Continuous improvement concepts and systems failure analysis
Quality measurement and reporting concepts
Using failure analysis as a preventive measure
The value of a priori failure cause identification
Brainstorming, mind-mapping, and Ishikawa diagrams
Fault tree analysis history, applications, and capabilities
Fault tree analysis construction
Fault tree gate usage and interpretation
Quantifying top undesired events
Using fault trees to identify redundancy-defeating failure modes
Case study
Day 2: Isolating Failure Causes and Corrective Action
Evaluating potential failure modes
Using Failure Mode Assessment and Assignment (FMA&A) matrices
“What’s Different” analysis
Test and inspection data, material certifications, and SPC data
Using flow charts for product performance and process evaluations
Interviewing techniques for use with assembly, test, and inspection personnel.
Failed hardware analysis
Evaluating failed hardware conformance
Component failure analysis technologies, including optical microscopy, SEM, FTIR, EDAX, X-ray, N-ray, SIMS, and Auger analysis
Basic metallurgical and electronic component evaluations
Evaluating leaks
Designing tests to confirm failure causes
Corrective action alternatives, including design modifications, process modifications, requirements relaxation, screening, and other corrective actions.
Using the FMA&A matrix for corrective action identification and tracking
A suggested failure analysis procedure
Creating a product-oriented Lessons Learned document
