Quality and reliability requirements for LED modules in headlamp applications are increasing on the account of design requirements, extended functionalities and increasingly complex technologies. It must be noted that many complex modules are being developed and manufactured more and more quickly, and have to meet the requirements of both functional safety and cost efficiency. This results in a large demand for robust components and modules, and for fast and reliable development and validation processes. The development of robust LED headlamp systems first needs the knowledge of the condition of use (mission profile). A close cooperation between OEM, Tierl and LED supplier is needed to generate the mission profile. The mission profile has to be translated from the system level over the LED modules down to the component level (LED). The improvement of robust LED and LED modules also requires knowledge of the failure mechanisms and failure modes and the possible interactions between different failure mechanisms. New failure mode and causes will be able to be stated as the results of "End-of-life tests" or "Test to failure" during prototype and design validation phases of the LED component or LED module. The development of a robust LED headlamp requires close cooperation between different technical disciplines (material science, engineering, mechanics, optics, electronics, thermal engineering, chemistry etc.) in order to analyze the more and more complex interactions of tolerances and chain of effects systematically for continual optimization, and the establishment of assessment skills for technology fields as a major key to success of front-loading.