This document defines failure and outlines a failure analysis process. It defines failure as the inability of a system or component to perform its required functions under stated conditions for a specified period of time. It then lists potential causes of failure such as production issues, out of specification operating environments, component flaws, design flaws, wear out, software issues, and mechanical issues. Finally, it outlines a failure analysis process that involves receiving components from the production line, performing visual inspections, analyzing date codes, mapping component locations, and investigating various potential root causes through testing, data analysis, and component inspections.

1. Joel Mandel
Nov,2012

2. The inability of a system or component to perform its required functions
under stated conditions for a specified period of time(IEEE)
Failure
Definition

3. Failure routes
 A system card component fails for the following
reasons:
a. Production/assembly soldering process , etc.
b. Out of Spec Operation environment(Env. load,etc )
c. Component malfunction(Component
manufacturer flaw)
d. System Design flaw
e. Ware out
f. Software
g. Mechanical

4.  Is the system designed for the task it is performing ?
Do we have a problem ?

5. Receive from
Production
line
Components
Repair Pareto
Visit line Speak to Repair Technician
Save all components replaced
(Date Code Analysis)
Visual inspection of card
with proposed component failure
before repair has been done
Same
date
code
Group with
Components
Replaced
at same time
Define
Problematic
components
Many
compon
ents ?
Component Failure
analysis (send to
component
manufacturer) or
internal analysis joey
Yes
No
Map components
per location
Physical location
and electrical location
majority
Physical
location
majority
Electrical
location
majority
Random
Investigate
SMT
production
Investigate
external
phenomeno
n
Visual
signs
corrosion
Yes
Investigate
Customer
Operation
Cabinet
temp
control etc
Ware out
investigate
operational
environment
Failure Flow Analysis
Yes
No
Test
station
ok
Verify test
failure
criteria
Yes
Analyze Country
/City Location
dependence
Investigate
Out of Spec
Operation
lightning
No
Analyze
Production
Yield data
Correlati
on?
Analyze part
assembly X-ray
Cross-section Analyze Time dependence