Reliability Services in the Prototype Phase
Closed-Loop Corrective Action Process (CLCA) Setup
This process has different names in different industries. Some call it a Corrective and Preventative Action (CAPA) System, some call it a Failure Reporting Analysis and Corrective Action System (FRACAS). But it is essentially the same process - to identify, analyze, and correct a problem with a product or process.
During all of the testing, a robust Closed-Loop Corrective Action (CLCA) Process must be utilized to capture, analyze, and, if necessary, correct all failures discovered.
The objective of a CLCA is to provide corrective action in a timely manner for any problem, and to have a means of verifying that the failure did indeed fix the problem.
VALUE TO YOUR ORGANIZATION
A good CLCA process is vital to an organization. It is the method by which problems get tracked and fixed in a methodical fashion.
An example of Reliability Integration during CLCA is as follows:
A CLCA can help classify failures as to their relevancy
During HALT, many failures are likely to be uncovered. However, not all failures will be relevant. The FMECA process will find many of these non-relevant failures, but for those that are first found in HALT, a CLCA will help make the determination of the relevancy by use of a variety of tools.
The steps of a Closed Loop Corrective Action Process are:
1) Plan/Outline of Process
We shall develop a plan that outlines a failure analysis process tailored to your company and situation. This plan will identify the flow of the process from each area in which a failure can occur, including HALT, DVT, HASS, Customer Site, and more. This plan will also identify all of the resources necessary to make the process successful on an on-going basis, including responsible parties for signing off.
2) Choice of Failure Analysis Software Tool
Once we have identified the process, it is time to choose a tool to use for the process. Anything from Excel to Oracle can be used. Special modules are also available from reliability software houses such as ReliaSoft and Relex. We will help choose the best tool for your particular application, or we can help develop one custom for you. This tool must link well with the Field Failure Tracking Tool.
3) Drive Implementation of Failure Analysis Software Tool
We will work with the software tool manufacturer to implement it within your organization and make sure the appropriate personnel are trained.
4) Education/Training of Failure Analysis Software Tool and Process
We shall educate key individuals on your staff on how to use the tool and how to effectively manage the process.
The following case studies and options provide example approaches. We shall tailor our approach to meet your specific situation.
1) Instituting a New Closed-Loop Corrective Action (CLCA) System
A small Networking company had a disjointed corrective action system and seemed to always be in the reactive mode. We helped develop a plan that outlined a failure analysis process fit for them, identifying each area in which a failure can occur as well as identifying all of the resources necessary to make the process successful on an on-going basis, including responsible parties for signing off. Then we helped them develop and implement a simple but customized failure analysis tool that tracked each failure through the entire process and also created a Field Failure Tracking Tool that linked to it. We then trained the appropriate personnel on how to use this new tool.
2) Upgrading an Outgrown Closed-Loop Corrective Action (CLCA) System
A medium size Computer manufacturer had an existing CLCA process, but it was apparent that they had outgrown the process and it was no longer effective. We came in and evaluated their current needs as well future needs based on current growth and recommended a CLCA package to migrate to. We then trained the appropriate personnel on how to use this new tool.