Reliability Lab Testing, Consulting, Training.

Ops a la Carte

Call: (408) 654-0499, x204

Email: info@OPSaLaCarte.com

Engineering Success with Reliable Products.

Root Cause Analysis

Root Cause Analysis (RCA)

DEFINITION

RCA is a structured, team-based and streamlined approach for solving chronic failure problems in a process, product, or service. RCA applies practical, systematic methods for analyzing performance problems to uncover root causes. It prioritizes which problems should be analyzed first, and then explores effective ways of gathering data for root cause determination. Finally, RCA resolves to the primary root cause where the problem is found and fixed.

The Value of RCA:

  • Prioritizes which problems to tackle first utilizing the 80/20 concept
  • Facilitates a concise RCA agenda to effectively brainstorm potential causes
  • Drills down to the Root Cause by implementing the “5 Whys” technique
  • Implements an immediate short-term fix, and the long-term Corrective Action

OBJECTIVES

It is often a common practice that equipment and system failures are often investigated at a superficial level. As a result, maintainers and operators keep running unreliable equipment, causing repeated losses. Also, they become experts at fixing rather than preventing the problems. What is left is a very reactive method of fixing equipment rather than a pro-active method of solving problems. RCA is a structured, team based, analytical approach that when used correctly can alleviate chronic failure problems in a facility.

In this seminar, you will learn to apply several practical, systematic methods for analyzing performance problems to uncover root causes. Your understanding of these tools will be reinforced by worked examples. In addition, you will explore effective ways of gathering data for root cause analyses, how to determine which problems should be analyzed, and how to design, develop, and implement a root cause analysis program for your company. The effective use of RCA will improve the reliability of equipment and overall equipment availability and this seminar will show you exactly how.

Download brochure (pdf)

WHO SHOULD ATTEND

This course is intended for those involved in performing Root Cause Analysis on any type of issue – product or process – from engineering to operations, from finance to sales/marketing.

OUTLINE

Introduction and Objectives

  • Importance of Root Cause Analysis
  • Areas and uses for Root Cause Analysis
  • 7-Step Process

    1. Define the problem
    2. Gather data/evidence
    3. Ask why and identify the causal relationships associated with the defined problem
    4. Identify which causes if removed or changed will prevent recurrence
    5. Identify effective solutions that prevent recurrence, are within your control, meet your goals and objectives and do not cause other problems. The solution should not just address the problem at hand, but should assure that similar problems also do not occur
    6. Implement the recommendations
    7. Observe the recommended solutions to ensure effectiveness

Identifying/Defining Problems

  • Developing/Testing a Hypothesis
  • The need for data
  • Collecting data for problem solving

Analyzing Data for Root Cause

  • Identifying contributing events (brainstorming)
  • Event charting
  • Available tools
  • Fault Tree Analysis
  • Stress-Strength Analysis
  • Design of Experiments (DOE)
  • Material Analysis
  • Finite Element Analysis (FEA)
  • Dynamic Load Analysis
  • Thermal Analysis
  • Computational Fluid Dynamics (CFD)
  • Probabilistic Evaluations

Identifying Root Causes

  • Pareto Analysis and Ishikawa (fishbone) diagrams
  • Finite Element Analysis
  • The 5 Whys technique
  • Workshop – applying the 5 Whys technique

Environmental Considerations and Their Role in Accelerating Failures – a partial list

  • Temperature
  • Vibration
  • Humidity
  • Drop/Shock

RCA Across Different Disciplines

  • Electrical
  • Mechanical
  • Chemical
  • Materials
  • Optical
  • Software
  • Manufacturing

Introduce the concept of multidisciplinary solutions

Electrical RCA: Typical Failure Modes for Different Types of Components – a few examples

  • Printed Circuit Boards
  • Manufacturing Defects
  • Handling Issues
  • ESD Effects
  • Conductive Anodic Filaments
  • Plated through hole fatigue
  • Electrochemical migration

Interconnects

  • Solderability Issues
  • Overstress
  • Intermetallic Formation
  • Wearout (Thermal Cycling, Vibration)

Die-Level

  • Passivation Cracking
  • Die Cracking
  • ESD/EOS
  • Electromigration
  • Dielectric Breakdown
  • Hot Carrier Injection
  • MMIC and Hybrid Processes

Passive Parts

  • Resistors
  • Capacitors
  • Inductors
  • Attenuators
  • Crystals
  • Microwave Components

Mechanical RCA

  • Stress Analysis
  • Fatigue Analysis
  • Fracture Mechanics and Creep Degradation
  • Nonlinear Finite Element Analysis (FEA)
  • Computational Fluid Dynamics (CFD)
  • Probabilistic Evaluations

Electrical and Mechanical RCA Component Level Tools

  • Radiography
  • Cross-Sectioning
  • Decapsulation
  • Optical Microscopy • Electron Microscopy
  • Ion Chromatography
  • Surface Analysis Techniques (FTIR, EDS, XRF, etc.)
  • Material Analysis Techniques (DSC, TMA, TGA, etc.)
  • Mechanical Analysis Techniques (Microtester, Bend Testing, Pull Testing, etc.)
  • Chemical and Electrochemical Processes (Etching, Defect Enhancement, Liquid Crystal Techniques, etc.

Software RCA

  • Understanding similarities and differences between Software RCA and Hardware RCA
  • Tools employed for Software RCA
  • Software FMEA
  • Software FTA
  • Targeted Code Reviews
  • Implementation of Phase Containment metrics

Root Cause Analysis Programs

  • Guidelines on conducting individual analyses
  • Resolving recommendations
  • Trending analysis results (plotting a timeline)

Creating a Root Cause Analysis Program

  • Integrating root cause analysis with other programs
  • Different Software Packages available vs. developing a “home-grown” system
  • Workshop – Creating a root cause analysis program

Wrap-Up

  • Course Summary/Question and Answer Session

Call Us: (408) 654-0499, x204

Email Us: info@OPSaLaCarte.com

Address: 990 Richard Ave, Suite 101, Santa Clara, CA 95050

Contact Us

Empowering companies to create happy customers, with well-engineered products.

Script

OPS A La Carte, Engineering Success with Reliable Products. We are a leading reliability engineering consulting firm since 2001. We have helped many companies create robust products and elevate them to great success, even become the leader in their industry. We are known for providing the whole gamut of reliability lab testing, consulting, and training. With over 25 reliability engineer-experts around the world, with diverse backgrounds and experience, we serve both domestic and global businesses in all areas of reliability, in depth and width. Hi, my name is Jay Muns, owner and CEO. I have more than 30 years of experience in engineering and business operations.

OPS A La Carte have produced very high-quality results for us, with fast turnaround times. Their engineers are the best in their field, are a pleasure to work with, and their work is of the highest standards available. This has helped us obtain critical product approvals…” We help companies see from outside of their forest and understand what they didn’t know before. Companies come to us out of three scenarios: First, when their products fail. We help put out the fire by identifying problems and providing solutions. Second, after a product is designed, to check the box and move on with getting their product into the marketplace. The best is third: to get engaged early, by including reliability as a part of their initial product design goals. This will save time, money and energy. It is much better to have a worry-free product that addresses reliability issues upfront, than dealing with deficiencies after a product is developed, or worse, already manufactured and sold to the end users. Being proactive with reliability engineering will save a business tons of money and trouble. In all scenarios, you receive professional expertise with integrity and at a fair price. Many of our clients are repeat customers for years because of the value we consistently deliver.

Our ENGINEER-consultants each have over 20 years of experience and perform lab testing, consulting and training based on actual reliability science. They follow well established industry standards, such as “HALT” (highly accelerated life test,) and “HASS” (highly accelerated stress screen.) These engineers evaluate, make recommendations and validate results based on highly relevant lab data, co-relating to real world data. Whether your company has a reliability department or not, you can take advantage of our entire testing-consulting-training package, or any portion of it. We also offer Failure analysis and safety certification services such as UL, CE, and other environmental testing services, like solar, UV, SALT spray testing, ESD (electro-static discharge,) and EMC (electro-magnetic compatibility.)

“Ops A La Carte trained us to use HALT methodology as a proactive tool, to root out key failures in our early and advanced prototypes, and that made it possible for us to deliver dependability that our customers demand, in pilot and production units."“...OPS has played a key role in our evolution from a research company to a manufacturer of ‘mission-critical’ components.” A couple of companies describe our HALT/HASS training as “highly informative, engaging and exciting.” “The benefit far exceeds the price."

Our mission is to enable companies to create their happy customers, with a well-engineered product. By helping our clients understand the real problems and the real solutions, we help improve their careers and reputations. Achieving the win-win-win results for our clients and their customers is our ultimate satisfaction. We have a family-like company culture with positive energy and great teamwork. An improved and reliable product is our own small way to contribute to a better humanity and a slightly better world. Call us at (408) 654-0499, or email us at info@opsalacarte.com, or visit our website www.opsalacarte.com. Thank you!

A couple of our clients' testimonials:

"The expert team at OPS assisted us in evaluating the available reliability testing possibilities, and with their help, we crafted a customized test program precisely sized to meet the needs of our project. The resulting program proved to our team, our customers, and our regulatory auditors that our product was robust, met its reliability goals effectively, and satisfied all safety risk factors."

"...Ops A La Carte worked with us to develop a testing program based on HALT and HASS to effectively assess low-temperature operation capability and screen the boards for assembly and component defects. They then facilitated and supported the HALT and HASS testing effort. It was quicker and more efficient than we had expected. The boards for the first four strings have been delivered. We are looking forward to working with them through completion of the project."