An Analytical Survey of Root Cause Analysis Techniques for Mechanical Failures

Abstract

The failure of mechanical systems has a serious effect on safety reliability and continuity in the operations of important engineering systems such as energy, transportation, aerospace, and manufacturing. Complex interactions of material degradation, cyclic stresses, environmental exposures, design constraints, manufacturing variability, and operational practices contribute to these failures. Root Cause Analysis (RCA) has come out as a systematic and structured approach to the identification of the root technical, operational, and organizational causes of such failures. This paper survey of the RCA technique with mechanical failure investigation, in which the classification of failure mechanisms, hierarchical causation modeling, and systems engineering concepts are incorporated in the unified framework. The qualitative and quantitative instruments of analysis, such as Cause-Effect Diagram, Fault Tree Analysis (FTA), Failure Mode and Effects Analysis (FMEA), and reliability measures, such as MTBF, MTTR, failure rate, etc., are taken critically. Complex diagnostic methods, such as fractographic characterization, vibration signal processing, non-destructive testing (NDT), and finite element analysis (FEA), are integrated to promote evidence-based validation of failure mechanisms. The suggested analytical framework enhances methodological rigor, aids in the quantification of reliability, as well as allows proactive corrective actions in terms of sustainable mechanical systems functioning and reducing the risk.