FAILURE ANALYSIS

FAILURE ANALYSIS
By Keith Morganstein
www.maxeffortengines.com

A Failure Analysis program helps you determine why things fail and how to prevent them from happening again. The eight step program outlined below is borrowed from the diesel and earthmoving industry. This type of "closed loop failure analysis program" has been a key to success in a very tough working environment. The science behind this program is rock solid and can be easily implemented by racing teams and engine builders.

These are the steps to the program:

Step 1) Identify the problem - identify the failed components and observable symptoms. This may include unusual wear, fractures or deformed parts. Noises, odors, colors etc...

Step 2) Gather facts - examine everything carefully including all related and connected parts or components. AVOID PRECONCEIVED IDEAS about the failure. JUST COLLECT THE FACTS. Determine type of fracture (i.e. brittle, ductile) or type of wear etc... Use available resources to identify the type of fracture or wear to avoid guessing.

Step 3) Collect and record the facts - Be accurate, record everything, take photos, write down measurements, and review service records. Document everything.

Step 4) Think logically and identify all the events of the failure - Relate the facts to the events of the failure.

Step 5) Identify the most probable ROOT CAUSE of the problem - By ESTABLISHING A TIMELINE OF THE EVENTS, using the concept of "good to bad", establish this timeline of events. Some events may overlap. When all events are correctly laid out on the timeline, you will see the sequence with one event leading to another. From cause to failure.

Step 6) Communicate with the responsible party - This will help with corrective action and may reveal important circumstances affecting it.

Step 7) Make repairs as directed - Use your timeline analysis to repair the root cause of the problem and to prevent the problem from recurring.

Step 8) Follow up - Set a schedule for follow up to be sure your corrective action fixed the problem.