The act of gathering and examining failure data is known as failure analysis, and it is often used to determine the underlying reason for an asset malfunction or breakdown. By using this knowledge, maintenance procedures, schedules, and machine/component designs may all be improved. Its ultimate objective is to increase asset dependability.
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Usually, the failure analysis procedure is carried out following an actual failure. It is a crucial step in the Root Cause Analysis (RCA) procedure. To choose and implement the best preventative measures, it may also be utilized to identify different elements that can contribute to a possible failure.
Failure analysis can be carried out by reliability engineers, plant and maintenance engineers, or failure analysis engineers, depending on the goal.
Primary failure analysis is carried out by maintenance engineers using their understanding of plant operations. Hiring consultants who offer failure analysis services is advised if the internal team lacks the necessary experience.
Finally, to increase fault tolerance and guarantee the resilience of a system, reliability engineers use various failure analysis methodologies.
Typical applications of failure analysis
Below is a discussion of the most popular justifications for performing failure analysis.
Determining the primary causes of failure
Machine breakdowns are frequently the outward sign of more serious issues that were not promptly resolved. An unanticipated collapse can occasionally result from a confluence of many events.
Maintenance personnel must work hard to prevent malfunctions since they are costly and disruptive. The greatest method to prevent breakdowns, other from regular maintenance, is to identify and eliminate the underlying reasons of failure.
Avoiding possible failures
Numerous interdependent and interrelated parts make up a machine or system. These elements are less likely to result in a failure that affects the entire system. The likelihood of possible failures may be examined using the system’s information and data.
To identify the weakest points and strengthen them, whether via design modifications or adjustments to operation and maintenance guidelines, tests and simulations can be conducted.
Designing better products
Failure analysis may be used to enhance the design of components or equipment, as we just said in the previous paragraph. To find possible problems in their designs, engineers might use a variety of failure analysis approaches.
From a more pragmatic perspective, they can also do destructive testing to assess the properties of the materials and components they want to utilize in their finished product.
The quality of the product is created or enhanced using the knowledge gathered from these tests and analysis.
Maintaining conformance
Failure analysis is frequently necessary to comply with government or industry-imposed regulations and standards. To make sure the product meets the necessary criteria, failure analysis techniques are applied.
Evaluation of liability
Failure-related legal actions necessitate an analysis of the failure’s cause. To make that the terms of the contract are fulfilled, the same is carried out as part of some insurance claim settlements. Failure analysis may be required by law in several situations.
Failure analysis results can, of course, also be utilized as legal defense.
Typical methods for failure analysis
Analysis of failures is not a precise science. It may be seen as a craft and is an intriguing investigation into the real reason for failures.
Failure analysis, however, cannot be carried out without a framework. Many methodologies that may be used as a framework to examine various failures have been created by engineers throughout the years.
How to draft a report on failure analysis
It’s time to compose the report once you’ve completed the analysis. Although no one like doing administrative labor, it may be very helpful for failure analysis in the future to document methods performed, solutions attempted, and conclusions reached.
The kind and extent of the study you are conducting will determine how thorough your failure analysis report is.
For instance, thorough documentation is required for a field failure investigation conducted following a product recall. It is advised in this situation to gradually compile records and documentation as you proceed. You may then request that all participating teams submit their work, combine it, and complete your failure analysis paper.
On the other hand, a one-page report would be adequate for a brief investigation conducted to examine the breakdown of conveyor belt #3.