Failure Diagnostics

Stages of Failure Diagnosticss

This is a more formal methodology that must be employed, and in situations where there is a dispute, or warranties at play, our apporach must show impartiality, maintain transparency, be objective and factual and be inclusive. The four main stages are:

1. Discovery
2. Analysis
3. Review
4. Remediation

These we discuss in turn below.

Discovery

When we conduct our discovery, using the problem statement, and scope definition as our guiding inputs, we go out and gather information. This involves us joining our customer´s plant managers and maintenance teams and dismantling machines in situ, (this can be a messy business!!)) and gathering all the inputs required to complete a thorough analysis. The "inventory" differ each time but can include any of the following:

1. quality management documentation
2. certs - mill, hardening, testing etc
3. design docs & calculations
4. engineering drawings
5. installation inspection and measurement taking
6. maintainance records
7. staff interviews
8. gathering of samples

This stage has a focus on gathering all the inputs (and versions sometimes) required to conduct an analysis on why a disc spring stack has failed (broken) or (not operated as required).

Analysis

After gathering all the artefacts and sources of information in the Discovery stage, we must use these to establish facts from which we can reach conclusions. The facts we need include:

1. an analysis of the disc springs themselves - material composition, hardness & hardening, contact flats, radii, dimensions etc
2. a verification of the engineering design - stresses, loads etc

These theoretical calculations and objective test results are then matched to the following:

• the manner of installation of the disc springs - clearances, alignment, lubrication etc
• the actual physical dynamics of the stack - pre-load and final design load and travel etc

So by end of this stage we can assess whether the design was "fit for purpose", whether the manufacture of the disc springs themselves was an issue, or whether the installation and the eco-system is the problem..

Review

This stage is our opportunity to reach consensus on process, make sure that every interested party has an opportunity to provide reasonable input, and remove every opportuity that could possibly arise for an objection to arise. The completeness of the exercise reaches consensus on:

1. validity of the inputs,
2. reliability of the facts,
3. accuracy of calculations,
4. consensus on the findings,

It is in these briefings and working sessions that the remediation options emerge. NOTE: In no way is this a legal assessment, we do not check contracts and the like. This is an engineering exercise.