Error Analysis Tests

Error Analysis Tests

Learning the cause of a product or device malfunctions is the basis for finding a solution to the problem. Error analysis helps an enterprise reach the source of product failure. More importantly, it provides the manufacturer with the necessary information to troubleshoot and fix the problem that caused the error.

Error Analysis Tests

Error analysis test it is usually a multidisciplinary process. Tools used by EUROLAB during an analysis include visual inspections, metallography, environmental, chemical analyzes and simulation tests.

The specific tests used depend on the product type and malfunction mode. Root cause failure examinations are designed to identify the cause of the error and the necessary corrective actions to prevent it. However, product failure can be a complicated process. In our experience, device failure is rarely caused by a single incident.

The most obvious signs of physical failure, such as a cracked metal component or a faulty electronic device, are the most obvious. However, these signs are usually slightly more than signs of failure. EUROLAB looks for the root cause of the error.

Possible causes of device failure include:

  • Product design
  • Production processes
  • Contamination of source materials
  • Product packaging
  • Product storage
  • Misuse

Identifying the root cause of an error is a three-part process.

Step 1: Data Collection

The first step of the error analysis test is data collection. During this step, information is collected about how the device failed and when it occurred. In addition, the manufacturer can work with the manufacturer to determine your goals for the failure analysis exam, determine how the part should work, and consult additional subject experts if necessary.

The type and width of the questions we asked during this step may be surprising for an organization that has not previously conducted failure analysis. Some of the important information that should be collected at this stage are:

  • What are the steps of the production process?
  • What is included in each process step?
  • What are all the components on the device?
  • What are the objectives of the particular component?
  • What are the ways each of these components fail?
  • How serious is the impact of these potential failures?
  • What kind of device errors actually occur?
  • At what point does a malfunction affect the function of the device?
  • What is the probability that device malfunctions are noticed before reaching the consumer?
  • What is the history of the defective unit?
  • What is the occurrence of faults?

At this stage, we do tests on the product analyzed. We test a representative example of faulty devices and proper workers. This can help determine which components have failed and when the error occurred.

Whenever possible, we prefer non-destructive testing in the failure analysis test. This helps provide the most accurate data and is more economical for the customer. Sometimes failure analysis requires sections of the material or perform a thermal test. In these cases, we perform these tests later in the data collection process.

Step 2: Analyze the Data Collected to Identify Root Cause Failure

The next step in the error analysis process is to identify the root cause of the error. Device failure is rarely the result of a single event. Our experience has shown that there are a lot of inputs, even in a "simple" error. This indicates that there are usually different ways to prevent failure in the future.

Take this example of electronic device failure. If an organization periodically receives customer complaints of a short-circuited device and applies for failure analysis, electronic failure analysis tests are performed. This test shows component short circuits because, depending on where the metal in the part is located, the metal used has the wrong hardness.

Step 3: Determining Corrective Actions

For most organizations, identifying corrective actions is the most important part of root cause failure analysis. When you work with EUROLAB for error analysis, you get a comprehensive report on both the causes and effects of device failure. EUROLAB can also make suggestions to fix problems.

Most suggestions to fix a problem are minor changes that can have a significant impact. Small changes in the testing, processing and storage of source materials and product components can significantly reduce device failure.

In other cases, we find that failure occurs when customers use a device for too long or under improper operating conditions. In these cases, our recommendations may include additional product training for marketing and sales staff. These employees can then provide this information to customers. This prevents device malfunctions from being protected from improper use or application.

We can also help you determine if corrective action is required. Some organizations may decide that there is no need for economic costs to fix rare product failures. If the device malfunction is rare and has minimal results, replacing the defective components may be more cost effective than changing the manufacturing process. The error analysis test can provide the information needed to make an informed decision.

Damage Analysis Tests

Error and failure analysis uses various tests to determine the true source of a product failure. These tests fall into two categories: non-destructive tests that keep the product intact; and destructive tests that require replacement of the product to study cross-sections or thermal behavior.

EUROLAB begins its analysis with non-destructive analysis (NDA) because these tests aim to prevent further damage to the product. Starting with NDA is usually more cost-effective. This is also the preferred method of maintaining evidence of the failure mode.

Sample Test Procedures Performed by EUROLAB Laboratories

Test Description Type (NDA / DPA)
Visual Inspection Destructive
Optical Microscopy Destructive
Scanning Acoustic Microscopy Destructive
2D / 3D X-Ray Radiography Destructive
X-Ray Fluorescence Spectroscopy Destructive
Curve Trace / Electrical Control Destructive
Contamination Analysis Destructive
Thermal Analysis destructive
Destructive Physical Analysis (DPA) destructive
Section Analysis destructive

EUROLAB laboratories are equipped for a wide range of testing capabilities and are used for both non-destructive testing methods such as X-rays and microscopy, and destructive testing such as contamination analysis and thermal analysis. International Accredited It was.

Printed Circuit Board Failure Analysis

Most of the electronics produced today are based on printed circuit boards (PCB). From children's toys to advanced computers, PCBs are critical for many electronics. However, many printed circuit boards fail during the manufacturing process.

PCB failure analysis can help an organization determine why circuit boards fail and how to fix the problem. Root cause error testing for circuit boards is a holistic process that can help you find more answers than a simple point check.

We work with different printed circuit boards. EUROLAB has conducted hundreds of times, single-sided, double-sided, multi-layer circuit boards, flexible and root cause failure examinations on high frequency / PTFE boards, with blind and hole structures.

Some of the tests we used during PCB failure inspection are:

  • Section analysis
  • Solderability test
  • PCB contamination test
  • X-ray Inspection

EUROLAB's error analysis goes beyond identifying the cause of the problem. We can help you find ways to improve the product and fix errors in the PCB manufacturing process.

Electronic Component Failure Analysis

Electronic components and hardware failure can occur at many stages of a product's life cycle. In addition to problems in product design and manufacturing, electronic components may fail due to:

  • Storage
  • Packaging
  • Setup
  • Operation
  • Maintenance

We use both non-destructive and non-destructive tests to determine the root cause of electronic component failures. Our electronic components technicians work with a wide variety of tools and software to select the right test techniques for your products.

Signal generators, sniffers and vector signal analyzers are often used for fault analysis of electronic components. We also use microscopy, x-ray and contamination analysis when necessary. EUROLAB testers can also test hardware failure during installation and operation using various languages ​​and operating platforms.

Electronic Device Failure Analysis

Identifying the root cause of electronic device failure is often more difficult for other objects than to determine the root cause error. It is important to find a skilled laboratory in electronic device failure analysis regarding interactions between software and hardware.

EUROLAB laboratories are equipped to diagnose software and hardware problems that occur during electronic device failure and we select the appropriate tools and tests to analyze your device.

Metal Damage Analysis

Metal failure can have a major impact on products in the supply chain. Metal failure can have huge consequences, from contamination and corrosion that cause medical equipment to fail, to stress failures that affect structural integrity. Metal corrosion alone is estimated to cause approximately $ 300 billion in economic damage each year on the global market.

EUROLAB's metal failure test can help your organization determine why metal components fail and how to fix the problem. We provide metal testing for customers in a wide range of industries, including:

  • Space
  • Defense
  • Telecommunication
  • Consumer products

Error analysis is a complex process based on various techniques. Our most advanced data collection tools help us quickly identify the cause of metal failure and identify solutions to solve the problem. We regularly conduct corrosion tests, impact tests and fatigue tests on metal components. EUROLAB can also create special test rooms and fixtures for failure testing of large metal components.

EUROLAB is experienced in developing custom test programs that comply with both national and international certification standards. EUROLAB laboratories are accredited by ISO-17025 for root cause failure test of metal products.

Plastic / Composite Damage analysis

Plastics can fail in many different ways. Plastic products can fail stress fractures, fatigue, material degradation and contamination. Plastic products can also fail in no less serious ways: discoloration and deterioration can affect the integrity of plastic products. Determining the exact cause of the plastic malfunction requires a series of tests and extensive polymer knowledge.

The root cause test for plastic failures follows a process similar to that used for metal failure analysis. Plastic error analysis can be more complex because plastics often contain additives such as plasticizers, colorants and reinforcing fillers. As a result, failure testing for plastic products often requires special testing of the molecular and chemical structures in plastics.

EUROLAB laboratories are equipped with state-of-the-art equipment for plastic failure analysis. We use non-destructive testing techniques such as microscopy and spectroscopic analysis wherever possible.

EUROLAB provides root cause failure analysis for industrial components for the aviation and defense industries as well as plastic consumer goods. We focus on quickly determining the cause of the failure, and developing a solution to prevent further product failure.

Pollution Analysis

If there are contaminants in the supply chain, it is important to check them quickly. However, identifying pollutants can be a time consuming process that requires large resources.

The contamination analysis and identification of the EUROLAB laboratory can help you find the contamination that caused the product malfunction. The process we use to identify pollutants depends on the product, the type of contamination and the customer's goals.

The types of contamination analysis that we typically perform include:

  • Identifying the type and source of foreign particles in a product
  • Determining the level of affecting a pollutant's product integrity
  • Monitoring the source of contamination and developing corrective plans

Since contamination is often a multifaceted problem, we use a multidisciplinary approach to our contamination analysis.

EUROLAB is an accredited error analysis specialist. Especially for root cause failure analysis ISO 17025 and A2LA accreditations We have. This means that our laboratories meet high standards for testing and calibration, and our tests are accepted by a wide range of suppliers and regulatory authorities.

You can contact us immediately for your failure analysis test needs.

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