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MTBF Prediction and Optimization for An Automotive Sensor Manufacturer

automotive-sensor-manufacturer

Client:

Confidential(Automotive Sensor Manufacturer)

A leading automotive electronics supplier was facing a rise in warranty claims and inconsistent field reliability across its vehicle ECU sensors. Relteck provided a complete reliability engineering solution using Telcordia SR-332 standards to perform accurate MTBF prediction and calculation. By combining statistical reliability analysis with insights from FMEA and FMECA analysis. We identified component-level weaknesses, optimized sensor design, and reduced lifecycle costs.

The result: a 36% increase in MTBF, 29% reduction in warranty claims, and stronger product reliability across sensor lines.

Objective:

Reduce warranty-related costs and improve sensor reliability through predictive MTBF modeling and standards-based analysis.

The Challenge:

The client’s ECU sensors were experiencing unexpected failures during real-world operation, leading to costly replacements and customer dissatisfaction. Without a structured reliability prediction model or failure-mode analysis, pinpointing the root causes behind early-life failures was challenging.

Relteck’s Solution:

  • Applied Telcordia SR-332 Issue 4 for MTBF prediction and failure rate estimation.
  • Conducted FMEA and FMECA analysis to identify and rank high-risk components.
  • Used insights from prior RBD modeling and simulation projects to assess potential single-point failures and improve system-level design margins.
  • Delivered a detailed PDF and Excel report with MTBF calculations, risk ranking, and actionable design recommendations.

Results:

  • MTBF increased by 36% across tested ECU sensor models
  • Warranty claims reduced by 29% within the first 12 months
  • Provided a clear reliability baseline for future generations of sensor products.
  • Established a repeatable framework for integrating MTBF analysis with environmental stress analysis for electronics and other predictive reliability practices.

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Relteck’s offers MTBF prediction, PCB Sherlock simulation,
reliability consulting, and testing services. For more information,
contact sales or visit their Los Angeles or Fremont offices.