Schlumberger Private 1 Nash Asrar, Nash Asrar, Nash Asrar, Nash Asrar, Ph.D Materials Support and Failure Analysis Group EMS Centers, Sugar Land, TX – 77478 SMTA Expo & Tech Forum, Stafford Center, Houston, March 6, 2014 FAILURE ANALYSIS FAILURE ANALYSIS FAILURE ANALYSIS FAILURE ANALYSIS – – – Cause Cause Cause Cause to Prevention to Prevention to Prevention to Prevention
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Nash Asrar,Nash Asrar,Nash Asrar,Nash Asrar, Ph.DMaterials Support and Failure Analysis Group
EMS Centers, Sugar Land, TX – 77478
SMTA Expo & Tech Forum, Stafford Center, Houston, March 6, 2014
FAILURE ANALYSIS FAILURE ANALYSIS FAILURE ANALYSIS FAILURE ANALYSIS –––– Cause Cause Cause Cause
to Preventionto Preventionto Preventionto Prevention
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� FAILURE AND FAILURE ANALYSIS
� CONDUCTING FAILURE ANALYSIS
� TOTAL FAILURE MANAGEMENT – A Failure Prevention Process
� FAILURE OF FAILURE ANALYSIS
� EFFECTIVNESS of FAILURE MANAGEMENT – Success Stories
� CONCLUDING REMARKS
TopicsTopicsTopicsTopics
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Why Do Failures Occur??Why Do Failures Occur??Why Do Failures Occur??Why Do Failures Occur??
� Aggressive operation conditions (use or misuse)
� Improper maintenance (intentional or unintentional)
� Improper testing or inspection
� Assembly errors
� Fabrication/manufacturing errors
� Design errors (stress, material selection, and
assumed material condition or properties)
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Failure: A part in service –
� has become completely inoperable , or
� is still operable but incapable of satisfactorily performing
its intended function, or
� has deteriorated seriously, to the point that it has
become unreliable or unsafe for continued use.
Failure Analysis:
Failure analysis is an engineering approach to determining how and
why (cause and root cause) an equipment or a component has failed.
Failure and Failure AnalysisFailure and Failure AnalysisFailure and Failure AnalysisFailure and Failure Analysis
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Failure analysis has four major objectives:
� Understanding that failure occurred
� Determine the symptoms or the apparent manner a component has
failed (the mode)
� Determine the mechanism, primary cause(s) and root cause of the
failure
� Recommend feasible corrective and preventive action(s)
…..Failure analysis is a journey, prevention is the goal….March 12, 2014 5
Aims and ObjectivesAims and ObjectivesAims and ObjectivesAims and Objectives
FailureFailureFailureFailure----Prevention ProcessPrevention ProcessPrevention ProcessPrevention Process
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Failure analysis is a journey, PREVENTION is the Failure analysis is a journey, PREVENTION is the Failure analysis is a journey, PREVENTION is the Failure analysis is a journey, PREVENTION is the goalgoalgoalgoal
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FailureFailureFailureFailure
Failure AnalysisFailure AnalysisFailure AnalysisFailure AnalysisIdentification of cause and root cause of the
failure
PreventionPreventionPreventionPreventionImplementation of findings/learning of failure
analysis
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Concepts Of Failure AnalysisConcepts Of Failure AnalysisConcepts Of Failure AnalysisConcepts Of Failure Analysis
� Mission - Find out how the
failure occurred
� Purpose - Determine the cause
of the failure
� Affiliation - Not regarded as an
integral part of the
product development
and manufacturing
process
- Prevention
- Determine the root cause of
the failure
- Regarded as an integral
part of the product
development and
manufacturing process
Traditional Modern
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Cause and EffectCause and EffectCause and EffectCause and Effect
Effect Cause
Injury Caused By Fall
Fall Caused By Slipped
Slipped Caused By Wet surface
Wet surface Caused By Leaky valve
Leaky valve Caused By Seal Failure
Seal Failure Caused By Not maintained
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The Elemental Causal SetThe Elemental Causal SetThe Elemental Causal SetThe Elemental Causal Set
EffectEffectEffectEffect
Open fire
ConditionConditionConditionCondition
Oxygen, etc.
ConditionConditionConditionCondition
Combustible
material
ConditionConditionConditionCondition
Match exists
ActionActionActionAction
Match strike
EffectEffectEffectEffect
ConditionConditionConditionCondition
ActionActionActionAction
Caused
ByCaused
By
Elemental Causal Set
Example:
Why open fire?
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� Elemental causal set is the fundamental causal element of all that
happens. It is made up of an “effect” and its immediate cause, which
consists of an action and one or more conditions.
� Actions are momentary cause that bring conditions together to
cause an effect – Most easily recognized.
� Conditions are causes that exist over time prior to the companion
action – often ignored.
� Effect can be prevented by eliminating either action or conditions or
preventing them from combining. Example - Application of coating (a
barrier layer) for corrosion control.
March 12, 2014 14
The Elemental Causal SetThe Elemental Causal SetThe Elemental Causal SetThe Elemental Causal Set
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Cause Cause Cause Cause vsvsvsvs Root CauseRoot CauseRoot CauseRoot Cause
Primary cause
� Set of conditions or
parameters from which the
failure began
� For short term solution
Root Cause
� A process or procedure which
went wrong
� For long term solution
Hidden root
cause(s)
Evident
cause(s)
Systems and
indicators
Key point is that this is not typically obvious and often has not
been considered ……and most often hidden from view
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Collapse of a Building
Primary cause – Use of poor
quality of cement
Root cause – Budget constraint
OR poor specs, bad supplier, bad management, poor QC…..
Cause Cause Cause Cause vsvsvsvs Root CauseRoot CauseRoot CauseRoot Cause
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Difference between Primary Cause and Root Cause
Primary Cause (set of
conditions or parameters)Root Cause (process or procedure)
The finish on a machine part
was not as specified
The failure to check the finish after parts are
machined
The incorrect heat treatment
was applied
The failure to ensure that the heat treatment
furnace had sufficient control of changes in
temperature to produce the desired
microstructure and mechanical properties in
the part/component.
Corrosion and cracking of
drilling tools due to corrosive
environment
Lack of implementation of guidelines to
control corrosivity of environment (drilling
fluids).
Manufacturing defect of
component X, Y, Z….
Lack of a procedure to ensure provision of
proper instruction/design to the manufacturer
and/or lack of procedure for QC (quality
check)
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� TFM is a process through which knowledge of failure
mechanisms can be applied and lessons learned can be
implemented to reduce or prevent failure.
� Components of TFM;
� Failure mechanism investigation
�Root cause analysis
� Implementation of the lessons learned March 12, 2014 18