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Root Cause Analysis of Systems Failure Overview

  • 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
    • 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
    • Recap, Q/A, and evaluations
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