Production quality problems lead to costly scrap, rework, and extra inspections. So, preventing quality problems and quickly finding the root cause of quality problems are critical for keeping costs low. This applies to production of materials, components, and assemblies.
When quality problems occur, it is essential to perform a disciplined root cause analysis. This includes performing a failure analysis of the stock materials, components, or joints associated with the problem. The purpose of a failure analysis is to determine whether there is anything wrong with the materials and how the materials were affected by the manufacturing process.
The findings from a failure analysis help engineering teams quickly find the root cause and identify and implement corrective actions. However, one key engineering discipline is often absent from engineering teams, which leads to lingering quality problems.
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When quality problems occur, it is essential to perform a disciplined root cause analysis. The process helps engineering teams quickly find the root cause and identify and implement corrective actions. However, one key engineering discipline is often absent from engineering teams. This absence leads to lingering quality problems. The absent piece is materials engineering expertise.
The first step of a root cause analysis is to perform a failure analysis. This involves gathering information and data about the problem circumstances and materials involved. The information and data collected are used to identify the root cause. After identifying the root cause, identifying and implementing corrective actions are possible. Without the information and data, people waste time guessing at the root cause, and problems linger.
Key details about the problem circumstances include process conditions, materials used, problem frequency, and when the problem started. Data about the materials is obtained by analyzing the materials involved. The materials data is used to determine whether the materials meet requirements and how the materials react to the process conditions.
The failure analysis findings are used to identify the mechanism causing the problem and the source of the problem. Or at least to rule out sources. Then it is possible to focus on the area contributing to the problem and identify the root cause.
Here's another article to read to learn more about the failure analysis process we use.
Many companies do not have materials engineers on staff. Instead, engineers from other fields try to solve problems that involve materials. These are skilled engineers. But they lack materials science and engineering training and don't have expertise in materials analysis and using the data to understand problems. Also, they often don’t know the steps to take to solve quality problems.
So, problems linger while scrap, rework, and inspection costs add up, leading to high costs of poor quality.
See these articles if you’d like to learn more about failure analysis:
We provide failure analysis consulting to help solve quality problems. We work with engineering teams to help determine the root cause of quality problems and identify corrective actions to fix the problems.
Finally, we offer metallurgy consulting to help with product design and manufacturing decisions and problems. If you need help, let's talk for 15 minutes. Use this brief form to get started.
Michael Pfeifer, Ph.D., P.E. is President of Industrial Metallurgists and a metallurgical engineering consultant with more than 30 years of experience in product design, manufacturing, failure analysis, and metallurgy training. He helps clients worldwide solve design and manufacturing problems and is the author of Materials Enabled Designs.
