Root Cause Analysis of Systems Failure – Comprehensive
New Admin
Day 1: Introduction to Systems Failure Analysis
The need for efficient systems failure analysis
Systems failure analysis philosophy
The four-step problem solving approach
Systems and component failure analyses
The inherent value of failed hardware
Failure analysis definitions and basic failure analysis concepts
Continuous improvement concepts and the systems failure analysis contribution
A framework for systems failure analysis
Quality measurement and reporting concepts
Nonconformance data base approaches
Pareto analysis
Integrating the cost of quality of program
Understanding systems interactions and how systems operate
The value of a priori failure cause identification
Case study
Day 2: Fault Tree Analysis
Fault tree analysis history, applications, and capabilities
Defining the problem and developing fault tree analysis top undesired events
Relationships between logic operators and events
Fault tree gate usage and interpretation
Using inhibit functions to model probability distributions
Navigating from the failure site
Quantifying top undesired events
Failure rate sources
Using fault trees to identify redundancy-defeating failure modes
Using Failure Mode Assessment and Assignment (FMA&A) matrices for managing the systems failure analysis effort
“What’s Different” analysis
Use of test and inspection data, material certifications, and statistical process control data
Use of flow charts for product performance and process evaluations
Interviewing techniques for use with assembly, test, and inspection personnel. Failed hardware analysis
Case study
Day 3: Design of Experiments and Systems Failure Analysis
Basic experimental design concepts
Deterministic versus statistical thinking
Hypothesis testing
The normal distribution and other basic statistical concepts
Analysis of variance
Z-tests, t-tests, and f-tests
Identifying potentially critical design and process parameters
Identifying test objectives
Test readiness reviews
Inducing failures to confirm causes
Introduction to Taguchi philosophies and Taguchi design of experiment technologies
Designing a Taguchi experiment
Selecting test parameters
Two and three level orthogonal arrays
Selecting output parameters and data collection approaches
Strategies for minimizing test risk
Signal-to-noise ratios
Defining test specimen configurations
ANOVA applied to Taguchi experiments
Typical test strategies
Multiple level experiments
Case study
Day 4: Specialty Analyses, Corrective Action, and Course Wrap Up
Evaluating failed hardware compliance
Assessing technical data package adequacy
Common technical data package shortfalls
Tolerance analysis
Quality Assurance compliance assessment tools
Optical microscopy, SEM, FTIR, EDAX, X-ray, N-ray, SIMS, and Auger analysis
Monte Carlo simulations
Evaluating leaks
Basic metallurgical and electronic component evaluations.
Customer/supplier interface issues
Commercial failure analysis laboratories
The advantages of eliminating repair, rework, and use as is dispositions
Corrective action order of precedence
Design modifications, process modifications, requirements relaxation, screening, and other corrective actions
Use of statistical process control as a corrective action
Using the FMA&A matrix for corrective action identification and tracking
Day 5 (Workshop Day): Participants will work together to analyze a failure specific to your organization. The workshop day can be scheduled a few weeks after the first four days of this course to allow time for “home work”.
Course Wrap-up
A suggested failure analysis procedure
Creating a product-oriented Lessons Learned document
