Failure Analysis: A Step-by-Step Procedure
Failure analysis is the process of identifying and diagnosing the root cause of a failure in a system or component. It is an essential part of quality assurance and product reliability. By analyzing why a failure occurred, corrective action can be taken to prevent similar failures from occurring in the future. In this article, we will discuss the steps involved in a typical failure analysis procedure.
Receiving
The first step in the failure analysis procedure is receiving the sample. Customers submit their samples with a completed service request form, which includes the urgency and approval for the service request. There are three categories of urgency and approval for the service requests: Critical (Manager Approval – Job to be completed within one week), Urgent (Superintendent approval- Job to be completed within three weeks) and Routine (Supervisor approval – Job to be completed within 1½ month).
Assigning a Job Service Request Number and Staff
Once the samples are received, they are assigned a sequential 4-digit Service Request Number (SRN). Technicians and engineers working on the job are designated by the laboratory group leader and the Supervisor.
Sample and Micro Labeling System
The samples are inscribed with the assigned SRN, e.g., SRN-1234 using a permanent marker. If more than one sample for the same job is received, the samples are inscribed with the same SRN followed by a sequential number commencing with one, etc., e.g., SRN-1234-1, SRN-1234-2, etc.
Micro Storage
All micros are stored in air-tight cabinets with active desiccant. Engineers are usually assigned one cabinet each to store their micros. Technicians are tasked to periodically verify that the desiccant is replaced well-prior to its used-up period.
Deposit Analysis
When required by the engineer, deposits from the samples received may be sent to the R&DC for analysis of corrosion product or contaminants to support the failure analysis. Normally, X-Ray Diffraction (XRD) or X-Ray Fluorescence (XRF) or both are carried out by R&DC.
Sample Disposal
Metal samples are kept in the yard or inside the laboratory for a maximum period of 30 days; thereafter, they will be scrapped if unclaimed by the engineer or the customer. In some cases, some samples are kept for longer periods if they are deemed to be good teaching tools for training and development of technicians and engineers.
Conclusion
Failure analysis is a detailed process that requires careful and precise steps. By following a logical procedure, engineers and technicians can identify the root cause of a failure, enabling them to take corrective action to prevent similar failures from occurring in the future.
