A B S T R A C T A newly designed hinge kit system (HKS) of a commercial refrigerator was subjected to a robust reliability methodology during the design phase of the system. This methodology included setting the overall parametric accelerated life test (ALT) plan of product and identifying failure mechanisms and modes in field. The ALT included a sample size equation to improve several of the HKS design parameters. Reliability of the new HKS was targeted to be 10 years over B1. Failure sites in

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... the HKS were identified through returned products from the field. The first ALT confirmed a failure that occurred at the housing of HKS. The missing design parameters of HKS housing for the refrigerator were that it had no support ribs in the original design. The supporting structure of HKS in the refrigerator was modified based on the action plan. Cracks were identified in a second ALT that was generated in the torsional shaft. Due to it having squared off corners, the HKS torsional shaft did not have not enough strength to withstand repetitive stresses. The shaft was modified as a consequence of the ALTs. The reliability of redesigned HKS is now guaranteed as B1 10 years. The design methods -load analysis and three ALTs were very effective in identifying the missing design parameters during the design phase. The robust design method presented in this paper might be applicable to the other mechanical systems.