9 Practical Ways Sherlock Analysis Improves Reliability and Prevents Failure

When products fail in the field, the cost goes far beyond repairs. It affects customer satisfaction, brand trust, and long-term profitability. Sherlock analysis has become a powerful solution for predicting and preventing failures before they happen. Instead of relying on guesswork, this simulation-based tool uses real mechanical, thermal, and material data to evaluate how products behave under stress.

In this blog, we will take a practical look at what Sherlock analysis is, why it matters, and how companies use it to design more reliable products. The goal is to make the process easy to understand, even if you’re not a simulation expert.

What Is Sherlock Analysis?

Sherlock is a reliability prediction software used to simulate the physical stresses that electronic assemblies and components experience throughout their lifecycle. It uses detailed material properties, layout data, and environmental profiles to estimate how long a product will last and where it is most likely to fail.

Instead of waiting for physical testing or field failures, Sherlock provides early-stage predictions that guide smarter design decisions. It helps engineers find weak spots, optimize layouts, and reduce the need for redesigns.

Why Sherlock Analysis Is Different

Traditional reliability testing often happens late in development. By that time, making changes is expensive and slow. Sherlock offers a digital approach that allows teams to predict reliability earlier in the design process.

Here’s what sets it apart:

• Physics-based modeling instead of generic estimates

• Integration with PCB layouts and CAD tools

• Ability to simulate multiple stress types at once

• Lifecycle-based predictions rather than single-condition testing

This helps reduce guesswork and leads to more accurate results.

Common Applications of Sherlock Analysis

Sherlock is used in industries where failure is not an option. Typical applications include:

• Automotive electronics

• Aerospace and defense systems

• Medical devices

• Consumer electronics

• Industrial controls

• Telecom hardware

These industries rely on high reliability, strict compliance, and long product lifecycles. Sherlock supports those requirements by predicting how components will perform in harsh or dynamic environments.

Key Reliability Risks Sherlock Can Predict

Sherlock helps identify several failure mechanisms such as:

• Thermal cycling fatigue

• Vibration and shock damage

• Creep and warpage

• Solder joint fatigue

• Mechanical stress fractures

• PCB layer failures

By simulating these conditions, Sherlock estimates time to failure and highlights high-risk areas. This gives design teams the chance to reinforce weak points or choose better materials.

How Sherlock Analysis Works Step by Step

To understand how Sherlock improves reliability, let’s walk through the process most teams follow:

1. Import PCB and BOM Data

Sherlock reads layout files and part information directly from CAD tools.

2. Assign Material Properties

The software uses libraries and user inputs to match materials with accurate behavior data.

3. Define Environmental Conditions

You can simulate thermal cycling, vibration, shock, humidity, or custom mission profiles.

4. Run Failure Predictions

Sherlock processes the data and predicts the likelihood and timing of failures.

5. Review High-Risk Areas

It generates visual maps, graphs, and reports showing critical components and stress points.

6. Optimize the Design

Teams adjust layout, material selection, or support structures based on the results.

7. Validate with Testing

Once optimized, the design can move into physical testing with greater confidence.

Benefits of Using Sherlock Early in Design

Using Sherlock early delivers major advantages:

• Avoids costly late-stage redesigns

• Reduces time to market

• Improves component placement and layout

• Provides data for reliability reports and certifications

• Supports cross-functional decision making

• Enhances customer confidence

Early insights often save months of development time and thousands of dollars in testing and rework.

Sherlock vs Traditional Testing

The best approach combines both. Sherlock predicts issues, then physical testing confirms final performance.

Real-World Example

An automotive electronics manufacturer used Sherlock to evaluate solder joint fatigue due to thermal cycling. The analysis showed two components were at high risk. The team changed the layout and selected a more durable solder material. As a result, lifetime reliability increased by more than 40 percent before any prototypes were built.

This type of proactive design change is exactly why Sherlock is becoming a standard tool for reliability-driven companies.

What You Need to Use Sherlock Effectively

To get accurate results, you need:

• Clean PCB layouts and BOM data

• Realistic environmental conditions

• Accurate material properties

• Clear mission profiles

• Collaboration between design and reliability teams

The more precise the input, the more meaningful the output.

Sherlock as a Competitive Advantage

Companies that adopt Sherlock gain a significant edge. They build more reliable products, reduce field failures, and improve customer trust. They also shorten development cycles, which increases speed to market.

In industries where reliability defines reputation, Sherlock can help you stand out.

Final Thoughts

Sherlock analysis gives you the ability to predict failures before they happen. It brings reliability into the design phase, where it has the biggest impact. Whether you’re building electronics for critical applications or consumer products, using Sherlock helps you avoid risk, improve quality, and make smarter engineering decisions.

When reliability matters, waiting for failures is not an option. Sherlock lets you prevent them from the start.