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Book Chapter
Aspects of a Failure Investigation
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 August 2005
DOI: 10.31399/asm.tb.horfi.t51180061
EISBN: 978-1-62708-256-3
... Abstract Statistics, data analysis, root cause analysis, and problem-solving processes play a key role in failure investigations. This chapter explains how to collect failure investigation data, how to build and maintain a database for company-related failures, and how to use corresponding...
Abstract
Statistics, data analysis, root cause analysis, and problem-solving processes play a key role in failure investigations. This chapter explains how to collect failure investigation data, how to build and maintain a database for company-related failures, and how to use corresponding statistics including type of failure, material, and root cause. It describes the purpose and benefits of conducting a root cause analysis and the factors, namely relative failure importance and company value, that determine when an investigation should be performed. The chapter also discusses the four-step problem-solving process as it applies to failure investigation, how to assemble an investigation team, and the details of organization and planning. It concludes with a case history of the Firestone 500 steel-belted tire failure, stressing the importance of a systematic approach to failure investigations.
Book Chapter
Why Perform Failure Analysis?
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 30 November 2013
DOI: 10.31399/asm.tb.uhcf3.t53630xvi
EISBN: 978-1-62708-270-9
... variety of factors, and many failures are the result of multiple related factors. In a larger, more encompassing context, failure can be defined as “the inability of a component, machine, process, or culture/thinking to function properly” ( Ref 2 ). A failure is not just a broken part but can...
Abstract
Designs and materials continue to become more complex, with novel technologies developed to create them, and novel instruments invented to analyze them. Engineers at all stages of the design and manufacturing process should appreciate the reasons why formal failure analysis is performed. This chapter describes why failure analysis is conducted and outlines the responsibilities of the failure analyst.
Book Chapter
Pedigree Analysis
Available to PurchaseBook: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780075
EISBN: 978-1-62708-268-6
...). The failure analysis team may find sloppiness or errors in the inspection documentation, again suggesting an inspection escape. Inspection records: In a manner similar to that described previously, most companies retain their inspection records to show that the products and materials they used met all...
Abstract
A product pedigree describes its design and how it was built and shows that it was built in accordance with the drawings and other documentation defining the product configuration. Evaluating the pedigree of a failed product can help to rule in or rule out hypothesized failure causes. This chapter describes various areas that can be examined by the failure analysis team to assess the pedigree of the failed system. If the failure analysis team suspects product pedigree anomalies it should confirm conformance through independent means.
Book Chapter
Change Analysis
Available to PurchaseBook: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780081
EISBN: 978-1-62708-268-6
... with suppliers if the suppliers provide items related to hypothesized failure causes. Sometimes, the purchasing department changes suppliers. Such information is not always readily apparent (even if the company investigating the failure is the one that made the switch in suppliers). Subtier suppliers can also...
Abstract
This chapter targets areas that determine if a change occurred and if the change induced the failure: change or what's different analysis. It describes the different sources of changes that induce process deficiencies: design, process, test and inspection, environmental, supplier lot, aging, and supplier changes. The chapter presents an example of a cluster bomb failure to explain how the failure analysis team found and corrected the failure cause.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2019
DOI: 10.31399/asm.tb.mfadr7.t91110262
EISBN: 978-1-62708-247-1
... and fabless companies rely on FA results to build defect pareto charts and identify problems that have the most impact to manufacturing yield ramp. Figure 2 Typical IC manufacturing time to market cycle Time to market can be shortened by finding root cause failures earlier and implementing...
Abstract
Over the revolutionary era of semiconductor technology, Computer-Aided Design Navigation (CADNav) tools have played an increasingly critical role in silicon debug and failure analysis (FA) in efforts to improve manufacturing yield while reducing time-to-market for integrated circuit (IC) products. This article encompasses the key principles of CADNav for various aspects of semiconductor FA and its importance for improved yield and profitability. An overview of the required input data and formats are described for both IC and package devices, along with key considerations and best practices recommended for fast fault localization, accurate root cause analysis, FA equipment utilization, efficient cross-team collaboration, and database management. Challenges with an FA lab ecosystem are addressed by providing an integrated database and software platform that enable design layout and schematic analysis in the FA lab for quick and accurate navigation and cross-tool collaboration.
Book Chapter
Failures Come in All Shapes and Sizes
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 August 2005
DOI: 10.31399/asm.tb.horfi.t51180029
EISBN: 978-1-62708-256-3
... Abstract Many companies conduct only metallurgical evaluations in the wake of failures, discovering nothing more than the physical mechanism by which the failure occurred. The origin of failures, however, is often complex, involving not only physical mechanisms, but also human behavior...
Abstract
Many companies conduct only metallurgical evaluations in the wake of failures, discovering nothing more than the physical mechanism by which the failure occurred. The origin of failures, however, is often complex, involving not only physical mechanisms, but also human behavior and latent factors. Failures may also involve multiple parts, entire machines, or processes of any size and shape. The chapter examines the unique aspects of many failures and explains how they can sometimes be traced to systemic issues. It also covers the reasons why products fail, including improper service or operation, improper maintenance, improper testing, assembly errors, fabrication or manufacturing errors, and design errors. The case of the Tacoma Narrows Bridge collapse is presented to illustrate the consequence of overlooked factors, in this case, wind dynamics, and the importance of identifying root causes to prevent repeat failures.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2006
DOI: 10.31399/asm.tb.ex2.t69980551
EISBN: 978-1-62708-342-3
.... In addition to the product and service provided, the customer considers the social and corporation aspects of the company. This includes the social politics, integration into the region, and environmental issues. The quality of a company is the sum of these properties. It can be used as a yardstick...
Abstract
The aim of every extrusion plant is the efficient production of competitive products that meet the appropriate quality requirements. This chapter discusses the processes involved in the selection and introduction of a quality management system, along with its application, advantages, and disadvantages. It describes the process chain for order processing within the quality circle and provides information on product liability legal issues. In addition, the chapter discusses the processes involved in quality control, along with its organization, responsibilities, audits, and testing.
Book Chapter
A Few Pitfalls and More Useful Tools
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 August 2005
DOI: 10.31399/asm.tb.horfi.t51180127
EISBN: 978-1-62708-256-3
... Abstract This chapter describes some common pitfalls encountered in failure investigations and provides guidance to help engineers recognize processes and “quick fixes” that companies often try to substitute for failure analysis. It discusses three important skills and characteristics...
Abstract
This chapter describes some common pitfalls encountered in failure investigations and provides guidance to help engineers recognize processes and “quick fixes” that companies often try to substitute for failure analysis. It discusses three important skills and characteristics that a professional engineer must improve to conduct an effective and successful failure investigation, namely technical skills, communication skills, and technical integrity. The chapter also provides information on the additional basic tools available for failure investigation and root cause determination: the Kepner-Tregoe structured problem-solving method, PROACT software for root cause analysis developed by the Reliability Center, Inc., and other processes and methods developed by the Failsafe Network, Inc., and Shainin LLC.
Book Chapter
Training Needs for the Failure Analyst
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2019
DOI: 10.31399/asm.tb.mfadr7.t91110673
EISBN: 978-1-62708-247-1
... of its systems. This brought about the need for analysis capabilities to understand failure mechanisms associated with these integrated circuits. As these parts grew in popularity, the requirement for failure analysis grew. During the late 1960’s many companies began taking the first steps toward...
Abstract
Education and training play an important role if the failure analyst is to be successful in his or her work. This article discusses the history of training activities in the failure/product analysis discipline and describes where this area is heading. It provides information on three areas of education and training that should be given to the analyst for him or her to be successful developing and fielding modern semiconductor components: analysis process, technology, and technique training.
Book Chapter
Nine Steps of a Failure Investigation
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 August 2005
DOI: 10.31399/asm.tb.horfi.t51180091
EISBN: 978-1-62708-256-3
... corrective action(s). Evaluate the effectiveness of the selected corrective action(s). The first five steps relate to steps 1 and 2 of the four-step problem-solving process discussed in Chapter 3 . The next four steps relate to steps 3 and 4 of the four-step problem-solving process. Many failure...
Abstract
This chapter describes the nine steps of a failure investigation. The steps add detail to the problem-solving process introduced in Chapter 3. The first five steps are (1) understanding and negotiating the investigation goals, (2) obtaining an understanding of the failure, (3) objectively and clearly identifying all possible root causes, (4) evaluating the likelihood of each root cause, and (5) converging on the most likely root cause(s). Many failure investigations stop at this point, but significant value is provided in the next four steps, which are (6) identifying all possible corrective actions, (7) evaluating each corrective action, (8) selecting the optimal corrective action(s), and (9) evaluating the effectiveness of each corrective action. Each step is discussed in detail with examples along with information on the procedures to be followed and resources needed for the investigation.
Book Chapter
Basic Understanding of Environment
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 June 1985
DOI: 10.31399/asm.tb.sagf.t63420027
EISBN: 978-1-62708-452-9
... Abstract This chapter provides an overview of environmental factors when studying a gear failure. Environmental factors discussed are lubrication, temperature, and mechanical stability. failure analysis gears lubrication mechanical stability temperature Environment is a set...
Abstract
This chapter provides an overview of environmental factors when studying a gear failure. Environmental factors discussed are lubrication, temperature, and mechanical stability.
Book Chapter
What Is a Failure?
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 August 2005
DOI: 10.31399/asm.tb.horfi.t51180001
EISBN: 978-1-62708-256-3
... it to failure. Learning the proper steps for organizing a failure investigation ensures success. Failure investigation crosses company functional boundaries and is an integral component of any design or manufacturing business operation. However, a poorly organized investigation may not provide the necessary...
Abstract
Failure investigation is an integral part of any design and manufacturing operation, providing critical information to solve manufacturing problems and assist in redesigns. This chapter addresses several aspects of failure investigation, beginning with the challenges of organizing such efforts and the need to define a clear and concise goal, direction, and plan prior to the investigation. It covers the causes of failure and the training and education organizations require to understand and prevent them. The chapter emphasizes the importance of discovering the root cause of failures, and uses examples to explain the factors involved and how to recognize them when the first appear.
Book Chapter
The Integrated Steel Industry—1901 to 1959
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 May 2018
DOI: 10.31399/asm.tb.hma.t59250187
EISBN: 978-1-62708-287-7
... were $25 million, the top executives received bonuses of $14 million. The press and Wall Street condemned the secret bonus plan, both for the extreme bonuses and for the company’s failure to reveal this information to the shareholders and to the public. FIG. 11.8 Eugene Grace was president...
Abstract
This chapter discusses the formation and growth of various integrated steel companies from 1901 to 1959, namely the United States Steel Corporation, Bethlehem Steel Corporation, and a few of the notable smaller steel companies. The chapter discusses labor unrest and the growth of organized labor in the steel industry in the twentieth century.
Book Chapter
The Decline of the Integrated Steel Industry
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 May 2018
DOI: 10.31399/asm.tb.hma.t59250207
EISBN: 978-1-62708-287-7
... industrywide problems and failures that had existed for many years. Among them were poor labor relations, delayed modernization, an unbalanced product mix, and inconvenient mill locations in relation to the market. Other problems included steady price increases to cover union contracts rather than productivity...
Abstract
This chapter is an account of the various events that led to the decline of the integrated steel industry during the 1950s. These include the steel strike of 1959, the improvements in technology and increase in imports since 1950s, widespread closures of steel companies, the decline of the minimill industry, and the rapid growth of Mittal Steel.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 May 2018
DOI: 10.31399/asm.tb.hma.9781627082877
EISBN: 978-1-62708-287-7
Series: ASM Technical Books
Publisher: ASM International
Published: 01 November 2023
DOI: 10.31399/asm.tb.edfatr.t56090069
EISBN: 978-1-62708-462-8
... many challenges for yield ramp and diagnostics. This chapter examines these challenges and the growing demand for innovative solutions to help failure analysts quickly and accurately isolate faults. It also assesses the capabilities and future potential of ATPG scan diagnostics, streaming scan networks...
Abstract
A typical mobile processor die may contain, among other things, a variety of high-performance as well as low-power processing cores along with 5G modems, Wi-Fi modules, image processors, GPUs, and security modules, with a total transistor count exceeding 10 billion. Such designs pose many challenges for yield ramp and diagnostics. This chapter examines these challenges and the growing demand for innovative solutions to help failure analysts quickly and accurately isolate faults. It also assesses the capabilities and future potential of ATPG scan diagnostics, streaming scan networks, and advanced fault models for diagnosing embedded memory.
Book Chapter
Analysis of Structure
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 December 2003
DOI: 10.31399/asm.tb.cfap.t69780343
EISBN: 978-1-62708-281-5
... Note: See Fig. 2 . PE, polyethylene; PP, polypropylene; PVC, polyvinyl chloride; PA, polyamide; PI, polyimide; PET, polyethylene terephthalate. Dacron, E.I. DuPont de Nemours & Co. A brief scheme of structure analysis as it relates to material failure is presented in Table 2 . The examples...
Abstract
This article introduces procedures an engineer or materials scientist can use to investigate failures. It provides a brief survey of polymer systems and key properties that need to be measured during failure analysis. The article begins with an overview of the problem-solving approach pertinent to structure analysis. This is followed by a review of the characterization of plastics by infrared and nuclear magnetic resonance spectroscopy. The article then provides information on the distribution of molecular weight of an engineering plastic. It further discusses the methods used in thermal analysis, namely differential thermal analysis, thermogravimetric analysis, thermal-mechanical analysis, and dynamic mechanical analysis. The following sections provide details on X-ray diffraction for analyzing crystalline phases and on a minimal scheme for polymer analysis and characterization to assist the design engineer. The article ends with a discussion on the thermal-analytical scheme for analyzing the milligram quantities of polymer samples.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 August 2005
DOI: 10.31399/asm.tb.horfi.t51180151
EISBN: 978-1-62708-256-3
... of a failure to the person or company destroying the evidence, even though they may not have caused the original failure. The goal of every failure analyst is to determine not only the fracture mechanism that results in the failure but also the root cause of the failure. Often the root cause is related...
Abstract
This appendix focuses on procedures, techniques, and precautions associated with the investigation and analysis of metallurgical failures that occur in service. It describes the steps of an orderly failure analysis from collecting and examining samples to performing mechanical and nondestructive tests, preparing and examining fractographs and micrographs, determining failure mode, writing the report, and developing follow-up recommendations. It also examines the fundamental mechanisms of failure, why they occur, and how to identify them by their characteristic features.
Book Chapter
Introduction to Fatigue and Fracture
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2012
DOI: 10.31399/asm.tb.ffub.t53610001
EISBN: 978-1-62708-303-4
..., if other time-related failure modes occur concomitantly with repeated loads and interact synergistically, then the task becomes even more challenging. Inasmuch as humans always desire to use more goods and place more demands on the things we can design and produce, the challenge of fatigue is always going...
Abstract
This chapter provides a brief review of industry’s battle with fatigue and fracture and what has been learned about the underlying failure mechanisms and their effect on product lifetime and service. It recounts some of the tragic events that led to the discovery of fatigue and brittle fracture and explains how they reshaped design philosophies, procedures, and tools. It also discusses the influence of material and manufacturing defects, operating conditions, stress concentration and intensity, temperature and pressure, and cyclic loading, all of which play a role in the onset of fatigue cracking and thus should be considered when predicting useful product life.
Book Chapter
Failure Analysis in Tool Steels
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 September 2008
DOI: 10.31399/asm.tb.fahtsc.t51130311
EISBN: 978-1-62708-284-6
... Abstract This chapter focuses on the failure aspects of tool steels. The discussion covers the classification, chemical composition, main characteristics, and several failures of tool steels and their relation to heat treatment. The tool steels covered are hot work, cold work, plastic mold...
Abstract
This chapter focuses on the failure aspects of tool steels. The discussion covers the classification, chemical composition, main characteristics, and several failures of tool steels and their relation to heat treatment. The tool steels covered are hot work, cold work, plastic mold, and high-speed tool steels.
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