FAILURE ANALYSIS
Failure Analysis Engineering is an engineering discipline that partners across a company to solve problems. Failure Analysis Engineers leverage complementary analytical techniques to determine the physics-based root cause of issues. At the core of most hardware-based failures is Materials Engineering and Physics. A durable Failure Analysis function is one that contains large depths of knowledge for the specializations related to the predominant issues a company faces. These specializations can include metallurgy, fractography, analytical chemistry, polymer science, radiography, spectroscopy, and fault isolation; to name a few. As each company will have a different need for internal capabilities, a durable Failure Analysis organization will always need to supplement internal resources with external experts and resources. Finding the right expert is a combination of available financing, required turnaround time, and technical expertise. This can be difficult to navigate for new companies as Failure Analysis is similar to a non deterministic function. This means a single failure mode may have multiple failure mechanisms and analytical due diligence needs to be performed to confirm or deny hypotheses. An execution-based lab may not be well equipped to solve intricate problems and the Failure Analysis function needs to be able to navigate these intricacies.
Multiple processes can be leveraged to help navigate complex root cause analysis including 8D, 5 Whys, and fishbone diagrams. These industry processes need to be paired with intentional sequencing of analytical techniques. For example, non-destructive (e.g. Fault Isolation, XRAY, CT Scan) techniques should always be leveraged prior to destructive techniques (e.g. Cross-Section, FIB, SEM).
Failure Analysis functions are best empowered to be part of the solution as opposed to just a service center. Once root-cause is known, Failure Analysis Engineers have fundamental knowledge on the physics behind an issue. This physics-of-failure knowledge can, and should, be leveraged in identifying the right mitigation.
From an organizational perspective, Failure Analysis is a group of various Subject Matter Experts (SMEs) that partner with cross-functional experts. For this function to have maximized impact, psychological safety has to be established early. Failure Analysis is an exchange of ideas, where debate and discussion need to be leveraged as tools to converge on the correct root cause. In the absence of strong cross-functional psychological safety, Failure Analysis functions will either be operated as a service-center or the function will not be leveraged for fear of debate. Both of these outcomes will adversely affect impact and deliverables.
How have you seen Failure Analysis be successful? How about falling short?
