Case Study · Case Study
Manufacturing Failure Analysis Case Study
An anonymized manufacturing FA walkthrough: problem → evidence → hypothesis → verification → root cause → corrective action → prevention.
Problem
A recurring electrical open on a PCBA family after assembly. Customer returns showed intermittent opens under thermal stress. Product names, customer names, and part numbers are withheld.
Approach
- 01Define the problem in measurable terms (failure mode, rate window, detection point).
- 02Collect physical and process evidence (microsection, AOI history, reflow profiles — anonymized).
- 03Generate competing hypotheses and design verification tests for each.
- 04Separate true root cause from contributing process factors.
- 05Deploy corrective action and recurrence prevention with process owners.
Outcomes
Verified root cause with evidence chain
Corrective action closed with process verification
Prevention controls added to process audit checklist
Reusable FA narrative template for international quality communication
Demo content. No real customer names, part numbers, or confidential parameters.