Hi Pete,
In order to get any handle on reliability projections, you need to know the 
root cause of the problem. Good solder joints do not crack due yo mishandling. 
If you get brittle interfacial separation, you are not having good solder 
joints. So now the question becomes, what is wrong with SJs? Fix that, and your 
problem goes away.
Having brittle interfacial failures means that more likely most of your 
cracks are complete ones—but no bets here.
Your management really needs to answer the question whether the company can 
survive for its flagship product to have early field failures.



Werner



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