{"id":5233,"date":"2025-03-20T12:18:59","date_gmt":"2025-03-20T18:18:59","guid":{"rendered":"https:\/\/limblecmms.com\/?p=5233"},"modified":"2025-06-27T16:04:30","modified_gmt":"2025-06-27T22:04:30","slug":"failure-analysis","status":"publish","type":"post","link":"https:\/\/limblecmms.com\/blog\/failure-analysis\/","title":{"rendered":"6 Steps to Conduct Failure Analysis"},"content":{"rendered":"<div class=\"wpb-content-wrapper\"><p>[vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column][vc_column_text]<span style=\"font-weight: 400;\">Failure analysis techniques vary widely based on the specific use cases. That being said, steps for conducting failure analysis follow the same pattern.\u00a0<\/span><\/p>\n<h2><b>Step #1: Define the problem<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">A well-defined problem statement is essential for any deep analysis. Failure analysis requires the engineers to define the problem as clearly and concisely as possible. The problem statement should contain details about:\u00a0<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">The failure that occurred\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">The data that needs to be collected\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">The failure analysis technique to be used\u00a0<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">The expectations for the failure analysis (goals)<\/span><\/li>\n<\/ul>\n<h2><b>Step #2: Collect failure data<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">All relevant data has to be collected. This includes both quantitative data and qualitative data.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Quantitative data refers to the operations data, maintenance data, age of the machine, etc. It can be obtained:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">From maintenance records<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">From the <\/span><a href=\"https:\/\/limblecmms.com\/cmms\/cmms-software\/\"><span style=\"font-weight: 400;\">CMMS<\/span><\/a><span style=\"font-weight: 400;\"> database or any other tool used to monitor asset health and performance<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><a href=\"https:\/\/limblecmms.com\/blog\/what-is-troubleshooting\/\"><span style=\"font-weight: 400;\">Through troubleshooting<\/span><\/a><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">By <\/span><a href=\"https:\/\/limblecmms.com\/blog\/visual-inspection\/\"><span style=\"font-weight: 400;\">performing a visual inspection<\/span><\/a><span style=\"font-weight: 400;\"> (as a part of failure investigation)<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">Qualitative data cannot be easily quantified. Such data is obtained by interviewing machine operators, maintenance technicians, operations managers, etc. All relevant data concerning the failure should be collected.<\/span><\/p>\n<h2><b>Step #3: Create a failure timeline\u00a0<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">Root causes result in a chain reaction that forms the surface-level failures we observe. The collected failure data can shed light on the event sequences that happened. With enough information, the team performing the analysis can create a failure timeline. This serves as a visual and mental aid to the analysis process.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">Hopefully, the timeline will provide clarity into the cause-and-effect relationship between the events.\u00a0<\/span><\/p>\n<h2><b>Step #4: Select useful data and discard the rest<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">The timeline created in the previous step is also used to identify useful data. Quantitative and qualitative data collected in step #2 is mapped to the events in the timeline. The data that finds a place in the timeline is useful for the final analysis.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">The rest of the data can be discarded as it is not relevant to the events that caused the failure. This way, failure analysis teams won\u2019t waste time and effort analyzing irrelevant information.<\/span><\/p>\n<h2><b>Step #5: Administer the chosen failure analysis technique<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">The next step is to conduct the chosen failure analysis technique (we will discuss them in the next section). The method selected depends on the specific use case, industry, and the experience of failure analysis engineers conducting the analysis.<\/span><\/p>\n<h2><b>Step #6: Review results, test and apply a solution<\/b><\/h2>\n<p><span style=\"font-weight: 400;\">The result of failure analysis is studied in detail. In most instances, the purpose of failure analysis is to implement remedies that can prevent future failures. Different solutions proposed are tested and the best solution is used to improve the system\/machine.<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">How to write your failure analysis report<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">After you\u2019ve done the analysis, it is time to write the report. While administrative work is nobody\u2019s favorite job, documenting used procedures, tested solutions, and found conclusions can be extremely useful for future failure analysis.<\/span><\/p>\n<p><span style=\"font-weight: 400;\">How exhaustive your failure analysis report is going to be will depend on the type and scope of the analysis you are performing.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">For example, an in-depth <\/span><a href=\"https:\/\/limblecmms.com\/blog\/field-failure-analysis\/\"><span style=\"font-weight: 400;\">field failure analysis<\/span><\/a><span style=\"font-weight: 400;\"> performed after a product recall needs to have very detailed documentation. In this case, it is recommended to slowly gather documentation and records as you go through the process. Later on, you can ask all involved teams to send over what they have, merge it, and finalize your failure analysis document.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">In stark contrast, for a quick analysis performed to analyze the breakdown of conveyor belt #3, a single-page report might suffice.\u00a0\u00a0\u00a0<\/span><\/p>\n<h3><span style=\"font-weight: 400;\">What to include in the failure analysis report<\/span><\/h3>\n<p><span style=\"font-weight: 400;\">There is no universal report you can follow as every organization has its own procedures and goals.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">We recommend that you use good old common sense. When someone looks at the report 15 months later when troubleshooting a similar problem, which information will make their job safer\/faster\/easier? Of course, the purpose of the report and how \u201cofficial\u201d it needs to be will also have an impact on its structure and things that need to be included.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">In general, look to cover the following:<\/span><\/p>\n<ul>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Introduction<\/b><span style=\"font-weight: 400;\"> (why the analysis is performed, the scope of the analysis\u2026)<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Problem description <\/b><span style=\"font-weight: 400;\">(what happened, the chronology of events that created the issue\u2026)<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>General information <\/b><span style=\"font-weight: 400;\">(who performed the analysis, failure analysis techniques, and tests used to gather data and analyze the problem)<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Findings<\/b><span style=\"font-weight: 400;\"> (what was the root cause, as well as any other notable findings that might not necessarily be related to the initial purpose of this investigation)<\/span><\/li>\n<li style=\"font-weight: 400;\" aria-level=\"1\"><b>Recommendations for corrective actions<\/b><span style=\"font-weight: 400;\"> (a good report should focus on solutions and prevention more than assigning blame)<\/span><\/li>\n<\/ul>\n<p><span style=\"font-weight: 400;\">This might still sound rather abstract so let\u2019s look at some templates.<\/span>[\/vc_column_text][\/vc_column][\/vc_row][vc_row content_placement=&#8221;middle&#8221; kd_background_image_position=&#8221;vc_row-bg-position-bottom&#8221; kd_top_separator_style=&#8221;skew-left&#8221; kd_top_separator_height=&#8221;separator-height-small&#8221; kd_bottom_separator_style=&#8221;skew-left&#8221; kd_bottom_separator_height=&#8221;separator-height-small&#8221; kd_top_separator=&#8221;true&#8221; kd_bottom_separator=&#8221;true&#8221; css=&#8221;.vc_custom_1682969576554{margin-bottom: 40px !important;padding-top: 120px !important;padding-right: 40px !important;padding-bottom: 50px !important;padding-left: 40px !important;background: #dde4e8 url(https:\/\/limblecmms.com\/wp-content\/uploads\/cta-laired-hex-4.webp?id=9077) !important;background-position: center !important;background-repeat: no-repeat !important;background-size: cover !important;border-radius: 0px !important;}&#8221; css_tablet_landscape=&#8221;.vc_custom_1682969576554{padding-bottom: 80px !important;}&#8221; css_tablet_portrait=&#8221;.vc_custom_1682969576555{padding-bottom: 80px !important;}&#8221; css_mobile=&#8221;.vc_custom_1682969576555{padding-bottom: 80px !important;}&#8221;][vc_column][vc_row_inner kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column_inner]<header class=\"kd-section-title col-lg-12 text-center  subtitle-below-title kd-animated fadeIn   vc_custom_1682969598832\" data-animation-delay=200><h2 class=\"separator_off\" style=\"font-size: 42px;font-weight: 500;margin-bottom:30px;\">Checklist for Creating a Preventive Maintenance Plan<\/h2><h6 class=\"subtitle\" style=\"color: #152232;\">Following a consistent Preventive Maintenance Plan can make life easier. Use this checklist to create your own!<\/h6><\/header>[\/vc_column_inner][\/vc_row_inner][vc_row_inner content_placement=&#8221;top&#8221; kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column_inner width=&#8221;1\/2&#8243; css=&#8221;.vc_custom_1631866454223{padding-right: 50px !important;padding-left: 0px !important;}&#8221; offset=&#8221;vc_col-lg-6 vc_col-md-12 vc_col-xs-12&#8243; css_tablet_landscape=&#8221;.vc_custom_1631866454223{padding-right: 0px !important;}&#8221; css_tablet_portrait=&#8221;.vc_custom_1631866454223{padding-right: 0px !important;}&#8221; css_mobile=&#8221;.vc_custom_1631866454224{padding-right: 15px !important;}&#8221;][vc_raw_html]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[\/vc_raw_html][\/vc_column_inner][vc_column_inner width=&#8221;1\/2&#8243;][vc_single_image source=&#8221;external_link&#8221; alignment=&#8221;center&#8221; css_animation=&#8221;fadeIn&#8221; custom_src=&#8221;https:\/\/3975608.fs1.hubspotusercontent-na1.net\/hubfs\/3975608\/Content%20Downloads\/PM%20Checklist%20mockup.png&#8221;][\/vc_column_inner][\/vc_row_inner][\/vc_column][\/vc_row][vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column][vc_column_text]<\/p>\n<h3><span style=\"font-weight: 400;\">A few failure analysis report examples<\/span><\/h3>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-8567 aligncenter\" style=\"border: black; border-width: 2px; border-style: solid;\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/failure-analysis-report.png\" alt=\"failure analysis report template\" width=\"676\" height=\"814\" \/><\/p>\n<p style=\"text-align: center;\"><i><span style=\"font-weight: 400;\">A sample of a basic failure analysis report. Source: <a href=\"http:\/\/www.inpaspages.com\/failure-analysis-report\/\" target=\"_blank\" rel=\"noopener\">Inpaspages<\/a><\/span><\/i><\/p>\n<p style=\"text-align: center;\"><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-8568 aligncenter\" style=\"border: black; border-width: 2px; border-style: solid;\" src=\"https:\/\/limblecmms.com\/wp-content\/uploads\/failure-analysis-report-form.png\" alt=\"failure analysis report form\" width=\"636\" height=\"900\" \/><i><span style=\"font-weight: 400;\">More comprehensive failure analysis report form. Source: <\/span><\/i><a href=\"https:\/\/www.dexform.com\/download\/failure-report-form\" target=\"_blank\" rel=\"noopener\"><i><span style=\"font-weight: 400;\">Dexform<\/span><\/i><\/a><i><span style=\"font-weight: 400;\">\u00a0<\/span><\/i><\/p>\n<p><span id=\"key-takeaways\"><\/span><span style=\"font-weight: 400;\">You can find many other examples on the web by searching for \u201cfailure analysis report\u201d and taking a look at Google\u2019s \u201cImages\u201d section.<\/span><\/p>\n<h2><span style=\"font-weight: 400;\">Key takeaways<\/span><\/h2>\n<p><span style=\"font-weight: 400;\">Failure analysis is a versatile tool that has many purposes. It can be used to investigate past failures, understand failure mechanisms, and predict the modes of future failures.\u00a0<\/span><\/p>\n<p><span style=\"font-weight: 400;\">There is no &#8220;one size fits all&#8221; solution to conducting failure analysis. The technique selection will depend on the goal of the analysis, available resources, access to relevant data, and what the failure analysis team knows and prefers to use.<\/span>[\/vc_column_text][\/vc_column][\/vc_row]<\/p>\n<\/div>","protected":false},"excerpt":{"rendered":"<p>[vc_row kd_background_image_position=&#8221;vc_row-bg-position-top&#8221;][vc_column][vc_column_text]Failure analysis techniques vary widely based on the specific [&hellip;]<\/p>\n","protected":false},"author":24,"featured_media":28573,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[3],"tags":[],"class_list":["post-5233","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-maintenance"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v25.7.1 (Yoast SEO v25.7) - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>6 Steps to Conduct Failure Analysis | Limble CMMS<\/title>\n<meta name=\"description\" content=\"Everything you ever needed to know about conducting failure analysis and how to use it to help improve your maintenance operation today. Learn more.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/limblecmms.com\/blog\/failure-analysis\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"How to Choose The Right Technique For Failure Analysis\" \/>\n<meta property=\"og:description\" content=\"Learn what is failure analysis, how it is conducted, the right technique for your use case, and how to write a failure analysis report.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/limblecmms.com\/blog\/failure-analysis\/\" \/>\n<meta property=\"og:site_name\" content=\"Limble CMMS\" \/>\n<meta property=\"article:publisher\" content=\"https:\/\/www.facebook.com\/limblecmms\/\" \/>\n<meta property=\"article:published_time\" content=\"2025-03-20T18:18:59+00:00\" \/>\n<meta property=\"article:modified_time\" content=\"2025-06-27T22:04:30+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/limblecmms.com\/wp-content\/uploads\/blog_tile_6_steps_to_conduct_failure_analysis.webp\" \/>\n\t<meta property=\"og:image:width\" content=\"1200\" \/>\n\t<meta property=\"og:image:height\" content=\"751\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/webp\" \/>\n<meta name=\"author\" content=\"Bryan Christiansen\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:title\" content=\"How to Choose The Right Technique For Failure Analysis\" \/>\n<meta name=\"twitter:description\" content=\"Learn what is failure analysis, how it is conducted, the right technique for your use case, and how to write a failure analysis report.\" \/>\n<meta name=\"twitter:creator\" content=\"@LimbleCMMS\" \/>\n<meta name=\"twitter:site\" content=\"@LimbleCMMS\" \/>\n<meta name=\"twitter:label1\" content=\"Written by\" \/>\n\t<meta name=\"twitter:data1\" content=\"Bryan Christiansen\" \/>\n\t<meta name=\"twitter:label2\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data2\" content=\"5 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\/\/schema.org\",\"@graph\":[{\"@type\":\"WebPage\",\"@id\":\"https:\/\/limblecmms.com\/blog\/failure-analysis\/\",\"url\":\"https:\/\/limblecmms.com\/blog\/failure-analysis\/\",\"name\":\"6 Steps to Conduct Failure Analysis | Limble CMMS\",\"isPartOf\":{\"@id\":\"https:\/\/limblecmms.com\/#website\"},\"primaryImageOfPage\":{\"@id\":\"https:\/\/limblecmms.com\/blog\/failure-analysis\/#primaryimage\"},\"image\":{\"@id\":\"https:\/\/limblecmms.com\/blog\/failure-analysis\/#primaryimage\"},\"thumbnailUrl\":\"https:\/\/limblecmms.com\/wp-content\/uploads\/blog_tile_6_steps_to_conduct_failure_analysis.webp\",\"datePublished\":\"2025-03-20T18:18:59+00:00\",\"dateModified\":\"2025-06-27T22:04:30+00:00\",\"author\":{\"@id\":\"https:\/\/limblecmms.com\/#\/schema\/person\/a3ef98afa60af6b427b9f68b67eaadd5\"},\"description\":\"Everything you ever needed to know about conducting failure analysis and how to use it to help improve your maintenance operation today. 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