The degraded performance of a power MOSFET affects customer system reliability and consumer perceptions of quality. Building a reliable product and associated application specific lifetime models to predict the suitability of a power device for a given solution can enable competitive advantages, increased quality, enhanced performance and result in market share gains. This paper describes the methodology employed to configure an application specific reliability test, the failure rates and modes observed, the package modelling, and design improvements implemented. The validation of such relative to its original form and competitor products is discussed where we demonstrate a doubling in performance and an approximate 50% increase in current handling capability. This type of analysis and application specific approach to innovation enables one to focus design improvements in areas most relevant to customer concerns while at the same time adding credibility to specified product limits.