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Novel Product Test Helps Client Improve Product

Test results showing thermal imaging from failure analysis

“We needed to understand why parts were failing in service. Not only did ARTIS find the reason they found a work around to what would have been a very costly redesign of our manufacturing process. What’s more the test they devised could add to our manufacturing process to assess the correct tolerance of components prior to shipping.”

 Our client is involved in supplying critical safety products made of several components and rely on every part functioning fully to provide protection to the user. Industries include:

Personal Protective Equipment (face masks)

Automotive (brakes)

"We require testing that is able to discern between good and bad parts. This points us to the areas in our process that need our attention and better selection of materials. This reduces scrap, increases output and makes us more efficient, giving us scope to develop new and innovative products."

Executive Summary

Reason for product failures were determined and put in to practice within 6 months saving more than £1m in lost production.

Material was discounted as the source of failure.

Quick simple test method developed to validate new designs and test future components.

 

 

The Challenge

Product was failing in the field and production had to be stopped due to the safety-critical nature of the device.

Reason for failure was unknown and product had been in production for an extended period without showing signs of failure.

Speed to resolution was critical.

 

By developing an activation test that mimicked in-service conditions we were able to understand that there was a simple pass fail criteria. With the need to test multiple designs and multiple materials at accelerated conditions in order to predict time to failure for each design the test we designed enabled us to proceed with considerable speed in determining the cause of the failure.

The outcome of our investigations led us to identify that the failure point was material independent but design dependent.

Conclusion

Our test method allowed our client to quickly understand the root cause of the problem enabling validation of alternative solutions.

The failure mode was dependent on design geometry which was going to be very difficult to change as a result we developed a new material.

The new material resulted in improved performance and we were able to show that it met the expected performance lifetime.

The test we devised was capable of being included in the manufacturing process.

“We needed to understand why parts were failing in service. Not only did ARTIS find the reason they found a work around to what would have been a very costly redesign of our manufacturing process. What’s more the test they devised could add to our manufacturing process to assess the correct tolerance of components prior to shipping.”

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  • Summary:

    Reason for product failures in a critical safety device were determined and put in to practice within 6 months, saving more than £1m in lost production costs.

  • Category Tag:
    • Case Studies
    • Testing
    • Testimonials
    • Material Testing

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