> > Most people are happy paying moderate prices for 99.9% reliability. Very few people are willing to pay extreme prices for 99.99999% reliability.
> Actually, 1000dppm (99.9% defective parts per million) is not acceptable except for hobbyists.
Exactly: There are many more hobbyists than manufacturers, so most people are content to pay lower prices for lower reliability.
Where this is going a bit nuts is that that it's hard to make 100 gold contacts last for 1000 compression cycles at 1 dppm (better than 6 sigma!). That requires a lot of excess maintenance on the test infrastructure! That will be expensive... and your assembly connectors/SMT is likely orders of magnitude higher defect rate than 10dppb so it won't improve final assembly performance.
Also, I think you need another 9 on that 99.99999% to hit 10ppb and realistically 2, if you want to have an acceptable yield rate, and 3 on the test equipment since they are used 10k times every day.