Return Materials (RM) Analysis by André Vondran

Purpose
The primary purpose of this task is to reduce component or engine failures in the field. Of equal importance is the building of failure mode knowledge base. A failure mode database hastens Failure Analysis Corrective Action Reports (FACARs).

Requirements
Return Material Analysis is required for any DDC new product design, for major redesign of existing product, or for existing product applied to new application or environment.

Prerequisites
The key inputs for this task include:

i. Material: Customer-returned, field-failed materials or components  as well as associated hardware.

ii. Service Record: Each failed component should be accompanied with a service history. The service history should record number of hours in operation, operating environment and such other relevant information up to time of failure

iii. Tools: State-of-the-art tests and analysis equipment

iv. Personnel Training: Metallurgists. Personnel trained in the use of computerized equipment.

Organization
Responsibility
The owner of this task is the Return Materials Analysis Coordinator who is a member of several Cross-Functional Teams (CFT) for different product lines. The CFT is responsible for investigating and validating the cause(s) of identified field-failures.

Timing
Return Materials analysis should be performed for select returned field-failed component that are under warranty. RM analysis supports Warranty Data analysis and cost reduction. MSRP 2.0 calls for the introduction of Return Materials Analysis as early as at the Concept Approval Stage in order to identify customer concerns and prioritize appropriate resolutions. However, this activity may also be used as a tool in the Validation Stage and the Continuous Improvement Stage.

Procedure

1. Component recovery from DDC distributor system is covered in DDC Engineering Procedure #22

2. RM failure analysis is determined by good judgment of the Reliability or Engineering personnel initiating the action. Reliability investigators may be oriented toward a determination of the root cause(s) of failure. Engineering investigation may be oriented towards wear rates and evidence of product life limits. Options include direct inspection by DDC personnel and experts, supplier personnel or occasionally by DDC consultants. For components that are purchased as assemblies from suppliers, the failed or worn components may be turned over to the supplier for analysis and report.

3. Metallurgical analysis of return material is routinely performed by the DDC "Met Lab". In situations where the supplier has capability, the supplier may also perform metallurgical analysis.

Final Output
The output of this task is a completed Return Material Failure Analysis Report.

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Best Regards · Mit freundlichem Gruß · Cordialmente · 

André Vondran

Think Green! Please don’t print if it’s not necessary.

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Best Regards · Mit freundlichem Gruß · Cordialmente · 

André Vondran

Think Green! Please don’t print if it’s not necessary.

Follow Me on Instagram