Even the slightest failure in a sensor or analyzer can lead to costly downtime, compromised processes, or reduced product yield. That’s exactly what a global OEM was facing with its infrared silicon tetrafluoride (SiF₄) gas analyzer, a key component in semiconductor fabrication.
When they needed to boost reliability and cut failure rates, they partnered with Boston Engineering and achieved dramatic results.
The focus and discipline of DFX is a powerful tool if used as part of a broader strategic approach to developing product/process differentiation, and a sustainable advantage against competition. Involve Design for X in Strategy. Once your team has determined the focus of your strategy, place the focus of design on developing competitive advantage.
At Boston Engineering, DFX is a core part of creating values during our product development process. We focus on several key DFX areas that align with our expertise:
Learn more about Design for X (DFX) at Boston engineering: Boston Engineering Design for X
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The gas analyzer was experiencing unacceptable failure rates, undermining the client's ability to deliver reliable systems to semiconductor producers. With increasing pressure to enhance performance and reduce costs, the OEM needed a solution that could:
Improve mean time between failure (MTBF),
Preserve or exceed existing performance metrics,
And do all this without increasing manufacturing costs.
The solution would require a thoughtful balance of electrical, mechanical, and firmware engineering, plus a deep understanding of how design impacts long-term reliability.
Boston Engineering focused on a strategic redesign of the SiF₄ gas analyzer’s most critical components to improve durability and functionality.
Their engineering updates included:
Each change was implemented with minimal disruption to the existing design, ensuring the product could scale in manufacturing while delivering enhanced reliability in the field.
Interested in providing your product development team with DFX skills? Learn More about our Applied DFX process and development workshops.
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The results were impressive and measurable:
57% Reduction in Failure Rates – The enhanced design significantly improved mean time between failures (MTBF), boosting customer confidence and product uptime.
Lower Manufacturing Costs – Despite the performance improvements, the redesign also reduced production costs, thanks to smarter component choices and system simplification.
Improved Long-Term Performance – The microcontroller integration and custom PCB not only solved current problems but also future-proofed the analyzer for expanded capabilities.
This case study highlights how Boston Engineering applies targeted innovation to achieve maximum impact, not by overhauling systems unnecessarily, but by focusing on the right components at the right time. Their solution helped this OEM deliver a more reliable, cost-effective product to semiconductor manufacturers operating in some of the world’s most demanding environments.
Need to extend product life and cut failure rates?
Boston Engineering specializes in in redesigns that enhance reliability, cut costs, and improve performance, without disrupting your production cycle. Reach out today to see how we can help solve your toughest engineering challenges.
In this eBook, we’ll dive into the real-world experiences of DFX subject matter expert John DePiano, exploring the common areas where existing product owners excel, as well as the key opportunities where targeted DFX support can drive major improvements.
Understanding the Importance of a DFX approach
Applying Design for X (DFX) methodologies upfront in product development optimizes the entire lifecycle by improving manufacturability, testability, reliability, usability, and other critical characteristics. This avoids costly redesigns later on, facilitates high-quality products that satisfy customers, reduces manufacturing and service costs, and supports flexibility through modularity and platforms. The holistic perspective of DFX drives efficient, cost-effective delivery of successful products that provide competitive advantage. Investing in DFX early pays dividends across the entire product lifespan.
Do you offer training on DFX for engineering teams?
Education is critical to effectively implement DFX principles. We provide training tailored to your engineers’ roles and product lines. This includes overall DFX methodology, deep dives into specific disciplines like design for reliability or manufacturability, and practical application workshops. Our hands-on approach combines real-world examples and case studies with tutorials on leading DFX software tools. The goal is building organizational DFX expertise and establishing repeatable processes that endure beyond individual projects. Investing in DFX knowledge pays dividends across your entire product portfolio.
Ready to Begin your next DFX Project?
No matter the challenge, our team possesses the expertise in the engineering disciplines and technologies you need to bring your vision to life. Impossible Challenge? Try Us.
Impossible Challenge? Try Us.
Selecting a partner to help you complete your design project is a valuable option to reduce project duration and save money.
The Boston Engineering product development system encompasses DFX to ensure a smooth product launch and success in the marketplace. Boston Engineering has DFX knowledge and experience to address aspects and values of a product such as manufacturability, test, reliability, safety, serviceability, cost, and compliance with industry standards and government regulations.
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