Subject to 2010 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

The Study of Komatsu Failure

Investigations

Module 1

Komatsu America Corp.

Cartersville Georgia USA
Copyright © 2010 All rights reserved.

Copyright © 2010 Training Presentation COT0057710E0-1R

 Subject to 2010 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Failure
Investigation

Organized Fact Gathering – Root Cause or Results

Think - Communicate

Komatsu America Corp.

Cartersville Georgia USA
Copyright © 2010 All rights reserved.

Copyright © 2010 Training Presentation COT0057710E0-1R

Introduction of Komatsu Study of Failure Investigation
Subject to 2010 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

2010 Terms of Use of Komatsu Training Materials

These training materials represent the confidential and proprietary information of

Komatsu America Corp. (Komatsu). These training materials have been issued to,
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Introduction of Komatsu Study of Failure Investigation
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Overview

Failure Investigation is Exciting and Enjoyable

When unexpected failures occur and corrective actions fix failure root
causes.

Failure Investigation can be exciting but not so enjoyable

When we fix symptoms or results of a failure and not the root cause and
face unhappy customers.

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Introduction of Komatsu Study of Failure Investigation
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Who should complete The Study of Failure Investigations

. Service Managers . Warranty Administrator

. Shop Foremen . Warranty Clerks
. Lead Technician . Service Department
. Field Service Technicians Clerks
. Technicians . Training Instructors
. Field Service Dispatchers . Technical Communicators
. Customer Support . Parts and Service Sales
Manager Representatives

Note: Anyone involved in machine failures,

machine maintenance and repairs

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Introduction of Komatsu Study of Failure Investigation
Subject to 2010 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Course Overview

Failure Investigation course modules

• Introduction
• Failure Management
• Visual Examination
• Metallurgy
• Wear / Corrosion / Erosion
• Fractures
• Threaded Fasteners
• Lubrications

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Introduction of Komatsu Study of Failure Investigation
Subject to 2010 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Failure Investigation Course Objectives

Module 1 Introduction to Failure Investigation

Upon completion of this Module you will be able to:

. List the principal steps to follow in performing a failure investigation

. State the role of visual examination in the failure investigation
process
. Describe the Failure Investigation process
. Explain why great care must be taken not to alter the failure scene or
failed parts
. Name two failure mechanisms

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Introduction of Komatsu Study of Failure Investigation
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Failure Investigation Course Objectives

Module 2 Managing Failure Investigation

Upon completion of this Module you will be able to:

. Explain five of the eight steps discussed in Managing Failure

Investigation
. Define the main purpose of a failure investigation
. Outline steps used when developing a failure investigation
team
. Summarize the team members job responsibilities
. Recognize two areas in quality fact gathering
. Define the term Whole Brain Thinking

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Introduction of Komatsu Study of Failure Investigation
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Failure Investigation Course Objectives

Module 3 Principles of Visual Examination

Upon completion of this Module you will be able to:

. Explain how to obtain background facts

. Review why you obtain, identify and protect failure parts
. Demonstrate how to clean parts properly for visual examination
. Explain visual examination using good lighting
. State why you would use unaided eye first during a visual exam
. Explain why you look at all part surfaces
. Demonstrate the use of low magnification when examining failure
parts
. Review why and how you identify and record the failure facts
. List the proper procedure in protecting and storage of failure parts

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Introduction of Komatsu Study of Failure Investigation
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Failure Investigation Course Objectives

Module 4 Principle of Metallurgy

Upon completion of this Module you will be able to:

. Review the metal refining processes

. Explain two different metal forming methods
. Summarize the metal heat treatment process
. Name two metal processing flaws and how they relate to
metal failures
. List one metal non-destructive test methods

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Introduction of Komatsu Study of Failure Investigation
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Failure Investigation Course Objectives

Module 5 Principles of Wear

Upon completion of this Module you will be able to:

. Define wear
. List two major types of wear
. Recognize the role friction plays in wear phenomena
. Explain how parts hardness reduces wear
. State one type of laboratory wear test

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Introduction of Komatsu Study of Failure Investigation
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Failure Investigation Course Objectives

Module 6 Principles of Fractures

Upon completion of this Module you will be able to:

. Name two metal properties

. List two of the three different fracture types
. Explain how temperature affects metal strength
. Identify two fatigue fracture characteristics
. Describe metal strength as it relates to metal hardness
. Explain how material loading could causes fractures
. Review how material stress raiser effects material strength

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Introduction of Komatsu Study of Failure Investigation
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Failure Investigation Course Objectives

Module 7 Principles of Threaded Fasteners

Upon completion of this Module you will be able to:

. Define the function of threaded fasteners

. Explain the structure of threaded fasteners
. Describe the threaded fastener manufacturing processes
. List proper procedure of fastener installation
. Recognize fastener problems and how to correct them
. Describe an actual fastener failure

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Introduction of Komatsu Study of Failure Investigation
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Failure Investigation Course Objectives

Module 8 Principles of Lubrications

Upon completion of this Module you will be able to:

. Define two main purposes of lubrication

. List three different lubricant types
. List two functions of liquid lubricants
. List three liquid lubrication additives
. Review lubrication failure modes

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Introduction of Komatsu Study of Failure Investigation
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Komatsu – Eight Steps of Failure Investigation

Eight Steps of Failure Investigation

1. State problem clearly & concisely
2. Organize fact gathering
3. Observe and record facts
4. Think clearly and logically with all facts
5. Identify most probable root cause
6. Communicate with responsible party
7. Make repairs as directed
8. Follow-up with customer

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Introduction of Komatsu Study of Failure Investigation
Subject to 2010 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Before Starting a Failure Investigation

We must Think Orderly

In order
“To Work Orderly”

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Introduction of Komatsu Study of Failure Investigation
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During the Failure Investigation

We must Work Orderly

“To Think Orderly”

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Introduction of Komatsu Study of Failure Investigation
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Beware of Preconceived Ideas

Beware of
Preconceived Ideas
Think Clearly with All Failure Facts

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Introduction of Komatsu Study of Failure Investigation
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Failure Investigation Course

. This course concentrates on basic ideas and procedures.

 Ideas regarding people and parts
 Procedures covering visual examination, failure management, wear
types, metallurgy and lubrication
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Introduction of Komatsu Study of Failure Investigation
Subject to 2010 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Module 1 Objectives

Upon completion of this Module you will be able to:

. List the eight principal steps to follow in performing a

failure investigation
. State the role of visual examination in failure investigation
process
. Describe the failure Investigation process
. Explain why great care must be taken not to alter the
failure scene or failed parts
. Name two failure mechanisms

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Introduction of Komatsu Study of Failure Investigation
Subject to 2010 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

14 General Stages of a Failure Investigation

Although the sequence is subject to variation depending

upon the nature of the failure, the principal stages that
comprise the total investigation are typically as follows:

.Collection of background data and selection of samples

.Preliminary examination of the failed part (visual examination and
record keeping)
.Nondestructive testing
.Mechanical testing, including hardness and toughness testing
.Selection, identification, preservation and/or cleaning of all specimens
.Macroscopic examination and investigation (fracture surfaces,
secondary cracks and other surface phenomena)

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Introduction of Komatsu Study of Failure Investigation
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14 General Stages of a Failure Investigation

. Continued
. Microscopic examination and analyze of wear surfaces
. Selection, preparation, examination, and analyze
. Determination of failure mode
. Chemical investigation
. Consideration of fracture and or wear mechanisms
. Testing under simulated service conditions
. Investigation of all the evidence
. Follow-up recommendations

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Introduction of Komatsu Study of Failure Investigation
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Failure Investigation Principles

Failure Investigation Principles

. Visual Examination
. Wear / Corrosion / Erosion
. Fractures
. Metallurgy

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Introduction of Komatsu Study of Failure Investigation
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Visual Examination

Visual Examination

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Visual Examination

Visual Examination

. Obtain background facts

. Obtain, identify, protect parts
. Clean parts properly
. Use good lighting
. Use unaided eye
. Look at all surfaces
. Use magnification
. Identify & record facts
. Protect parts for storage

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Introduction of Komatsu Study of Failure Investigation
Subject to 2010 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Wear Types

Seven Common
Wear Types
• Abrasive wear
• Adhesive wear
• Corrosive wear
• Erosive wear
• Cavitation erosion
• Contact stress fatigue
• Fretting corrosion

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Introduction of Komatsu Study of Failure Investigation
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Fracture Types

. Ductile
. Brittle
. Fatigue

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Introduction of Komatsu Study of Failure Investigation
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Indicators

. Just as we have physical indicators

when we have heath problems,
machinery and equipment also have
indicators

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Introduction of Komatsu Study of Failure Investigation
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Indicators

Our equipment also has indicators

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Indicators

. Unusual sounds . Hard starting

. KOWA results . High or low exhaust temp
. Exhaust smoke . High or low coolant temp
. Vibration . Oil leaks / blow by
. Oil consumption . Short component life
. Low power . Fuel consumption

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Indicators

. Just as we expect our doctor to identify our problems

by measuring and observing indicators
. Our customers expect us to read indicators and identify
the failure root cause

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Introduction of Komatsu Study of Failure Investigation
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Interview

. We appreciate a quality
interview with the doctor after
his inspection and tests

. Our customers appreciate a

quality interview with us to
discuss the results of our
inspection and tests

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Facts and Indicators

. Type of wear or fracture

. Crack initiation sites
. Stress raisers
. Temperatures
. Loading
. Abuse

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Background Facts

Sources Important Areas

.Operators .System conditions
.Servicemen .Lubrication quality and
.History files quantity
.Oil sample reports .Recent problems
.Tips/TSI/PSN, TSR .Repair history
and field campaigns .Parts installation

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Failure Investigation Fact Sources

1. Job Site

2. Failed Parts

3. Metallurgy Lab

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Introduction of Komatsu Study of Failure Investigation
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Failure Investigation Definition

A thoughtful review of failure facts collected

regarding people, parts, product and environment
leading to the identification of the most probable
failure root cause.

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Introduction of Komatsu Study of Failure Investigation
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The Failure Investigation Challenge

. What caused the problem

. Best corrective action

. Identify the root cause, making sure the

problem does not happen again

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Komatsu Failure Investigation 8 Step Review

Eight Steps of Failure Investigation

1. State problem clearly and concisely

2. Organize fact gathering
3. Observe and record facts
4. Think clearly and logically with all facts
5. Identify most probable root cause
6. Communicate with responsible party
7. Make repairs as directed
8. Follow-up with customer

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End of Introduction to the

Study of Failure
Investigation
Module 1

Komatsu America Corp.

Cartersville Georgia USA
Copyright © 2010 All rights reserved.

Copyright © 2010 Training Presentation COT0057710E0-1R