What are the steps to conduct a failure analysis on a manufacturing product?

1 Plan the analysis

Before you start the failure analysis, you need to plan the scope, objectives, and methods of the analysis. You should define the problem, the failure mode, the expected outcome, and the resources needed. You should also collect relevant information and data about the product, such as its design, specifications, history, usage, environment, and maintenance. You should also identify the stakeholders and communicate with them throughout the process.

2 Isolate and inspect the product

The next step is to isolate and inspect the product that failed or malfunctioned. You should handle the product carefully and avoid any damage or contamination that could affect the analysis. You should document the product's condition, appearance, markings, and location. You should also perform a visual inspection and look for any signs of wear, corrosion, cracks, deformation, or other anomalies. You should use appropriate tools and techniques to measure and record the product's dimensions, weight, temperature, pressure, and other parameters.

3 Perform non-destructive testing

Non-destructive testing (NDT) is a method of examining the product without destroying or altering it. It can help you detect and characterize any defects, flaws, or discontinuities in the product's structure, material, or performance. Some common NDT methods include ultrasonic testing, magnetic particle testing, dye penetrant testing, radiographic testing, and eddy current testing. You should select the most suitable NDT method based on the product's type, size, shape, and failure mode.

4 Perform destructive testing

Destructive testing (DT) is a method of testing the product by applying stress, load, temperature, or other factors that cause it to fail or break. It can help you determine the product's strength, durability, fracture toughness, fatigue resistance, or other mechanical properties. Some common DT methods include tensile testing, bending testing, impact testing, hardness testing, and fatigue testing. You should perform DT only when necessary and on a representative sample of the product.

5 Analyze the data and results

After performing the tests, you should analyze the data and results to identify and understand the root causes of the failure or malfunction. You should use appropriate tools and techniques to interpret and visualize the data and results, such as graphs, charts, tables, diagrams, or software. You should also compare the data and results with the product's design, specifications, standards, or expectations. You should look for any patterns, trends, anomalies, or deviations that could explain the failure or malfunction.

6 Report and recommend

The final step is to report and recommend the findings and conclusions of the failure analysis. You should write a clear, concise, and comprehensive report that summarizes the problem, the methods, the data, the results, and the root causes of the failure or malfunction. You should also include any recommendations or suggestions for improving the product's quality, reliability, or performance, or for preventing or mitigating future issues or risks. You should also share the report with the stakeholders and solicit their feedback and input.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?