Abstract
Pressure to Decrease Downtime and Increase Reliability in Industries a Major
Driver for Failure Analysis
Broadly classified into two categories -- predictive and post-mortem --
failure analysis is becoming more or less mandatory as industries attempt to
incorporate greater reliability in products as well as achieve the elusive
'zero downtime' in industrial processes. This is driving the development of
highly advanced techniques, since many industries are unable to reduce
downtime to desired levels using existing failure analysis devices. Upgrading
to predictive failure analysis and intelligent maintenance systems could,
therefore, help companies achieve their most critical aims: nil downtime,
reduced labor costs, and enhanced safety. Emerging software packages can
analyze raw sensor data and thereby, warn operators of imminent failures.
These advanced packages also integrate maintenance and asset management
systems with predictive failure analysis devices and are rapidly gaining
importance within industries.
The research service analyzes various technologies that form an integral part
of predictive and post-mortem failure analysis systems. It focuses on major
emerging failure analysis techniques as well as analytical techniques and
instrumentation.
Predictive Technologies Improve due to Progress in Information Technology
Capabilities
Predictive failure analysis technologies are becoming increasingly
sophisticated due to advancements in sensors, failure analysis software, and
enhanced control systems. Information technology has played a big part in
enabling condition monitoring systems to develop into predictive warning
systems with the advent of innovative software that helps in processing sensor
signals. "Software solutions are now available that use data from different
condition monitoring techniques such as vibration analysis and oil analysis to
predict asset health, schedule optimum maintenance work, and execute work
through existing computer maintenance management systems or enterprise asset
management systems," notes the analyst of this research service. "In addition,
finite element analysis and simulation software are used to perform virtual
failure analysis."
While oil analysis was earlier done by physically taking oil samples for
testing to the laboratory, present-day oil analysis technologies allow
real-time, continuous monitoring of oil to get a picture of machine health.
Currently, even computer hard disks have a self-diagnostic feature that alerts
the user about an expected breakdown, thereby preventing loss of valuable data
and resulting in significant cost savings.
Analytical Instruments Must Keep Pace with Miniaturization Trend
In tandem with improvements in failure analysis technologies, analytical
instruments are advancing due to the need for greater accuracy in various
applications. Combined with the use of innovative techniques such as computer
3D imaging techniques, these instrument-related advancements are leading to
new opportunities. Microscopy-based imaging techniques are the main analytical
instrument technologies. However, the magnification of microscopic analytical
instruments is also a key factor required for failure analysis. This becomes a
challenge given that there is a growing need for analytical instruments to be
more sensitive and accurate due to the decreasing size of semiconductors and
electronics.
"The greatest challenge for the development of failure analysis analytical
instruments lies in the area of testing microelectromechanical systems (MEMS),
microelectronics, and packages," says the analyst. "The miniaturization of
these devices is pushing developers to go for higher resolutions and greater
sensitivity in order to efficiently test them."
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