What do you do if you want to learn from failure and prevent recurring errors in automotive engineering?

Los sistemas de gestión de la calidad en la industria automotriz definen las herramientas que deben usarse para la corrección y prevención de errores. Cuando hablamos de corrección (garantías, quejas, rechazos internos) debemos tener un proceso de solución de problemas que además de analizar el problema y su(s) causa(s), determine acciones efectivas de corrección, incluya la definición de acciones de prevención. La herramienta requerida para la prevención de errores es el FMEA (Dise?o y Proceso) que se alimenta del análisis de fallas potenciales y las lecciones aprendidas del pasado. Para aprender de las fallas, deben documentarse en los respectivos FMEAs para que éstos reflejen las lecciones del pasado y el estado actual del proceso.

The rapid evolution of automotive technologies means that failures will inevitably occur, and lessons need to be learned. It is critical that we conduct a thorough 5Why or 8D analysis to identify the root cause and create a strategy for preventing recurrence. To build autonomy within the team, we must perform knowledge management and consistently improve our skills. Generative AI and machine learning are being carefully embraced by the automotive software development industry. It is crucial that we create a culture of knowledge sharing through ongoing learning. As we move toward the new architecture paradigm for software-defined vehicles and toward electric vehicles and cloud technology, we must once again do the basics brilliantly.

When we make decisions that don't produce the desired outcome, we often view it as a failure. However, I choose to see each failure as an opportunity to learn and grow. If something goes wrong, I carefully analyze the situation by reviewing every step, identifying the root cause, and then revising my strategies. This process allows me to move forward with renewed insight and a better plan for success."

To learn from failures and prevent recurring errors in automotive engineering, it is crucial to begin by carefully analyzing the errors. This involves thorough investigation to identify the root causes of the problems, is important to have previous information including historical errors from previous design or carry-over design. This can improve detail during cause-effect analysis using tools like Ishikawa diagram for example.

Implement a culture of continuous improvement within the organization. Encourage feedback from all stakeholders involved in the design, manufacturing, and maintenance processes. Regularly review and update processes, standards, and training programs based on lessons learned from past failures.

Once the causes of errors have been identified, it's important to implement effective solutions to correct these issues. This may involve adjustments in design, changes in manufacturing processes, or updates to quality control systems. Its important to have in mind the concepts of ICA (Interim Containment Action), PCA (Permanent Corrective Action) and PRA (Preventive Reocurrence Action).

Encourage knowledge sharing among engineers and teams by organizing regular meetings, workshops, and seminars focused on lessons learned from past failures. Creating a platform for sharing experiences and best practices can help prevent recurring errors.

Understanding the lessons learned from errors is crucial, but equally important is sharing these learnings with the entire team and even with other stakeholders. This can be done through post-failure review meetings, detailed technical reports, or formal presentations. By actively sharing lessons learned, it's possible to prevent others from making the same mistakes and promote a culture of continuous learning within the organization.

Foster collaboration between different departments, such as design, manufacturing, quality assurance, and maintenance. Each department brings unique perspectives and expertise that can contribute to identifying and addressing potential failure modes.

An organizational culture that values learning from failures is essential for preventing recurring errors. This involves encouraging a mindset of continuous improvement, where errors are seen as learning opportunities rather than individual failures. Leaders play a key role in modeling this behavior and rewarding learning and improvement initiatives.

In addition to addressing specific failures, it's important to continuously refine processes and procedures to reduce the likelihood of errors in the future. This may include implementing new data analysis tools, updating testing protocols, or revising design specifications. For example, a company may introduce additional quality checks at critical stages of the manufacturing process to identify and correct issues before they become failures in the final product.

Foster a culture of continuous improvement within the organization. Encourage employees to actively seek out and report potential failure modes, near misses, or quality concerns. Regularly review and update processes, procedures, and design standards based on lessons learned from past failures.

Finally, continuous learning is crucial to avoiding the repetition of errors. This involves investing in the training and development of the team, ensuring that all members are up-to-date with best practices and the latest technologies. Additionally, it's important to closely monitor industry trends and emerging innovations to stay at the forefront of automotive engineering and avoid issues arising from obsolescence or lack of updated knowledge.

To learn from failure and prevent recurring errors in automotive engineering, conduct thorough root cause analysis to identify underlying issues. Implement corrective and preventive actions based on RCA findings to address systemic weaknesses. Utilize Failure Mode and Effects Analysis to anticipate potential failure modes and mitigate risks proactively. Establish robust quality management systems incorporating lessons learned to foster continuous improvement and error prevention.