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Failure Data retrieval through Failure Experience Matrix:

Under-utilization of information learned from failure experience is often induced by inadequate reporting, inappropriate organization, and non-accessibility of failure data. Only through increasing service experience will the gap between readily acceptable and rejectable defects be narrowed in practice. At the moment, detailed computer simulations of crack growth or instability conditions in complex structures are possible. However, uncertainties in design analysis, material properties, NDT techniques, and the service environment continue to make assessing structural reliability under actual service conditions difficult, and in the long run, only experience can provide the intuition required to define safety and reliability standards, as well as the means by which predictions can be made.

Because of the unorganized manner in which failure data was processed and the unavailability and inaccessibility of such data in the past, full use of previous failure experiences was not possible. Accuracy and pace are the most critical aspects of failure reporting. Any failure analysis report should adhere to the 5Cs: completeness, correctness, consciousness, transparency, and coherency. As a consequence, there is a need for failure data to be recorded and processed in a structured and generalized manner, with fast retrieval, so that it can be useful to the entire engineering industry. The failure experience matrix (FEM) is a tool for achieving this goal.

The FEM is a three-dimensional cell matrix generated by plotting elemental mechanical functions on the first axis, failure modes on the second, and corrective actions on the third. At the intersection of each failure mode, elemental mechanical feature, and corrective action, a spatial cell is formed. Information on the identification of the sections that failed due to that particular combination of the three matrix constituents, as well as the specifics of the corrective steps taken and their efficacy, is available within the cell.

The FEM has a wide range of applications in the fields of failure analysis, architecture, reliability, and product development. FEM can be used to quickly solve service failure issues. A field service engineer's sole responsibility is to determine the elemental mechanical role of the failed portion, enter the matrix and determine the various modes by which the component may have failed, identify the mode by which the component has failed, and then research the subsequent remedial action that is most likely to avoid future failures. Any reliability prediction is just as strong as the data fed into it, so FEM acts as a repository for failure data based on real-world experience. It gives the designer access to historical design flaws and the approaches that have been used to address them. R&D staff may use the FEM to define places where more knowledge is needed and where resources could be better spent.