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Ever wondered if you're wasting resources by setting unnecessarily high confidence levels for your reliability requirements? You're not alone. Many engineering teams default to 95% or 99% confidence without considering the downstream impact on testing timelines and resources.

This episode tackles a question that's been coming up frequently from listeners: how to choose appropriate confidence levels for reliability requirements and test methods. Rather than making arbitrary decisions, I share a practical approach using your existing Failure Mode and Effects Analysis (FMEA) as a guide. This risk-based method helps you match your confidence levels to the actual risks associated with potential failures.

When you connect your testing strategy to your risk analysis, you create a logical framework for deciding where to invest more testing resources and where you might reasonably accept lower confidence levels. I walk through exactly how to do this by examining the severity of potential failures, the number of possible effects, and what other controls might already be in place. The beauty of this approach is that it leverages work your cross-functional team has already done during FMEA development, providing an objective foundation for your test planning decisions.

For those new to the Quality During Design podcast, this episode exemplifies our philosophy that emphasizes using quality tools early in the development process to make better decisions. Whether you're struggling with reliability testing or just looking to optimize your design process, you'll find practical insights to help you create better products with fewer resources. Subscribe to the podcast, visit qualityduringdesign.com for additional resources, or sign up for our monthly newsletter to stay informed about the latest quality design methodologies.

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About me
Dianna Deeney is a quality advocate for product development with over 25 years of experience in manufacturing. She is president of Deeney Enterprises, LLC, which helps organizations optimize their engineering processes and team performance by promoting the use of reliability and quality methods during design. She offers consulting services for managers and directors, training for engineers through the Quality During Design program, and other practical resources.