What are the most effective strategies for conducting a mechanical failure analysis?

1 Define the problem

The first step is to define the problem clearly and precisely. What is the failure mode, the failure mechanism, and the failure cause? How did the failure affect the function, performance, and reliability of the system or component? What are the criteria for success or failure? What are the relevant standards, regulations, and specifications? By answering these questions, you can set the scope, objectives, and expectations of the analysis.

2 Collect and preserve evidence

The next step is to collect and preserve evidence from the failed system or component. This may include physical, visual, documentary, or testimonial evidence. You should document the failure scene, the operating conditions, the maintenance history, and any other relevant information. You should also inspect, measure, and photograph the failed parts, and store them in a safe and secure place. You should avoid cleaning, repairing, or altering the evidence, as this may compromise its integrity and validity.

3 Analyze the evidence

The third step is to analyze the evidence using various methods and tools. Depending on the type and complexity of the failure, you may use analytical techniques such as fracture analysis, stress analysis, fatigue analysis, corrosion analysis, wear analysis, or vibration analysis. You may also use testing methods such as non-destructive testing, destructive testing, chemical testing, or metallurgical testing. You should compare the results with the design specifications, the operating conditions, and the failure criteria.

4 Identify the root cause

The fourth step is to identify the root cause of the failure. This is the underlying factor or factors that initiated or contributed to the failure. It may be related to design, material, manufacturing, installation, operation, maintenance, or environment. You should use a systematic and logical approach to trace the cause-and-effect relationships among the various factors. You may use tools such as fault tree analysis, fishbone diagram, 5 whys, or root cause analysis matrix.

5 Recommend corrective actions

The final step is to recommend corrective actions to prevent or mitigate future failures. These may include design modifications, material substitutions, manufacturing improvements, installation adjustments, operation changes, maintenance enhancements, or environment controls. You should also evaluate the feasibility, effectiveness, and cost-benefit of the proposed actions. You should communicate your findings and recommendations in a clear and concise report that summarizes the problem, the evidence, the analysis, the root cause, and the corrective actions.

6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?