What is Failure Analysis?
Failure analysis refers to root-cause identification of component failure using data-driven methods. The method delivers actionable quality data for product release, process optimisation and root-cause analysis.
Scientific background
Methodologically, the procedure relies on standardised workflows covering data acquisition, segmentation, feature extraction and evaluation. Core elements include the linkage between defect morphology, load path and process history. Meaningful results only emerge from traceable criteria and defined acceptance limits.
Relevant key metrics
- Detection limit and misclassification risk for the relevant failure modes.
- Repeatability of the evaluation for identical input data.
- Relationship between indicators and functional load zones / specifications.
Standards and thresholds
- Standards: IATF 16949:2016, ISO 9001:2015 (in particular the corrective-action logic) as well as VDA QMC 8D fault categories (01/2023).
- Typical thresholds (in practice): Effectiveness is considered proven once the identified failure mechanism is reproducibly documented and the recurrence rate during the observation period drops to the target level.
- Validity: Evaluation depth and acceptance criteria are defined per risk, usage profile and customer requirement.
Application in industrial practice
- Data-based release decisions during ramp-up and series production.
- Early detection of deviations with cause-oriented prioritisation.
- Improved customer and supplier communication through objective CT reports.
Sources and reference date
- IATF 16949:2016 and ISO 9001:2015.
- VDA QMC: 8D fault categories (01/2023).
- Reference date: February 2026.