How to Organize And Run a Failure Investigation by Daniel P. Dennies

By Daniel P. Dennies

Studying the right kind steps for organizing a failure research guarantees luck. Failure investigations go corporation sensible barriers and are an indispensable component to any layout or production enterprise operation. Well-organized and professionally carried out investigations are crucial for fixing production difficulties and aiding in redesigns. This publication outlines a confirmed systematic method of failure research. It explains the connection among a variety of failure assets (corrosion, for instance) and the association and behavior of the research. It presents a studying platform for engineers from all disciplines: fabrics, layout, production, caliber, and administration. The examples during this e-book specialise in the definition of and requisites for a professionally played failure research of a actual item or constitution. despite the fact that, the various strategies have a lot better software than for investigating the failure of actual items. for instance, the booklet offers suggestions in parts equivalent to studying how to find goals, negotiating the scope of research, reading the actual facts, and using normal problem-solving suggestions.

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One day a failure was reported at the test stand when one of the engines exploded during the bird strike test. The technician shot the chicken into the engine, and the engine came to pieces— a very rare event. During subsequent review it was discovered that the new technician who performed the test had apparently skipped the step about first thawing the chicken. Needless to say, the engine failed the test when the frozen bird hit it with the destructive impact of a bowling ball. Low-cost personnel often equals clueless or untrained personnel.

I believed the test data had been mistakenly transposed when written on the report sheet. The supplier confirmed my theory and corrected the report sheet. The forging was acceptable. The company had just generated a $5000 piece of paper, and the engineer had spent hours on the evaluation by reviewing the documents and the drawings and familiarizing himself with the hard- Chapter 2: Failures Come in All Shapes and Sizes / 41 ware so he could explain it to me. Thousands of dollars were spent in engineering evaluation because the quality-control personnel did not have enough experience or training to look at the data and realize the numbers had been transposed.

Performing a metallurgical evaluation may reveal fatigue striations or corrosion as the physical root cause. However, that may not be the reason the failure occurred. Most failures are a cascade of events. For example, a failure may start as a stress corrosion crack, then turn into a fatigue crack, which eventually results in overload. That’s three different types of failures rolled into one. Now back up even further. What initiated the stress corrosion cracking? Could it be management’s decision to place the component in an environment for which it was not designed?

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