Approaches, procedures, and basic skills for failure analysis

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Approach to failure analysis: Define the objective: Determine whether the purpose of the failure analysis is to identify the root cause, propose corrective measures, or meet customer requirements. Information collection: Gather all information related to the failure, including product design, manufacturing process, operating conditions, environmental factors, etc. Hypothesis establishment: Based on the collected information, establish hypotheses for possible causes of failure. Verify the hypothesis: Validate the hypothesis through experiments and analytical methods, gradually eliminating impossible causes. Identify the root cause: Determine the most likely root cause during the verification process. Propose solutions: Put forward specific improvement measures based on the root cause. Preventive measures: Establish preventive measures to prevent similar failures from occurring again. Procedure for failure analysis: Failure investigation: Confirm the failure incident. Collect information and evidence from the failure site. Record the usage and maintenance history of failed products. Failure confirmation: Observe the failure phenomenon. Identify failure modes (such as fracture, corrosion, wear, etc.). Non-destructive testing: Preliminary analysis is carried out using methods such as visual inspection, X-rays, ultrasound, and magnetic particle testing. Destructive testing: Involves dissection, cutting, microscopic examination, chemical analysis, etc. of failed samples. Data analysis: Analyze the test results. Compare with design specifications, material properties, etc. Cause analysis: Determine the cause of failure based on the data analysis results. Verify hypotheses and rule out impossible causes. Report preparation: Prepare a failure analysis report, including the failure phenomena, analysis process, identification of causes, and improvement recommendations. Tracking verification: Conduct tracking verification on the proposed improvement measures. Verify the effectiveness of the improvement measures. Basic skills for failure analysis: Observation skills: The ability to carefully observe the appearance and internal structure of failed products. Analytical skills: The ability to use logical thinking and professional knowledge to analyze the causes of failures. Experimental skills: Proficient in various non-destructive and destructive testing techniques. Data processing skills: capable of processing and analyzing large amounts of experimental data. Report writing skills: Ability to write failure analysis reports clearly and accurately. Communication skills: Able to communicate effectively with team members, management, and clients. Problem-solving skills: The ability to address complex issues and come up with innovative solutions. Ongoing learning*: Continuously learning new failure analysis techniques and methods to keep professional knowledge up to date.