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Root Cause Analysis: Five Whys and Fishbone Method
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Root Cause Analysis: Five Whys and Fishbone Method

The proximate cause of a failure is almost never the root cause. A bearing seizes because lubrication failed — but lubrication failed because a seal was worn — and the seal was worn because the maintenance interval was set for a different operating environment. Stopping at the bearing and replacing it solves nothing. Root cause analysis is the discipline of following the causal chain back far enough that the corrective action prevents recurrence, not just repairs the immediate damage.

#Root Cause Analysis#Five Whys+4
Design for Reliability: Building Robustness into Products
Failure Analysis
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Design for Reliability: Building Robustness into Products

A reliability problem discovered in the field costs ten to one hundred times more to fix than one addressed during design. Design for reliability is the practice of translating a reliability target — a quantified probability of survival over a specified service life — into specific design decisions about materials, geometry, operating stress, and manufacturing tolerances before the first prototype is built. The tools are stress-strength analysis, design margin allocation, accelerated life testing, and derating — applied systematically to the highest-risk failure modes.

#Design for Reliability#Stress-Strength Analysis+4