When companies have consistent product failures in distribution, they may attempt to use traditional damage boundary testing to define bare product fragility, or perhaps increase free fall drop heights on packaged products, believing that higher drops must have caused the problem since the initial laboratory qualification levels appear to have been inadequate. This presentation will show why these traditional approaches failed and how the issue was resolved. Takeaways: Damage boundary testing works, but not always as expected. Increasing drop heights often finds the weakest link of a product design, but not always. This presentation will show how one product needed a different approach due to its unique characteristics. The audience will gain valuable insights as to the importance of replicating field failures in the lab, and how one must remain open minded on ways to achieve that damage. The results are different than anything I recall seeing at any previous conference.