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Failure Reporting (FR). The failures and the faults related to a system, a piece of equipment, a piece of software or a process are formally reported through a standard form (Defect Report, Failure Report). Analysis (A). Perform analysis in order to identify the root cause of failure. Corrective Actions (CA).
The analysis is sometimes characterized as consisting of two sub-analyses, the first being the failure modes and effects analysis (FMEA), and the second, the criticality analysis (CA). [3] Successful development of an FMEA requires that the analyst include all significant failure modes for each contributing element or part in the system.
A design failure modes and effects analysis, DFMEA, is a structured qualitative analysis of a system, subsystem, device design to identify potential failure modes and their effects on correct operation. The concept and practice of performing a DFMEA, has been around in some form since the 1960s.
Failure Modes, effects, and Criticality Analysis is an excellent hazard analysis and risk assessment tool, but it suffers from other limitations. This alternative does not consider combined failures or typically include software and human interaction considerations. It also usually provides an optimistic estimate of reliability.
Failure analysis is the process of collecting and analyzing data to determine the cause of a failure, often with the goal of determining corrective actions or liability. According to Bloch and Geitner, ”machinery failures reveal a reaction chain of cause and effect… usually a deficiency commonly referred to as the symptom…”. [ 1 ]
Metallurgical failure analysis is the process to determine the mechanism that has caused a metal component to fail. It can identify the cause of failure, providing insight into the root cause and potential solutions to prevent similar failures in the future, as well as culpability, which is important in legal cases. [ 1 ]
Fractography is the study of the fracture surfaces of materials. Fractographic methods are routinely used to determine the cause of failure in engineering structures, especially in product failure and the practice of forensic engineering or failure analysis.
Carefully observing and describing failure conditions, identifying whether failures are reproducible or transient, and hypothesizing what combination of conditions and sequence of events led to failure is part of the process of fixing design flaws or improving future iterations. The term may be applied to mechanical systems failure.