bad connections, or not?

Let me make several points on this issue �

POINT 1: Let�s be basic � Soldering and welding are examples of process that the quality types call "special processes".

Special process. The results of special processes cannot be verified fully by subsequent nondestructive inspections.

Soldering is a special process because it is difficult to test the quality of solder connections without damaging the connection. Companies control and perform special processes in accordance with written procedures.

POINT 2: Design types sometimes get very conservative near the end of design projects, possibly "butt covering" because: * Compound effect of all the "simplifying assumptions" they�ve made could come to roost. * Turning control of the project over to someone else provides an opening to broader criticism. * Want to do a good job * Don�t know what they�re doing.

POINT 3: Pushing forward, apart from � * Solder connections appear nice * You�re frustrated

� I don�t really understand much about the situation [but I�ve never let not that stop me from rattling on about a topic or my perception of what was the topic]. And as far as being on frustrated, you�ve come to the correct place. Since we don�t know what you�re talking about, we can only offer platitudes that tend to make you more frustrated [while not the intent]. Cool, eh?

When I�m frustrated, I really like to pull-out the ol� "Bozzo The Clown" blow-up punching bag and give it a cuppla upper cuts to the jaw. Unfortunately, the good feeling I get from smacking the clown is always so transitory, since Bozzo is always smiling and always pops back-up for an other shot to the snout. I wish I could do that!!! Anywho, I digress.

POINT 4: When you couldn�t figure-out what was wrong, you went with the gut � "Let�s bust the thing and see if we want figure-out what�s wrong with it." [A bit like medieval scientists carving-up people to try and figure-out how the human body worked.] Consider continuing with the approach by performing the following: * Design qualification. This highly accelerated stress test literally beats the living stuff out of products to identify design, component, process, etc weaknesses in order to correct these weaknesses before exposing customers the product. For an overview, checkout "Accelerated Reliability Engineering: HALT And HASS" Hobbs, J Wiley & Sons 2000 [047197966X] * Accelerated reliability testing. This accelerated test strips about a year from the life of a product before shipment to provide confidence that the design and manufacturing process are capable of meeting the goals for product performance. For recommendations and strategies, look at "Guidelines For Accelerated Reliability Testing Of Surface Mount Solder Connections" [IPC-SM-785]

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