Global state of reliability and hardware design survey results

Yet, the findings also suggested a sense of optimism for the future, driven by the prospects offered by key technologies such as artificial intelligence, machine learning, simulations, and advanced analytics.

Significantly, 91% of the survey participants acknowledged a strong link between delivering reliable products and maintaining trusted, proven supplier relationships. Consequently, 96% of respondents have replaced part suppliers due to reliability concerns, with over a quarter experiencing frequent changes. These supplier partnerships are proving to be increasingly vital, with 74% of respondents indicating that reliability is compromised by abbreviated design cycles.

Scott Whicker, Senior Vice President, and President of Transportation Innovative Solutions at Molex, reflected on the critical nature of reliability: “Reliability is a genuine intersection of theory and practice with extensive consequences throughout product development, manufacturing, and the end-user experience,” he commented. “Selecting the right partners, utilising the most efficient processes, and harnessing the latest data insights are imperative to hasten the design and creation of the most reliable products feasible. Our recent global industry survey provides insights into evolving expectations for product reliability and the realities of design compromises, along with the hopeful notion that AI and data-driven advancements will enhance product reliability substantially.”

Current state of reliability

Molex engaged Dimensional Research to conduct a survey among over 750 qualified global individuals responsible for hardware design or system architecture. The participants reported an increasing trend in reliability driving brand loyalty, with 54% affirming this sentiment. Furthermore, 52% believe consumers expect devices to function reliably under all environmental conditions, such as exposure to dust, water, and vibrations.

The majority of firms (64%) depend on their quality teams, with test engineering (60%) and product development (58%) also playing significant roles in promoting reliability. Specifically, in the automotive & transportation sector, test engineering was identified as paramount (71%) in ensuring products fulfil stringent reliability standards. Companies from various sectors reported a tendency to overengineer products almost twice as often as they opt for more cost-effective solutions. A notable segment (42%) designs hardware to exceed current industry certifications and standards, while 44% aim to meet potential future demands. Datacom respondents were particularly proactive, with over half (51%) addressing both current and future requirements. Although deemed crucial, a mere 18% of engineers devise verification and validation plans prior to commencing product designs, with the majority (44%) developing these plans concurrently with design efforts.

Reducing reliability risks

When prioritising the most challenging aspects of designing for reliability, the survey highlighted testing time (42%), with supplier quality, cost, and linking design attributes to reliability impact all tied at 37%. Engineers typically prioritised cost (50%), manufacturability (46%), and user experience (35%) over reliability in their trade-offs. Conversely, they were less likely to choose weight (35%), features (26%), and form factor/size (26%) over reliability.

Rise in AI and data-based tools

Presently, only 33% of respondents utilise data-based models for evaluating design trade-offs. This figure is expected to rise, with the survey uncovering a surge in confidence regarding the role of data in enhancing reliability. Nearly half of those surveyed (46%) cited AI, ML, simulations, and data analytics as the most promising avenues for improving the reliability of future electronic products. Notably, 83% are optimistic about the potential of AI to boost product reliability. Ranking AI applications, respondents noted the capabilities for identifying and predicting failures (43%), optimising designs for reliability (31%), executing more comprehensive verification and validation simulations (31%), and developing superior test plans and models (29%).

Workforce dynamics expected to increase concerns

Within the next five years, over half of the survey's participants (51%) anticipate that experience will become increasingly significant in grappling with product complexity, yet 92% foresee the loss of their experts due to retirement. This anticipated departure of vital engineering knowledge is expected to pose risks to employee satisfaction, brand reputation, and potentially lead to revenue loss, yet only 39% have a strategy to counter these risks.

Global consensus on reliability

Globally, engineering professionals concurred on the most significant factors affecting reliability. Respondents from the Americas displayed the greatest optimism for AI's role in improving product reliability within the next five years. Participants from Europe were particularly confident in AI's capacity to identify and predict failures, while those from the APAC region showed the highest awareness of the potential risks associated with the departure of key individuals with deep reliability knowledge.