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Karen Rayment, Case Forensics
1.
Anchorage Denver Honolulu Portland Salt Lake City San
Francisco Seattle Spokane www.case4n6.com info@case4n6.com assignment@case4n6.com 800.711.0704 SMALL UNMANNED SYSTEMS BUSINESS EXPOSITION 2015 Karen Rayment, MSEE, MBA, P.E., CFEI, PMP 510-775-3394 Mobile KRayment@CASEForensics.com 5 May 2015Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
2.
1. Definitions- Categorize
the Failure First, if Possible: Legal Framework 2. FA Tips and Techniques: Put up Walls! 3. Business Considerations a. Product Lifecycle to Help Clarify Remedies b. Artifacts of Catastrophic Failures- Business and Human Factors Losses 5 May 2015 2 Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
3.
1. Definitions- Categorize
the Failure First, if Possible: Legal Framework 2. FA Tips and Techniques: Put up Walls! 3. Business Considerations a. Product Lifecycle to Help Clarify Remedies b. Artifacts of Catastrophic Failures- Business and Human Factors Losses 5 May 2015 3 Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
4.
◊ “The biggest
problem in communication is the illusion that it has taken place.” - George Bernard Shaw 5 May 2015 4 Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
5.
5 May 2015Categorization
of Failures © Case Forensics 2014 – 2015, All Rights Reserved
6.
1. Design Defect:
Is a product inherently dangerous, due to the design specifications, for its intended purpose? 2. Manufacturing Defect: Were sub- standard materials or processes used in producing the unit in question, but design is according to specifications? 3. Foreseeable Product Abuse: What would a “reasonable person” do within the intended use environment? 5 May 2015 6 Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
7.
1. Definitions- Categorize
the Failure First, if Possible: Legal Framework 2. FA Tips and Techniques: Put up Walls! 3. Business Considerations a. Product Lifecycle to Help Clarify Remedies b. Artifacts of Catastrophic Failures- Business and Human Factors Losses 5 May 2015 7 Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
8.
5 May 2015Categorization
of Failures © Case Forensics 2014 – 2015, All Rights Reserved
9.
◊ Engineers MUST
set aside emotional language, such as customer reports ◊ Engineers MUST make a distinction between a failure and its effects ◊ Engineers should always follow the standard Scientific Method process flow NOTE: With a working hypothesis, additional questions will fall out- do one iteration of Scientific Method per question!!! 5 May 2015 9 Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
10.
5 May 2015
10 ◊ When products fail, people get panicky ◊ When people get panicky and don’t understand something, they tend to exaggerate the effects of failure ◊ CASE STUDY EXAMPLE 1 - Customer comment was, “You almost burned my house down, and my family almost died!” Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
11.
5 May 2015
11Consumer Product Field Failures © Case Forensics 2014 – All Rights Reserved ◊ The wall power supply had experienced overheating, and had a short between power and ground traces, which caused a SELF-EXTINGUISHING, SHORT DURATION, LOCALIZED FAULT ◊ NOT ENOUGH AVAILABLE ENERGY TO START A FIRE! ◊ Energy Considerations Include: Available Mechanical & Electrical Energy, and Time Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
12.
5 May 2015
12 ◊ CASE STUDY RESULTS: The wall power supply experienced a FAST, SELF- EXTINGUISHING, LOCALIZED FAILURE Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
13.
5 May 2015
13 ◊ We can’t both replicate root cause, and study field failure effects during the same iteration of an experiment – lose patterns ◊ It is much easier to form a hypothesis about root cause based upon observations of effects, and then replicate effects and backtrack to prove a hypothesis ◊ It is rare when a lab-created fault will EXACTLY replicate a field failure – don’t waste your time and effort Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
14.
5 May 2015
14 Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
15.
From Legal Definitions
- Categorize the Failure First, if Possible: Most Likely a Manufacturing Defect – Why? ◊ Product Lifecycle in the Market – Product has been in Field Use for 3.5 Years, and CPU Design is Older than the Product ◊ FA Tips and Techniques: Put up the Wall! Hypothesis: Intermittent Fault in CPU is Likely Due to Assembly Issue, not Bad CPU’s 5 May 2015 15 Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
16.
5 May 2015
16 Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
17.
May 5, 2015
17 ◊ Case Study Results: Glue on printed circuit board was contaminated by water Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
18.
May 5, 2015
18 Step 1: Photograph area of interest, where there is potential ionic contamination Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
19.
May 5, 2015
19 Step 2: Use a scanning electron microscope (SEM) to identify sample of interest Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
20.
May 5, 2015
20 Step 3: Use energy dispersive x-ray spectroscopy (EDS) to plot the elements Green arrows on the plot show the presence of salt - sodium chloride (NaCl) which indicates fresh water was present in or near the glue Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
21.
From Legal Definitions
- Categorized the Failure Legally: Most Likely a Manufacturing Defect – THIS WAS PROVEN ◊ Product Lifecycle in the Market – Product has been in Field Use for 3.5 Years, and CPU was Found to be Working Properly ◊ Outcome: Contaminated glue caused bridging between power and data lines - CPU was operating normally, but assembly defect caused intermittent data clocking errors 5 May 2015 21 Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
22.
1. Definitions- Categorize
the Failure First, if Possible: Legal Framework 2. FA Tips and Techniques: Put up Walls! 3. Business Considerations a. Product Lifecycle to Help Clarify Remedies b. Artifacts of Catastrophic Failures- Business and Human Factors Losses 5 May 2015 22 Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
23.
5 May 2015Categorization
of Failures © Case Forensics 2014 – 2015, All Rights Reserved
24.
245 May 2015 Categorization
of Failures © Case Forensics 2014 – 2015, All Rights Reserved
25.
1. Introduction: Not
well-known across a wide variety of field conditions 2. Growth: May have several revisions in the field, may have deviated from regulatory compliance bill of materials 3. Maturity: Most likely lifecycle stage for Manufacturing Defects 4. Decline: The least amount of Engineering is dedicated, but more component issues 5 May 2015 25 Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
26.
265 May 2015 ◊
Case Study: Test engineer for semiconductor company sent email to another engineer that was part of Discovery, “I don’t know why we bother to test and grade these processors- we know we are going to just sell them all anyway.” Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
27.
275 May 2015 ◊
Moral declined when the failures were mentioned by brand name in the news. ◊ Then the team became emotional - attention to detail declined, causing more sub-standard products to slip through the QA final checks, then more returns from customers. ◊ Downward spiral, company’s revenue plunged for 2 years due to one bad batch of approximately 50,000 units that were sold without internal communication that they may be sub-standard. People quit. Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
28.
285 May 2015 “The
San Jose, California - based company's fourth-quarter loss was $22.7 million, or $0.18 per share, compared to net profit of $27.2 million or $0.16 per share last year.” Categorization of Failures © Case Forensics 2014 – 2015, All Rights Reserved
29.
5 May 2015Categorization
of Failures © Case Forensics 2014 – 2015, All Rights Reserved
30.
The Small Unmanned Systems
Business Exposition 2015
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