Reliability Matters

What if passing the test is not enough? In reliability engineering, we often place a great deal of confidence in laboratory validation. We test, measure, analyze, and document. And when the product passes, we naturally assume it is ready for the field. But what happens when a product passes the lab test and still fails in the hands of the customer? Today, we are going to explore the gap between la...

Today, we’re going to explore a topic that seems to be touching nearly every industry, every workplace, and increasingly every part of our daily lives: artificial intelligence. But this conversation is not just about what AI can do. It’s about what AI assumes, what it values, what it misses, and what happens when powerful technologies are deployed into environments they were not designed to unders...

This is part two of a two-part series. In Part One, we explored how the electronics industry transitioned from a clean-everything approach to one where cleaning became optional. But what happens when the assumptions behind “no-clean” collide with modern electronics design? In this episode of Reliability Matters, Mike Konrad examines how the definition of cleanliness has fundamentally changed. As a...

This is the first of a two part series. For decades, cleaning circuit assemblies after soldering was not optional. It was standard practice across the electronics manufacturing industry. Then, almost overnight, that changed. In this episode of Reliability Matters, Mike Konrad takes you back to the origins of that shift. From the widespread use of CFC-based cleaning solvents to the global impact of...

Today, we’re going to explore a topic that doesn’t always get the attention it deserves, but has a direct impact on product quality and long-term reliability. I’m joined by Mehdi Nahali, founder of PCB Revision Control PRO. His platform is designed to replace spreadsheets, emails, and disconnected systems with a centralized approach to PCB revision lifecycle management and factory intelligence.  W...

Today’s episode is going to resonate with anyone responsible for uptime, efficiency, and ultimately, product reliability.  Because whether we’re talking about circuit assemblies, manufacturing lines, or entire facilities, reliability doesn’t start at inspection. It starts with maintenance. My guest today is Paul Ross, Chief Marketing Officer at Limble, a company providing modern maintenance and as...

What if your factory could predict failures before they happen, capture decades of human expertise, and make better decisions than ever before—without replacing the people who run it? Today’s guest sits right at the intersection of innovation and industry.  Bryan DeBois, Director of Industrial AI at RoviSys, is helping reshape what manufacturing looks like in the age of intelligent machines. From...

When we talk about reliability, we usually focus on materials, processes, test methods, and standards.  But what if one of the most overlooked reliability risks is who is not at the table when engineering decisions are made? Today’s episode focuses on women in STEM, Science technology engineering and mathematics, and why this conversation extends far beyond mere representation. It impacts how prob...

Artificial intelligence is being promoted as the next revolution in electronics manufacturing, but what happens when the people evaluating it aren’t traditional AI experts, aren’t software vendors, and aren’t selling anything?  Today’s conversation brings together engineers and professors who live at the intersection of education, reliability, and real-world manufacturing to separate meaningful pr...

If a $26,000 drone repair can be done in the field—but policy says it has to be shipped back to the manufacturer, do you really have a reliability problem… or a repair access problem? Today on the show, I’m joined by William Santos, International Sales Manager at ABI Electronics and a global advocate for the Right to Repair movement. William recently wrote a compelling article titled “Readiness Th...

When you talk to one manufacturer, you hear a story. When you talk to hundreds, patterns emerge. Today, we step back and examine what those patterns tell us about the real state of electronics manufacturing. Today’s episode takes a step back from individual processes and technologies to look at the electronics manufacturing industry through a broader, editorial lens.  My guest is Trevor Galbraith,...

In electronics manufacturing, defects don’t usually announce themselves. They happen in milliseconds, far faster than human perception, and often long before anyone realizes a process has drifted out of control. By the time failures show up in test, inspection, or worse, in the field, the root cause may be buried deep inside machine behavior that no one thought to question. When machines are assum...

Today, I’m joined by someone who has spent more than three decades at the intersection of materials science, automation, and high-reliability manufacturing.  Jon Urquhart is the Director of Global Applications Engineering at Precision Valve and Automation — one of the world’s leading developers of dispensing, coating, and industrial motion-automation systems. Since joining PVA in 1993, Jon has bec...

Since 2018, Reliability Matters has been building a knowledge vault, capturing the wisdom of industry experts for engineers everywhere.  In this special year-end episode, we celebrate the journey, the growth, and the community that made it possible.

Today, we’re continuing our dive into the world of contract manufacturing—a vital piece of the electronics ecosystem. Joining me are two industry leaders who know this space inside and out. First, we have Daniel Stanphill, SMT Process Engineer at Aurora Boardworks, and alongside him, Sean Kincaid, President of K & F Electronics.  Both Daniel and Sean represent companies that provide contract m...

The next two episodes will be all about contract manufacturing, an area that can make or break the reliability and success of a product.  My guest on this episode is Raymond Novara, founder and owner of East End Assemblies, a U.S.-based contract manufacturer recognized for its focus on quality, customer service, and compliance with AS9100 and IPC standards. During our conversation, I’ll be asking...

This is the fourth of four episodes on the subject of soldering materials. Today, we're diving into a topic that's reshaping how we think about thermal management, energy efficiency, and long-term performance in electronics manufacturing—low temperature soldering. Joining me is Dr. HongWen Zhang, Principal Metallurgist and R&D Manager of the Alloy Group at Indium Corporation.  Dr. Zhang is not...

This is the third of four episodes on the subject of soldering materials. Today, we’re continuing our deep dive into the world of soldering materials, from advanced alloys and flux chemistries to global manufacturing strategy and materials innovation, with one of the industry’s most respected leaders.   Joining me is Ross Berntson, President and CEO of Indium Corporation. Ross has been with Indium...

This is the second of four episodes on the subject of soldering materials. In today’s episode, continuing the subject of soldering materials, diving deep into the science, strategy, and subtleties behind one of the most foundational elements of electronic assembly: soldering materials.  Joining me are two experts from KOKI Solder—Shantanu Joshi, Head of Customer Solutions and Operational Excellenc...

This episode is all about SMTAI, surface mount Technology International, taking place OCTOBER 19 - 23, 2025 at the DONALD E. STEPHENS CONVENTION CENTER in ROSEMONT, ILLINOIS.  SMTA International is the premier gathering for innovation and collaboration in electronics assembly, surface mount technology, and advanced manufacturing. This year, SMTAI is more than just a conference and expo. It’s an op...

This is the first of four episodes on the subject of soldering materials. In this episode, I’m joined by Chris Ward, founder and Managing Director of Solderking Assembly Materials Limited, a UK-based manufacturer of solders and chemical consumables for electronic, electrical, and engineered assemblies. Chris brings decades of experience in soldering materials and chemical formulations—and he’s bui...

On this episode of Reliability Matters, we’re diving into a deceptively simple but incredibly important topic, humidity, and the massive impact it can have on electronic assembly reliability. Joining me is Viktoria Rawinski, a seasoned expert in materials science and reliability engineering, whose career spans decades of hands-on experience in failure analysis, process optimization, and design-for...

Today, I’m joined by two of the most respected names in the electronics manufacturing industry, Phil Zarrow and Jim Hall. Together, they bring decades of hands-on experience and unparalleled insight into the challenges and solutions within our field. Jim and Phil are the driving forces behind ITM Consulting, where they help manufacturers around the world improve processes, solve complex problems,...

In this episode, we’re diving into a topic that’s rapidly reshaping our industry: Artificial Intelligence in PCB Design. Far from a futuristic concept, AI is already being integrated into advanced design tools—improving efficiency, reducing design iterations, and helping engineers tackle increasing design complexity with shrinking timelines. Joining me today are two thought leaders who are at the...

As the electric vehicle market accelerates, the reliability of the charging infrastructure becomes increasingly vital. Chargers that are down or malfunctioning can hinder adoption and erode consumer confidence. But who ensures these chargers stay up and running? Today, we're diving into that very topic with a trailblazer in the EV service space. My guest is Kameale Terry, co-founder and CEO of Cha...