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Course Name: Root Cause Analysis of Component Failure: Understanding Human and Engineering Factors for Improved Product Performance Training
   
Deployment Options: Onsite - Instructor-Led Training
   
Course Duration: 3-4 days depending on audience background and options
   
Related Courses
 
 
Introduction:
 
If you are a design, quality, or manufacturing engineer or manager, this course will help you realize the benefits you can receive from well-executed fracture analysis. If you are a more experienced fracture analysis practitioner, it will help you improve your ability to interpret and communicate the data provided by the tests that are typically performed during failure analysis.

In this course, we will study concepts and techniques that are useful for a very broad range of materials used in machinery and structural components (not electronic assemblies) that are subject to deformation, fracture, corrosion and wear. Given the importance of human factors in failure analysis, we will also devote about 20% of the course time to the discussion of difficulties inherent in the failure analysis process, personality characteristics and people skills that are helpful in this field, and the common thinking errors. You will receive tips and perform practice exercises that will help you avoid the common pitfalls and think more clearly. The workshop version of this courses uses extended real-life case studies to help you further apply the techniques taught in your own job.
 
Audience:
 
Design, test, and maintenance engineers; failure analysts; technical purchasing agents and supplier quality engineers; and engineering managers looking to integrate the lessons of failure analysis into a more comprehensive design operation, and procurement process.
 
Prerequisites:
 
The standard presentation of this course assumes background in mechanical or materials (metallurgical) engineering. However, with some tailoring, the course can be understood by an audience with a bachelor’s in any engineering discipline.
 
Customize it:
 
This 3-4-day Root Cause Analysis of Component Failure: Understanding Human and Engineering Factors for Improved Product Performance Course will be customized to your needs and specifications. Eno.com will assist you in identifying those needs and specifications. A word to the wise, there are many vendors of telecommunication training. They will typically have a broad and general course, one size fits all, already developed and just put your organization?s name on the title slide. This minimizes their effort and time investment. At Eno.com, every course is made to your exact and exacting specifications. We help you ensure what you are getting is what you really eed even if at the beginning you weren't too sure of what that was. We fit the class to your needs. We never fit you into our standard, one size fits all, class. Please call or e-mail to schedule a no-obligation conference call to help us understand your audience background and training objectives.
 
Objectives:
 

On completing this course, you will be able to:

  • List levels of causes of failures
  • Approach and plan an investigation, write a fracture analysis protocol
  • Articulate and clarify objectives for a root cause failure analysis
  • Set up a failure investigation
  • Describe the key principles of materials science and engineering
  • Apply practical macro and micro fractography
  • Use optical metallography, NDT methods, composition analysis, mechanical tests, and FEA to analyze fractures.
  • Prevent failures
  • Gauge self-consistency in the conclusions of the various tests
  • Read and evaluate root cause failure analysis reports
  • Improve your ability to judge the quality of a failure investigation
  • Make use of failure analysis to improve durability and economy
 
Course Outline
 

Understanding Levels of Causes of Failures

  • Physical, mental, latent
  • Time of origin of causes: Design phase, manufacturing, maintenance, use, complex interactions

Getting Set up to Perform a Failure Investigation

  • Understanding human nature
  • Techniques to improve use of our knowledge
  • The failure analysis toolbox
  • Evidence preservation in the lab and in the field
  • Basic visual examination
  • Specimen selection
  • Use of "control" parts

Principles of Materials Science and Engineering: A Crash Course

  • Atoms, crystals, grains
  • Anisotropy
  • The process, structure, properties triangle

Practical Macro and Micro Fractography

  • Crack appearance in different loading geometries
  • --Axial
  • --Bending
  • --Torsion
  • --Direct shear
  • --Contact loading
  • Classical Microscale Features
  • --MVC (“ductile dimples”)
  • --Cleavage
  • --Intergranular
  • --Striations
  • --Dealing with the lack of published data on polymeric fractography

Fracture Analysis Techniques:

  • Optical metallography
  • NDT methods
  • Composition analysis
  • Mechanical tests
  • FEA in fracture analysis

Preventing Failures

  • Quantitative determination of an adequate hardening heat treating specification for steel components
  • How to specify steel for stampings
  • “Guess and Hope,” “Guess and Test,” and “Comprehensive Engineering” approaches to design

Putting It All Together

  • Evaluating self-consistency in the conclusions of the various tests
  • Putting together the component pieces of the analysis into a cohesive and incisive whole
  • How to read and evaluate root cause failure analysis reports
  • (Workshop only): Extended Case Studies
  • Wrap-up: Course recap, Q/A, and evaluations
 
Other Expertise:
 
 

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