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It is a common misbelief that the process of investigation of coating failures starts when the samples arrive in the laboratory. In fact, the process sequence starts earlier on the site of production. The whole process flow of failure analysis comprises:

 the investigation goal

 the design of experiment

 the sampling procedure

 the storage of samples

 the transport to the laboratory

 the first sample inspection

 sample preparation

 selection of the appropriate measurement technique

 sample measurement

 data evaluation

 data interpretation

 report

 perception of the results

Figure II.2: The risk to fail in the analytical process (arbitrary units)

Each step has its challenges and can ruin the whole outcome with respect to the final goal of removing the root cause of the fault. But what is the best path to a sustained solution of production failures? A close look at each step one realizes the obstacles that can appear. It will be demonstrated how internal production knowledge, low cost technical aids, laboratory analyses, expert knowledge and last but not least common sense generate a base on which a reliable solution can grow

Figure II.3: Coating failure analysis proceeding after sampling

Normally the trouble starts with suddenly and unexpectedly appearing failure parts. Of course, this requires immediate action in order to find the cause and define measures to eliminate the issue. But how?

Quite often the author has experienced a procedure like this when called to help with these issues:

 let us have a meeting

 let us look for someone guilty

 let us have a meeting again

 put pressure on the employees

 let us have a meeting again

 ask for different plans to solve the problem

 then panic

All these “actions” are driven by the understandable desire to get rid of the issue as soon as possible to make sure that the costumer can be served without any delay. The call for a systematic investigation of the root causes is often unheard facing pressure from costumers and financial accountants. Under the pressure of doing “something” plans and measures often suffer from a severe lack of reliable facts but are based on assumptions, rumours or feelings. Nevertheless, sometimes by chance the problems disappear, but nobody can say why. Moreover, nobody can guarantee that it will not pop up again and there is no solution for the future.

But what is the value of a removal of the issue instead of a solid solution? For sure, the systematic approach is slower and sometimes does not deliver “results” within a short period of time, but at the end it is more reliable and thus cheaper.

Of course, a good plan of what to do is a good start:

Figure II.3 shows the favourable path through the whole investigation process. The necessary tool are analytic methods to gather facts and place the latter in opposition to assumptions. But the analytical option is “only” delivering reliable data which are necessary to circle the source of the failure and the area of the production line, where it can be located. From that end to the real solution there is more to do.