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The four-step problem-solving process guides the systems failure analysis t...
Available to PurchasePublished: 01 December 2009
Fig. 1.2 The four-step problem-solving process guides the systems failure analysis technologies and approach addressed in the remainder of this book.
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Image
The four-step problem-solving process. This chapter focuses on the last two...
Available to PurchasePublished: 01 December 2009
Fig. 18.1 The four-step problem-solving process. This chapter focuses on the last two steps (identifying possible solutions and selecting the best solution).
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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
Systems Failure Analysis Introduction
Available to PurchaseBook: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780001
EISBN: 978-1-62708-268-6
... Abstract This chapter focuses on what can cause a system to fail and addresses the challenge in approaching a system failure. It then examines the steps involved in the four-step problem-solving process: defining the problem, identifying all potential failure causes and evaluating...
Abstract
This chapter focuses on what can cause a system to fail and addresses the challenge in approaching a system failure. It then examines the steps involved in the four-step problem-solving process: defining the problem, identifying all potential failure causes and evaluating the likelihood of each, identifying the potential solutions, and identifying the best solution. The chapter concludes by describing the responsibilities of a failure analysis team.
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
... 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...
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
Identifying Potential Failure Causes
Available to PurchaseBook: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780025
EISBN: 978-1-62708-268-6
... Abstract In the second step of the four-step problem-solving process, the failure analysis team should identify all potential failure causes. This chapter discusses the steps involved in five such techniques for identifying potential causes of failure, namely brainstorming, mind mapping...
Abstract
In the second step of the four-step problem-solving process, the failure analysis team should identify all potential failure causes. This chapter discusses the steps involved in five such techniques for identifying potential causes of failure, namely brainstorming, mind mapping, Ishikawa diagrams, the “five whys” technique, and flow charting.
Book Chapter
Corrective Action
Available to PurchaseBook: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780183
EISBN: 978-1-62708-268-6
... or interim corrective actions to overcome design, process, and other failure causes. The chapter concludes by describing the process of corrective action implementation. corrective action failure analysis failure causes problem-solving process THE FOUR-STEP PROBLEM-SOLVING PROCESS ( Fig. 18.1...
Abstract
Corrective action means the implementation or modification of things designed to eliminate or reduce failure causes. This chapter addresses developing potential solutions and selecting the best solution. It discusses the special operations that should be used only as temporary or interim corrective actions to overcome design, process, and other failure causes. The chapter concludes by describing the process of corrective action implementation.
Book Chapter
Black Liquor Recovery Boilers in the Pulp and Paper Industry
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 November 2007
DOI: 10.31399/asm.tb.htcma.t52080359
EISBN: 978-1-62708-304-1
... susceptible to corrosion. This chapter describes some of the problems that the pulp and paper industry has solved as well as ongoing issues and concerns. It includes an in-depth review of 304L cladding failures involving coextruded composite tubes used as floor tunes in the lower furnace, as superheater tubes...
Abstract
Black liquor recovery boilers are an integral part of the kraft pulping process used in paper mills. Besides recovering chemicals for reuse, they also produce process steam. High operating temperatures and exposure to process chemicals and combustion byproducts make recovery boilers susceptible to corrosion. This chapter describes some of the problems that the pulp and paper industry has solved as well as ongoing issues and concerns. It includes an in-depth review of 304L cladding failures involving coextruded composite tubes used as floor tunes in the lower furnace, as superheater tubes, and for other purposes such as smelt openings. It provides detailed images showing cracks on the outer surfaces of the tubes and explains where the tubes were used and how they were operated.
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
...: 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. failure investigation technical skills communication skills technical...
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
Engineering Ductile Iron Castings
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 January 2022
DOI: 10.31399/asm.tb.isceg.t59320163
EISBN: 978-1-62708-332-4
... defects and presents practical cases of problem-solving. casting defects chemical composition core-making ductile iron feeder design gating graphite morphology iron castings material grades matrix mechanical properties quality control THE DISCOVERY OF DUCTILE IRON was a technological...
Abstract
Ductile iron has far superior mechanical properties compared to gray iron as well as significantly improved castability and attractive cost savings compared to cast steel. This chapter begins with information on graphite morphology and matrix type. It then discusses the advantages and applications of ductile iron. Next, the effects of various factors on the grades, chemistry, matrix, and mechanical properties of ductile iron are covered. This is followed by a section detailing the ductile iron treatment methods and the quality control methods used. Guidelines for gating and feeder design are then provided. Further, the chapter addresses the technology of ductile iron castings, including the performance and geometric attributes, molding and core-making processes used, material grades, mechanical properties, and chemical compositions of a few applications. Finally, it describes ductile iron casting defects and presents practical cases of problem-solving.
Book Chapter
Failure Mode Assessment and Assignment
Available to PurchaseBook: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780067
EISBN: 978-1-62708-268-6
...&A be updated and distributed to all team members and other interested parties after each failure analysis team meeting. Evaluating Potential Failure Causes The analysis techniques covered thus far have been focused on steps 1 and 2 of the four-step problem-solving process ( Fig. 1.2 ). Potential failure...
Abstract
Failure mode assessment and assignment (FMA&A) is a tool designed to help organize the evaluation of hypothesized failure modes. This chapter begins by describing the process of preparing an FMA&A. It then describes the follow-on activities to evaluate the hypothesized failure cause. The chapter also provides information on evaluating the hypothesized potential causes.
Book Chapter
Systems and Systems Failure Analysis Concepts
Available to PurchaseBook: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780019
EISBN: 978-1-62708-268-6
... is discussed in much greater detail in the next several chapters. It is the basic tool primarily used for answering the second question in the four-step problem-solving process (What is the cause of the problem?). The technologies discussed in this book are equally applicable to identifying the root causes...
Abstract
A system failure occurs when a system does not do what it is supposed to do when it is supposed to do it, or it does something it is not supposed to do. This chapter provides a basic understanding of how failures occur, how systems operate, and the types of failures, namely intermittent and inadvertent system failures.
Book Chapter
Fault-Tree Analysis
Available to PurchaseBook: Systems Failure Analysis
Series: ASM Technical Books
Publisher: ASM International
Published: 01 December 2009
DOI: 10.31399/asm.tb.sfa.t52780035
EISBN: 978-1-62708-268-6
... and then graphically develops all potential causes of that event. In a systems failure analysis situation, the top undesired event is the system failure. From a systems failure analysis perspective, the top undesired event of the fault tree is the same thing as the first step in the four-step problem-solving process...
Abstract
Fault-tree analysis is a graphical technique that identifies all events and combinations of events that can produce an undesired event. This chapter emphasizes several fault-tree analysis concepts, examining with examples how all three categories of charting symbols (events, gates, and transfer symbols) come together to generate a fault-tree analysis.
Book Chapter
Phase Diagram Applications
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 March 2012
DOI: 10.31399/asm.tb.pdub.t53420289
EISBN: 978-1-62708-310-2
... 14.1 Industrial Applications of Phase Diagrams The following are but a few of the many instances where phase diagrams and phase relationships have proved invaluable in the efficient solving of practical metallurgical problems. The areas covered include alloy design, processing, and performance...
Abstract
This chapter discusses the use of phase diagrams in alloy design, processing, and performance assessment. The examples cover both ferrous and nonferrous metals and a variety of goals and objectives. The chapter also identifies limitations and pitfalls associated with the use of phase diagrams.
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
... components over a long period of time. This meant that the analyst could feed back information from field returns to the manufacturing line in time to make an impact. The process engineers could then make changes to the manufacturing line that would correct the problems seen by the customer. In the late...
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.
Series: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040091
EISBN: 978-1-62708-300-3
.... In practice, the solutions of mechanical and thermal problems are coupled in a staggered manner. After the nodal velocities are solved at a given step, the deformed configuration can be obtained by updating the nodal coordinates [ Li et al., 2001 ]. 9.4.2 Computer Implementation of the Finite Element Method...
Abstract
There are numerous approximate methods, both analytical and numerical, for analyzing forging processes. None are perfect because of the assumptions made to simplify the mathematical approach, but all have merit. This chapter discusses the slab, upperbound, and finite element methods, covering basic principles, implementation, and advantages and disadvantages in various applications.
Book Chapter
Inverse Analysis for Simultaneous Determination of Flow Stress and Friction
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 February 2005
DOI: 10.31399/asm.tb.chffa.t51040083
EISBN: 978-1-62708-300-3
... parameters in the flow stress model and the friction at the tool/workpiece interface. 8.2 Inverse Analysis in Metal Forming 8.2.1 Direct and Inverse Problems An FEA of metal forming process as illustrated in Fig. 8.1(a) is regarded as direct problem. The required input data for direct problem...
Abstract
This chapter discusses the role of inverse analysis in providing input data for finite element simulations of metal forming processes. It describes the basic procedures for determining flow stress and friction by inverse analysis and for comparing experimental measurements with corresponding computed data. It also includes an example in which flow stress and friction were measured in compressed aluminum rings and the results used to verify the accuracy of predicted values.
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
.... It can solve a manufacturing problem that can save money and save time. In the end, a well-run and organized failure investigation can even save lives. The Responsibilities of the Failure Analyst Failure analysts wield great power. Companies depend upon them to perform the task to the utmost...
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
Diffusion in Solids—Problems and Solutions
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 September 2022
DOI: 10.31399/asm.tb.dsktmse.t56050031
EISBN: 978-1-62708-432-1
... Abstract This chapter familiarizes readers with the use of Fick’s laws of diffusion in heat treating, coating, and other metallurgical processes. It contains worked solutions to nearly 30 problems requiring the calculation of activation energy, diffusion coefficient, concentration level...
Abstract
This chapter familiarizes readers with the use of Fick’s laws of diffusion in heat treating, coating, and other metallurgical processes. It contains worked solutions to nearly 30 problems requiring the calculation of activation energy, diffusion coefficient, concentration level, surface layer thickness, case depth, and processing time and temperature. The selected problems deal with various types of iron, steel, and nonferrous alloys and processes ranging from aluminizing, chromizing, carburizing, and plasma nitriding to hydrogen dissipation, decarburizing, and oxidation. A few diffusion problems involving single-crystal silicon are also included.
Book Chapter
Marine Systems Applications
Available to PurchaseSeries: ASM Technical Books
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.tb.ssde.t52310243
EISBN: 978-1-62708-286-0
... steel made since then have thankfully made these statements obsolete. Not only have basic corrosion problems been solved, stress corrosion cracking also can be avoided. More impressively, this can be done with alloys with strengths much higher than those of the alloys, such as 316, that they replace...
Abstract
This chapter reviews the major marine applications of stainless steels, including the desalination equipment, shipping containers, and heat exchangers that handle seawater.
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