estimated. This paper describes the adaptation of this technique to allow the functional, manufacturing and test process capability of electronic circuits to be found. This has been augmented through the use of response surface modelling to allow both the overall quality costs and the contribution that individual components make to this cost to be estimated. The assessment of test capability allows the cost effectiveness of proposed test strategies in reducing quality costs to be determined. This unified approach to design, manufacture and test quality cost assessment provides the designer with vital insight when balancing quality costs with component, process and test costs.
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