Failure Analysis as a Customer Service Tool

Slide 1: 

Failure Analysis as a Customer Service Tool IPD, Torrance, CA (USA) • www.ipdparts.com • All rights reserved

Too often companies tend to ignore problems in hopes that they will go away. : 

Too often companies tend to ignore problems in hopes that they will go away.

Most common reasons for misdiagnosing an engine failure.: 

Most common reasons for misdiagnosing an engine failure . Not clearly understanding the complaint or problem Preconceived opinions Evidence being discarded or destroyed Not gathering and organizing the facts Not recording and observing the facts Not taking time to logically go through the evidence

Where to begin?: 

Where to begin? Start with engine’s history What’s happened prior to the failure? Have fluid levels changed? Any issues of over-heating? Was overloading involved? Recent service and maintenance records?

Let’s start with Valve Train.: 

Let’s start with Valve Train. High Stress areas Keeper (lock) Grooves Fillet Radius Areas to look for damage or wear Tip & Keeper Grooves Stem to Guide Face and Head

Misalignment and Adjustment: 

Misalignment and Adjustment CAN RESULT IN VALVE BREAKAGE Bending Fatigue Rotational Bending Fatigue

Valve Heat Transfer: 

Valve Heat Transfer Majority of the valve’s heat is transferred through to the seat Valves overheat due to: Sticking in Guides Ingested Debris Deposits Intake or Exhaust restrictions

End Result of Valve Overheating.: 

End Result of Valve Overheating . VALVE GUTTERING

Actual Valve Failure…Really?: 

Actual Valve Failure…Really? Nobody likes to see this in the back of a customers’ truck.

Actual Valve Failure…Really?: 

Actual Valve Failure…Really? Intake valve head is lodged in port Multiple impact impressions in the crown of the piston

Impact Impression in the Piston.: 

Impact Impression in the Piston.

Magnification of the Impressions.: 

Magnification of the Impressions. Root cause was NOT an intake valve failure. ..and NOT a valve failure

Moving to Engine Bearings: 

Moving to Engine Bearings Getting a box full of bearings like this doesn’t make it any easier

Why do Bearings Fail?: 

Why do Bearings Fail? MAJOR CAUSES OF PREMATURE BEARING FAILURE Dirt ......................................... 45.4 % Misassembly .......................... 12.8 % Misalignment ......................... 12.6 % Insufficient Lubrication .......... 11.4 % Overloading ............................ 8.1 % Corrosion ................................ 3.7 % Improper Journal Finish ........ 3.2 % Other ...................................... 2.8 % Or a combination of these causes

Examples of the 45.4% dirt and 11.4% insufficient lubrication: 

Examples of the 45.4% dirt and 11.4% insufficient lubrication MAJOR CAUSES OF PREMATURE BEARING FAILURE Dirt ......................................... 45.4 % Misassembly .......................... 12.8 % Misalignment ......................... 12.6 % Insufficient Lubrication .......... 11.4 % Overloading ........................... 8.1 % Corrosion ............................... 3.7 % Improper Journal Finish ........ 3.2 % Other ...................................... 2.8 % Or a combination of these causes

Examples of the 12.8% misassembly and 12.3% misalignment : 

Examples of the 12.8% misassembly and 12.3% misalignment MAJOR CAUSES OF PREMATURE BEARING FAILURE Dirt .......................................... 45.4 % Misassembly .......................... 12.8 % Misalignment ......................... 12.6 % Insufficient Lubrication .......... 11.4 % Overloading ............................ 8.1 % Corrosion ................................ 3.7 % Improper Journal Finish ........ 3.2 % Other ...................................... 2.8 % Or a combination of these causes

An example of the 2.8% “Other” Bearing Failures: 

An example of the 2.8% “Other” Bearing Failures Electric Discharge Pitting MAJOR CAUSES OF PREMATURE BEARING FAILURE Dirt ......................................... 45.4 % Misassembly .......................... 12.8 % Misalignment ......................... 12.6 % Insufficient Lubrication .......... 11.4 % Overloading ............................ 8.1 % Corrosion ................................ 3.7 % Improper Journal Finish ......... 3.2 % Other ....................................... 2.8 % Or a combination of these causes

Let’s look at Cylinder Components : 

Let’s look at Cylinder Components CROWN SCUFFING Over fueled Air restrictions Timing Lack of Crown cooling

Cylinder Components : 

Cylinder Components QUARTER POINT SCUFFING Coolant Temperature Lack of heat transfer Lack of crown cooling Etc…

Cylinder Components : 

Cylinder Components CENTER POINT SCUFFING High RPM High Load Cold Starts

Cylinder Components : 

Cylinder Components PISTON CROWN EROSION Improper Timing…Defective Nozzle

Cylinder Components : 

Cylinder Components PISTON OIL COOLING Good Cooling PISTON OIL COOLING High Crown Temperatures

So, What’s Next?: 

So, What’s Next? Time Line Theory Cause

Summary, Failure Analysis as Customer Service Tool.: 

Summary, Failure Analysis as Customer Service Tool. Present your finding. Your customer may not agree with your analysis, but if you don’t try he will definitely not agree with you.

Thank you.: 

Thank you.