Root Cause Failure Analysis and Corrective Action

Increased Yield = Increased Profits

Low Field Failure Rate = Contented Returning Customers – Positive Reviews

Failure analysis for Production, Design Problems or higher than expected customer returns.

production

Production Yield

Root Cause Failure Analysis And Corrective Action doesn’t just apply to field failures. Healthy production yield is critical to improved profit margins. We work with your engineering and  production teams to root cause problems. 

Customers and manufacturers become frustrated when products fail out of the box, manufacturers become even more frustrated when working on low margins wasting time fault finding new products.

By analysing the data we collect we separate manufacturing issues from design failures, we asses the products DFM credibility and provide you and your team with corrective actions to improve yield and make sure the defect rates are within calculated expectations.

It is important to make sure the correct processes are in place and being followed, giving the operators the tools they require to alert supervisory staff when a process is trending out of control

By improving yield peace is restored, happy customers, reliable manufacturers and not forgetting improved profit margins for the business.

rejected

Field Failures

Low field failures and high reliability are key factors to keeping your customers loyalty. Customer confidence wanes very quickly when products they buy fail prematurely and don’t provide the modern expectations of reliability.

It is important to quickly determine if field failures are caused by manufacturing defects or more worrying design problems.

Manufacturing defects, whilst they can be expensive don’t carry the same cost of having to redesign an element of a product to fix the defect ratios. Having said that, some manufacturing defects can only be solved reliably then coupled to a design change.

Our experience in this field is well noted amongst some of the larger blue chip companies. We are retained today by customers who use us as their insurance policy, keeping an eye on the product development, it’s manufacture and monitoring for signs of field problems.

One or two failures may be considered random failures, but when the same fault starts appearing regularly its time to jump in and look harder.

product recall

Get It Right First Time

Unfortunately, even with the best will in the world, products can create unforeseen problems. We can use the relatively recent failure mode of a mobile device as an excellent example of what happens when root cause and corrective action is proved inconclusive.

What started as a design flaw with serious consequences, the initial root cause assessment was inadequate. Replacement products were released into the market just to fail again later in exactly the same way.

Only a very large business has a chance of recovering from this type of event, the financial implications alone are massive. An every day business could never recover and would most likely never stage a come back.