In recent years, developments in the micro electronics industry have f
ocused on semiconductors and semiconductor processes. However, microci
rcuit assembly technologies have lagged chip development. This has spu
rred research in interconnection and packaging creating many new techn
ologies and enhancing integration. These new microelectronic technolog
ies are enabling micro systems, and resulting in products, from portab
le work stations to advanced automotive electronics. This evolution of
technology has also created the need to reexamine how we achieve a re
liable system. Clearly, in highly competitive marketplaces, reliabilit
y is a key element in achieving successful products. To achieve a reli
able product in a cost effective manner, ''upstream problem solving''
must be employed which focuses on root cause of failure. This paper pr
ovides an overview of the reliability assessment process needed to ach
ieve effective microsystem development. A case study of reliability in
a complex multi-chip module is presented which includes an assessment
of the stochastic nature of via fatigue by applying Monte Carlo simul
ations.