Projects / Failure Analysis Project

The need

The client was interested in documenting production procedures and usage patterns of his products or of parts that are used in assembling his products for the purpose of:

A. Identifying defects in the production lines.

B. Identifying defects in product design.

C. Proactive identification of faults.

Business specification:

Significant parts group:

We identified the most significant parts group, which the focus needs to be on, by two criteria: Part cost and the implication of its failure to the machine productivity.

Data resources:

For every part and part, we identified its relevant data resources that included: manufacturing procedures, end of production quality checks, usage amounts, RMA procedures, and registration of failed product investigative procedures.

Report specification:

Reports required for daily routine activity and statistical reports.

A laboratory system:

Development of a registration and collection solution for tests executed at a laboratory that covered all inspection stations.

The solution:

Step 1

We developed a registration and management system for registration of inspection procedures in the laboratory.

Step 2

We developed a central data warehouse with data extraction processes from the data sources previously mentioned.

Step 3

We built a report system (Self Service BI), above the data warehouse, which allowed the client to investigate the data and prepare reports independently. The data warehouse enables utilization of a variety of tools for advance statistical analysis.


Business outcome for the company:

The solutions created for the company helped it to manufacture more durable products, thus reducing the failure rates for the machines in which they were installed.

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