Failure Analysis

The involvement of Failure Analysis

01 in ISO Block Diagram

02 What is a Failure ?

Contents 03 What is a Failure Analysis ?

04 Failure Analysis Methodology

05 summary
01: The Involvement of Failure Analysis
in ISO Block Diagram
01 The involvement of Failure Analysis in ISO Block Diagram

Input Process Output

repeatable steps QC Audit

Fig 1 ISO Block Diagram with Quality Control and Audit

Input = Failure Process = Failure Analysis Methodology Output = Prevented Failure

01 The involvement of Failure Analysis in ISO Block Diagram

Why are protocol and inspection important ?

Protocol

➢ is a set of rules and guidelines ,defined for The impacts of the ignoring
each step and process, during working Protocol and Inspection
methods under working safety condition.
1.The injuries or deaths
2.The wrong results
Inspection
3.Biased perspective of the
➢ An activity of measuring, examining, or failure, and so on.
testing and comparing the result with
specified requirements or standards.
01 The involvement of Failure Analysis in ISO Block Diagram

Case 1 : Follow the protocol and repeat the inspection.

Fig 2 An example of pilots performance

01 The involvement of Failure Analysis in ISO Block Diagram

The Consequence of Case 1 : Everybody is safe.

Fig 3 The consequence of following protocol and inspection

01 The involvement of Failure Analysis in ISO Block Diagram

Case 2 : Follow the weak protocol and ignore the inspection.

Fig 4 An example of maintenance men behavior

01 The involvement of Failure Analysis in ISO Block Diagram

Case 2 : Follow the weak protocol and ignore the inspection.

Fig 5 An example of maintenance men behavior

01 The involvement of Failure Analysis in ISO Block Diagram

Case 2 : Follow the weak protocol and ignore the inspection

Lost washer

Fig 6 An example of maintenance men behavior

01 The involvement of Failure Analysis in ISO Block Diagram

The Consequence of Case 2 : The cause of the maloperation, explosion, and injuries.

Fig 7 The consequence of following the weak

protocol and ignoring the inspection
01 The involvement of Failure Analysis in ISO Block Diagram
Behavior Examples Protocol Inspection

Table 1 The Comparison

between two behaviors
02: What is a Failure ?
02 What is a Failure ?

➢ the inability of a component, machine, or

process to function properly

➢ can be individual parts, entire machines,

or a process.

➢ There are 3 different levels of a failure.

1. A loss of function

2. A loss of service life Fig 8 the right engine failed of The Boeing 737 plane

3. An inoperable
02 What is a Failure ?

The 3 different levels of a failure

1. A loss of function: a system or component that

operates but does not perform
its intended function.

2. A loss of service life: a system or component that

performs its function but is
unreliable or unsafe.
Fig 8 the right engine failed of The Boeing 737 plane
3. An inoperable: a system or component cannot
operate.
02 What is a Failure ?

How do failures happen ?

➢ Misuse of the service or operation conditions

➢ Improper maintenance

➢ Improper testing or inspection

➢ Assembly errors

➢ Design errors
Fig 9 An improper maintenance
➢ Inadequate quality assurance or control, and so on.
03: What is a Failure Analysis ?
03 What is a Failure Analysis ?

➢ The critical step in the overall

problem-solving process
correcting and preventing failures

➢ The key component for achieving higher levels of quality

and reliability

enhancing customer satisfaction, etc.

04: Failure Analysis Methodology
04 Failure Analysis Methodology

1 Define

2 Data Collections

Failure Analysis 3 Propose a hypothesis

Methodology
4 Failure Mechanism

5 Preventive Action Report (PAR)

04 Failure Analysis Methodology

Step 1 : Define ➢ Identify and understand problems under

the scope and the boundary of work.

Step 2 : Data Collection ➢ The process of gathering and measuring information on

targeted variables to answer relevant questions and
evaluate outcomes
04 Failure Analysis Methodology

Step 2 : Data Collection

➢ Focus on terms of reference

➢ Observation
Methods of ➢ Focus Groups
Data Collection ➢ Interview
➢ Group Discussion
➢ Data Verification
04 Failure Analysis Methodology

Step 2 : Data Collection >> “ Focus on terms of reference ”

Fig 10 An Example of the Focus on terms of reference

04 Failure Analysis Methodology

Step 2 : Data Collection >> “ Focus Groups and Interviews ”

Fig 11 An Example of the Focus Groups and Interviews

04 Failure Analysis Methodology

Step 2 : Data Collection >> “ Observation ”

Fig 12 An Example of the Observation

04 Failure Analysis Methodology

Step 2 : Data Collection >> “ Observation ”

Fig 13 An Example of the Observation

04 Failure Analysis Methodology

Step 2 : Data Collection >> “ Observation ”

Fig 14 An Example of the Observation

04 Failure Analysis Methodology

Step 2 : Data Collection >> “ Observation ”

Fig 15 An Example of the Observation

04 Failure Analysis Methodology

Step 2 : Data Collection >> “ Group Discussion ”

Fig 16 An Example of the Group Discussion

04 Failure Analysis Methodology

Step 2 : Data Collection >> “ Data Verification ”

Fig 17 An Example of the Data Verification

04 Failure Analysis Methodology

Step 3 : Propose a hypothesis ➢ apply the collected data for proposing the hypothesis
before testing Failure Mechanism to answer relevant
questions and evaluate outcomes.

Fig 18 The hypothesis of the Concorde plane’s failure

04 Failure Analysis Methodology

Step 3 : Propose a hypothesis ➢ apply the collected data for proposing the hypothesis
before testing Failure Mechanism to answer relevant
questions and evaluate outcomes.

Fig 19 The hypothesis of the operation between

operate with and with out a washer
04 Failure Analysis Methodology

Step 4 : Failure Mechanism ➢ describe how the material failed. If the analysis is
correct, the mechanism will be consistent with the
hypothesis.

Fig 20 Testing Failure Mechanism with the washer Fig 21 Testing Failure Mechanism without the washer
04 Failure Analysis Methodology

Step 4 : Failure Mechanism ➢ describe how the material failed. If the analysis is
correct, the mechanism will be consistent with the
hypothesis.

Fig 22 The Result of the Failure Mechanism

04 Failure Analysis Methodology

Step 4 : Failure Mechanism ➢ describe how the material failed. If the analysis is
correct, the mechanism will be consistent with the
hypothesis.

Fig 23 Analyzing the cause of Failure

04 Failure Analysis Methodology

Step 5 : Preventive Action Report (PAR)

➢ A type of document that use to initiate a

corrective action that will prevent a mistake
from happening again.

➢ For example, All Boeing planes were

inspected at the same position that was the
cause of failure. The Boeing designs new Fig 24 The Boeing Plane
downstop to prevent the same mistake.
05: Summary
05 Summary

Define Data Propose Failure Preventive Action

Collection a hypothesis Mechanism Report (PAR)

➢ Focus on terms of reference

➢ Observation
➢ Focus Groups
➢ Interview
➢ Group Discussion
➢ Data Verification

Fig 25 Failure Analysis Methodology Block Diagram

05 Summary

prevent a mistake from happening again.

achieving higher levels of quality and

Failure Analysis reliability
Failure Outcomes
Methodology
enhancing customer satisfaction, etc.

plan future projects

QC
06 References

01 The Involvement of Failure Analysis in ISO Block Diagram

1. https://www.iso.org/management-system-standards.html

02 What is a Failure?
1.https://www.asminternational.org/documents/10192/23555666/ASM+Subject+Guide_FailureAnalysis.pdf/b4f19
efa-6fc5-425c-b006-ad9cc358e526

03 Failure Analysis Methodology

1.https://www.asminternational.org/documents/10192/23555666/ASM+Subject+Guide_FailureAnalysis.pdf/b4f19
efa-6fc5-425c-b006-ad9cc358e526
06 References

04 Failure Analysis Methodology

1.https://www.asminternational.org/documents/10192/23555666/ASM+Subject+Guide_FailureAnalysis.pdf/b4f19
efa-6fc5-425c-b006-ad9cc358e526
2.https://meadowsanalysis.com/the-importance-of-failure-analysis-in-
engineering/#:~:text=Failure%20analysis%20can%20help%20gather,you%20didn't%20know%20about.
3. https://www.greenlight.guru/glossary/corrective-preventive-action-
report#:~:text=A%20CORRECTIVE%20AND%20PREVENTIVE%20ACTION,A%20MISTAKE%20FROM%20HAPPENING%
20AGAIN.