A systematic approach for the development of a hardware qualification approach is described. This approach stems from the need to address the "Catch-22" of not flying new technology because it has not flown. A physics of failure approach is used to identify failure modes, and the impact and likelihood of these failures on the mission requirements is plotted in a Requirements Matrix. These same failure modes are plotted against the effectiveness of the available preventions, analyses, control, and tests (PACTs) at screening for, or eliminating, these failure modes in a test effectiveness matrix. Matrix multiplication results in a ranked set of PACTs that can be sorted according to cost and redundancy with other PACTs. This and other information resulting from the process allows project managers to make more informed decisions regarding the cost and risk tradeoffs inherent in any qualification program.

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