MADE 3.9.1 User Manual > Modelling > Failure Diagram > Failure Concepts
Causes
| Category | Sub-Category | Name (Cause) | Synonyms | Description | Example | Type |
|---|---|---|---|---|---|---|
| Assembly & Reassembly | Contamination | Biological contaminant | - | A living organism that can degrade or consume a substance or component. | - | Mechanical, Electrical, Plastics |
| Assembly & Reassembly | Contamination | Chemically reactive contaminant | - | An impurity that triggers chemical change in a substance or component. | The residue of assembly adhesives. | Mechanical, Electrical |
| Assembly & Reassembly | Contamination | Corrosive contaminant | - | An impurity that can degrade or consume a substance or component. | - | Mechanical, Electrical |
| Assembly & Reassembly | Contamination | Exposure to acid | - | The introduction of an item to a substance or gas that can cause corrosion. | - | Mechanical, Electrical |
| Assembly & Reassembly | Contamination | Gaseous contaminant | - | A vapor impurity that causes a substance or component to alter. | - | Mechanical, Electrical |
| Assembly & Reassembly | Contamination | Ionic contaminant | - | A residue or harmful material that is left behind during a manufacturing process. | - | Electrical |
| Assembly & Reassembly | Contamination | Liquid contaminant | - | A liquid impurity that causes a substance or component to alter. | - | Mechanical, Electrical, Plastics |
| Assembly & Reassembly | Contamination | Saline contaminant | - | An impurity consisting of salt that causes a substance or component to alter. | - | Mechanical, Electrical |
| Assembly & Reassembly | Contamination | Solid particle contaminant | - | A solid portion of matter that causes a substance or component to alter. | - | Mechanical, Electrical |
| Assembly & Reassembly | Electrical property | Open circuit | - | A scenario in a circuit where the normal path of current has been disconnected or interrupted. | - | Electrical |
| Assembly & Reassembly | Electrical property | Short circuit | - | A scenario in a circuit where the current is allowed to flow along an unintended path or with very low impedance. | - | Electrical |
| Assembly & Reassembly | Environmental Protection | Damage surface protection | - | The outer preservation or layer of an item is compromised. | - | Electrical, Mechanical, Plastics |
| Assembly & Reassembly | Geometry | Blocked opening | - | A congested inlet caused by incorrect assembly. | - | Mechanical |
| Assembly & Reassembly | Geometry | Disconnected | - | A separation of the connection between two or more items. | - | Electrical, Mechanical, Plastics |
| Assembly & Reassembly | Geometry | Dynamic Imbalance | - | An imbalance caused by the center of mass being out of alignment with the center of rotation. | - | Mechanical |
| Assembly & Reassembly | Geometry | Excessive Clearances | - | A gap that allows relative movement and is larger than needed. | - | Mechanical, Plastics |
| Assembly & Reassembly | Geometry | Insufficient Clearances | - | A gap that allows relative movement is too small for intended purpose. | - | Mechanical, Plastics |
| Assembly & Reassembly | Geometry | Loose Fit | - | An item that is unsecured or can move about freely. | - | Mechanical, Plastics |
| Assembly & Reassembly | Geometry | Mechanical interference | - | A disruption occurring between the connection of two mating physical items. | - | Mechanical, Plastics |
| Assembly & Reassembly | Geometry | Misaligned | - | An item having an incorrect position or orientation in an assembly. | - | Electrical, Mechanical, Plastics |
| Assembly & Reassembly | Geometry | Tight fit | - | An item that is overly secure or restricted in movement. | - | Mechanical, Plastics |
| Assembly & Reassembly | Geometry | Wrong part orientation | - | A part has been placed into a item with incorrect alignment. | - | Electrical, Mechanical, Plastics |
| Assembly & Reassembly | Humidity | High humidity | - | An excessive amount of moisture. | - | Electrical, Mechanical |
| Assembly & Reassembly | Material quality | Surface damage | - | The exterior destruction of an item. | - | Electrical, Mechanical, Plastics |
| Assembly & Reassembly | Mechanical loading | High mechanical loads | - | A higher than expected mechanical force is exerted on an item. | - | Mechanical |
| Assembly & Reassembly | Mechanical loading | Impact loads | - | A force exerted on an item that is generated by a moving object. | - | Mechanical |
| Assembly & Reassembly | Mechanical property | Weak bond | - | The adhesive strength of a bond between items is lower than expected. | - | Electrical, Mechanical, Plastics |
| Design | Chemical property | Chemically reactive material | - | The tendency of a substance to undergo a chemical reaction. | Metals that are galvanically incompatible, or possess grain boundary defects making them reactive with the environment. | Electrical, Mechanical, Plastics |
| Design | Electrical property | Capacitance high | - | A higher than expected amount of electrical charge. | - | Electrical |
| Design | Electrical property | Capacitance low | - | A lower than expected amount of electrical charge. | - | Electrical |
| Design | Electrical property | Dielectric strength high | - | Able to transmit a large amount of electric force without conduction. | - | Electrical |
| Design | Electrical property | Dielectric strength low | - | Only able to transmit a small amount of electric force without conduction. | - | Electrical |
| Design | Electrical property | Electrical Potential High | - | A larger than expected amount of electric field potential. | - | Electrical |
| Design | Electrical property | Electrical Potential Low | - | A smaller than expected amount of electric field potential. | - | Electrical |
| Design | Electrical property | Electrical Resistance High | Electrical conductivity high | The measure of opposition to current is higher than expected. | - | Electrical |
| Design | Electrical property | Electrical Resistance Low | Electrical conductivity Low | The measure of opposition to current is lower than expected. | - | Electrical |
| Design | Electrical property | Impedance mismatch | - | The source impedance and load impedance are not at the required values for maximum power transfer. | - | Electrical, Software |
| Design | Electrical property | Junction Defects | - | There are flaws present between the connections of electrical parts. | Incorrect junction depth. | Electrical |
| Design | Electrical property | Line Defects | - | There are flaws present in the cables or lines of an item. | Incorrect line width. | Electrical |
| Design | Electrical property | Open circuit | - | A scenario in a circuit where the normal path of current has been disconnected or interrupted. | - | Electrical |
| Design | Electrical property | Parasitic capacitance | Stray capacitance | The presence of unavoidable and unwanted capacitance between two items due to proximity. | - | Electrical |
| Design | Electrical property | Short circuit | - | A scenario in a circuit where the current is allowed to flow along an unintended path or with very low impedance. | - | Electrical |
| Design | Electrical property | Insufficient environmental constraints | - | A lack of or inadequate sealing between internal environments. | - | Electrical, Mechanical |
| Design | Electrical property | Insufficient surface protection | Insufficient insulation | A lack of or inadequate exterior preservation for an item. | - | Electrical, Mechanical, Plastics |
| Design | Electrical property | Susceptible to electromagnetic interference | - | The item is sensitive to electromagnetic induction. | - | Electrical |
| Design | Geometry | Blocked Opening | - | A congested inlet caused by design errors. | - | Mechanical |
| Design | Geometry | Disconnected | - | A separation of the connection between two or more items. | - | Electrical, Mechanical, Plastics |
| Design | Geometry | Dynamic imbalance | - | An imbalance caused by the center of mass being out of alignment with the center of rotation. | - | Mechanical |
| Design | Geometry | Excessive Clearances | - | A gap that allows relative movement and is larger then needed. | - | Mechanical |
| Design | Geometry | Inappropriate flow geometry | - | The geometric design of the system does not allow the ideal flow. | Poor flow geometry can cause excessive turbulence. | Mechanical |
| Design | Geometry | Incorrect size | - | The item sizing is to large or to small for intended purpose. | Excessively long columns are prone to buckling or creep buckling. | Electrical, Mechanical, Plastics |
| Design | Geometry | Insufficient clearances | - | A gap that allows relative movement is to small for intended purpose. | Small clearances may trap solid debris or suspended particles in a fluid. | Mechanical, Plastics |
| Design | Geometry | Loose fit | - | An item that is unsecured or can move about freely. | - | Mechanical, Plastics |
| Design | Geometry | Misaligned | - | An item having an incorrect position or orientation in an assembly. | - | Electrical, Mechanical, Plastics |
| Design | Geometry | Posseses curvature | - | An item has been designed with more curvature than is necessary. | Curvature of load bearing members generates different loadings. | Mechanical |
| Design | Geometry | Stress concentrations | Geometric discontinuities, stress raisers. | A localization and amplification of stress at a particular point of an item. | - | Mechanical |
| Design | Geometry | Tight fit | - | An item that is overly secure or restricted in movement. | - | Mechanical, Plastics |
| Design | Geometry | Wrong part orientation | - | A part has been placed into a item with incorrect alignment. | - | Electrical, Mechanical, Plastics |
| Design | Material quality | Incorrect material composition | - | The materials selected have an inaccurate formation for intended purpose. | - | Electrical, Mechanical, Plastics |
| Design | Mechanical loading | Residual stresses | - | A stress present in an object that was caused by a previous loading or process. | Residual stresses render an item vulnerable to overstress under normal applied loading conditions. | Electrical, Mechanical, Plastics |
| Design | Mechanical property | Brittle Material | - | The tendency to break without significant deformation. | Brittle surface materials vulnerable to cracking, fatigue or impact damage. | Mechanical, Plastics |
| Design | Mechanical property | Hardness mismatch | - | The ability to resist plastic deformation substantially differs between two connected items. | A hardness mismatch of mating surfaces causes yielding of the softer surface. | Mechanical, Plastics |
| Design | Mechanical property | Insufficient stiffness | - | An item has inadequate or poor rigidity. | Items with insufficient stiffness can undergo torsion. | Mechanical, Plastics |
| Design | Mechanical property | Soft material | - | An item is susceptible to being deformed by external loads. | - | Mechanical, Plastics |
| Design | Mechanical property | Stiffness mismatch | - | The rigidity substantially differs between two connected items. | - | Mechanical, Plastics |
| Design | Mechanical property | Thermal coefficient mismatch | - | The thermal resistance substantially differs between two connected items. | A thermal coefficient mismatch can cause high thermal stresses between the surfaces. | Electrical, Mechanical |
| Design | Mechanical property | Weak material | - | The material has a lower yield strength than its operating load. | - | Mechanical, Plastics |
| Design | Mechanical property | Wrong coefficient of thermal expansion | - | The incorrect correlation between geometry and thermal temperature of an item. | - | Electrical, Mechanical |
| Design | Operational capacity | Cannot withstand operational loads | - | The maximum load or force the item can endure is inadequate for usage. | - | Electrical, Mechanical, Platics |
| Design | Operational capacity | Insufficient capacity | - | The maximum volume or weight the item can store is inadequate for usage. | - | Electrical, Mechanical |
| Design | Software property | Arithmetic overflow | Wraparound, Integer overflow. | A variable has a value incremented larger than its type can store. | - | Software |
| Design | Software property | Dead code | Oxbow code | The developer has written a block of code that can never be executed. | - | Software |
| Design | Software property | Inaccurate iterative loop | Off by one, OBOE. | A loop has began one cycle too early or ended one cycle too late. | - | Software |
| Design | Software property | Inconsistent synchronisation | - | The class of an input domain contains both locked and unlocked access. | - | Software |
| Design | Software property | Incorrect assigned boundaries | - | The expression indicating the end points of the domain are incorrectly assigned. | - | Software |
| Design | Software property | Incorrect domain | - | The size of a input domain is insufficient or incompatible with the feature it is being used in. | - | Software |
| Design | Software property | Incorrect increment value | - | An expression used to increment a value is incorrect. | - | Software |
| Design | Software property | Incorrect operator | - | An imprecise operator is used for a function. | - | Software |
| Design | Software property | Incorrect string manipulation | - | The beginning or end of a string has been cut off incorrectly. | - | Software |
| Design | Software property | Incorrect invoked function | - | The program initiates a function in an incorrect manner. | - | Software |
| Design | Software property | Order violation | - | The developer has failed to identify every sequence in the way two threads are executed. | - | Software |
| Design | Software property | Unachievable path | - | The developer has created a path that is not executable. | - | Software |
| Design | Software property | Unexitable code | - | The developer has written a portion of code that has been entered with no possible exit path. | - | Software |
| Design | Software resource | Heap fragmentation | - | The memory request is less than any single block of memory. | - | Software |
| Design | Software resource | Imprecise type conversion | - | A conversion from a large type to a small type causing a loss of bits. | - | Software |
| Design | Software resource | Inadequate bandwidth | - | The rate at which data is transferred is insufficient. | - | Software |
| Design | Software resource | Inadequate memory | - | The allocated memory for a process or task is insufficient. | - | Software |
| Design | Software resource | Incorrect initial value | - | The initialized value of a variable was incorrect. | - | Software |
| Design | Software resource | Incorrect object nature | - | The object is incorrectly defined in the wrong nature as either a dynamic or static object. | - | Software |
| Design | Software resource | Incorrect object type | - | The object has been initialized as a type that does not cover the objects range. | - | Software |
| Design | Software resource | Incorrect priority assignment | - | A high priority task has impeded other tasks from running by taking up a large majority of the CPU bandwidth. | - | Software |
| Design | Software resource | Memory leak | - | A failure to clear unwanted memory. | - | Software |
| Design | Software resource | Missing volatile keyword | - | A variable has a volatile nature but has not been defined as such. | - | Software |
| Design | Software resource | Mutual exclusion | - | The developer has created a resource that can not be shared. | - | Software |
| Design | Software resource | No pre-emption | - | The developer has created a resource that can only be released voluntarily by the process holding it. | - | Software |
| Design | Software resource | Null deferencing | - | An object has not been initialized in every possible path. | - | Software |
| Design | Software resource | Pin driven incorrectly | - | An active high component driven as an active low or vice versa. | - | Software |
| Design | Software resource | Priority inversion | - | A high priority task is impeded from performing until a lower priority task is finished. | - | Software |
| Design | Software resource | Resource holding | Hold and wait | The developer created a path that requires a process to wait for a resource while holding a different resource. | - | Software |
| Design | Software resource | Stack overflow | - | The request stack has less memory available than the system attempts to use. | - | Software |
| Design | Software resource | Uninitialised memory | - | An object has not been initialized for its full range of values. | - | Software |
| Design | Software security | Broken authentication | CAPTCHA | The software contains little or no authentication security from bots or unauthorized personnel. | - | Software |
| Design | Software security | Canonicalisation errors | - | The same input has been decoded more than once. | - | Software |
| Design | Software security | Dynamic query interfaces | - | The developer has used dynamic queries for accessing data. | - | Software |
| Design | Software security | Externally controlled format string | - | The software accepts a format string controlled by an external source. | - | Software |
| Design | Software security | Failure to restrict URL access | - | The developer has failed to impede access of restricted URLs to unauthorized users. | - | Software |
| Design | Software security | Information leakage | - | The software has exposed sensitive data or details of the web server. | - | Software |
| Design | Software security | Insecure communications | - | The software has failed to encrypt sensitive communications. | - | Software |
| Design | Software security | Insecure cryptographic storage | - | The software contains poorly designed or a lack of cryptography to protect data in the system. | - | Software |
| Design | Software security | Insecure direct object reference | Indirect object reference map | The software has an uncovered reference to an internal implementation object. | - | Software |
| Design | Software security | Lack of firewall | - | The software has insufficient rules to prevent web servers making new connections to external and internal systems. | - | Software |
| Design | Software security | Lack of program integrity check | - | The software executes downloaded code without confirming code origin. | - | Software |
| Design | Software security | Missing function level code | - | The developer has exposed sensitive data or details of the web server detailing access to an unauthorized page for the user. | - | Software |
| Design | Software security | Non-enforced least privilege principle | - | One or more components in the software have access to information that is not needed for its purpose. | - | Software |
| Design | Software security | Non-specified output encoding | - | The developer has failed to specify the output encoding. | - | Software |
| Design | Software security | Simple escaping functions | - | The developer has used simple escape functions. | - | Software |
| Design | Software security | Weak input validation | - | The developer has written a weak validation of input data length, type and syntax. | - | Software |
| Design | Software security | Weak output encoding | - | The developer has failed to entity encode all supplied data from the user. | - | Software |
| Design | Software security | Weak parametrised query APIs | - | The variable data in the data storage statement has no place holder parameter. | - | Software |
| Maintenance | Contamination | Biological contaminant | - | A living organism that can degrade or consume a substance or component. | - | Electrical, Mechanical, Plastics |
| Maintenance | Contamination | Chemically reactive contaminant | - | An impurity that results in a substance or components to undergo a chemical change. | The residue of cleaning chemicals. | Electrical, Mechanical, Plastics |
| Maintenance | Contamination | Corrosive contaminant | - | An impurity that can degrade or consume a substance or component. | - | Electrical, Mechanical, Plastics |
| Maintenance | Contamination | Exposure to acid | - | The introduction of an item to a substance or gas that can cause corrosion. | - | Electrical, Mechanical, Plastics |
| Maintenance | Contamination | Gaseous contaminant | - | A vapor impurity that causes a substance or component to alter. | - | Electrical, Mechanical, Plastics |
| Maintenance | Contamination | Ionic contaminant | - | A residue or harmful material that is left behind during a manufacturing process. | - | Electrical |
| Maintenance | Contamination | Liquid contaminant | - | A liquid impurity that causes a substance or component to alter. | - | Electrical, Mechanical, Plastics |
| Maintenance | Contamination | Saline contaminant | - | An impurity consisting of salt that causes a substance or component to alter. | - | Electrical, Mechanical, Plastics |
| Maintenance | Contamination | Solid particle contaminants | - | A solid portion of matter that causes a substance or component to alter. | - | Electrical, Mechanical, Plastics |
| Maintenance | Environmental protection | Damaged surface protection | - | The outer preservation or layer of an item is compromised. | - | Electrical, Mechanical, Plastics |
| Maintenance | Humidity | High humidity | - | An excessive amount of moisture. | - | Electrical, Mechanical |
| Maintenance | Input | Incompatible input material | - | A substance or component used during maintenance is incorrect and will not function within the system. | - | Mechanical |
| Maintenance | Input | Incorrect lubricant | - | The wrong type of coating was used to reduce surface friction. | - | Mechanical, Plastics |
| Maintenance | Input | Insufficient lubricant | - | An inadequate amount of coating was used to reduce surface friction. | - | Electrical, Mechanical, Plastics |
| Maintenance | Input | Lack of coolant | - | An inadequate amount liquid/gas used to remove heat. | - | Mechanical |
| Maintenance | Material quality | Surface damage | - | The exterior destruction of an item. | - | Electrical, Mechanical, Plastics |
| Maintenance | Mechanical loading | Impact loads | - | A force exerted on an item that is generated by a moving object. | A maintenance tool dropped onto a composite material. | Mechanical |
| Maintenance | Procedure | Inadequate drainage when out of service | - | The outlet drain when unused or idle is insufficient. | - | Mechanical |
| Maintenance | Procedure | Insufficient cleaning | - | An inadequate amount of sanitation has been used. | - | Electrical, Mechanical, Plastics |
| Maintenance | Procedure | Mishandling | - | Improper handling of a component, leading to damage. | - | - |
| Maintenance | Procedure | Untimely inspections | - | The monitoring tasks performed to check item health are not conducted frequently enough. | - | Electrical, Mechanical, Plastics |
| Maintenance | Procedure | Untimely maintenance actions | - | The maintenance tasks performed to restore item health are not conducted frequently enough. | - | Electrical, Mechanical, Plastics |
| Manufacturing | Ambient temperature | High Temperature | - | The ambient temperature is higher then expected. | - | Electrical, Mechanical, Plastics |
| Manufacturing | Ambient temperature | Low temperature | - | The ambient temperature is lower then expected. | - | Electrical, Mechanical, Plastics |
| Manufacturing | Chemical property | Chemically reactive material | - | The tendency of a substance to undergo a chemical reaction. | Metals that are galvanically incompatible, or possess grain boundary defects making them reactive with the environment. | Electrical, Mechanical, Plastics |
| Manufacturing | Contamination | Biological contaminant | - | A living organism that can degrade or consume a substance or component. | - | Electrical, Mechanical, Plastics |
| Manufacturing | Contamination | Chemically reactive contaminant | - | An impurity that results in a substance or components to undergo a chemical change. | The residue of manufacturing chemicals. | Electrical, Mechanical, Plastics |
| Manufacturing | Contamination | Corrosive contaminant | - | An impurity that can degrade or consume a substance or component. | - | Electrical, Mechanical, Plastics |
| Manufacturing | Contamination | Exposure to acid | - | The introduction of an item to a substance or gas that can cause corrosion. | - | Electrical, Mechanical, Plastics |
| Manufacturing | Contamination | Gaseous contaminant | - | A vapor impurity that causes a substance or component to alter. | - | Electrical, Mechanical, Plastics |
| Manufacturing | Contamination | Ionic contaminant | - | A residue or harmful material that is left behind during a manufacturing process. | - | Electrical |
| Manufacturing | Contamination | Liquid contaminant | - | A liquid impurity that causes a substance or component to alter. | - | Electrical, Mechanical, Plastics |
| Manufacturing | Contamination | Saline contaminant | - | An impurity consisting of salt that causes a substance or component to alter. | - | Electrical, Mechanical, Plastics |
| Manufacturing | Contamination | Solid particle contaminants | - | A solid portion of matter that causes a substance or component to alter. | - | Electrical, Mechanical, Plastics |
| Manufacturing | Electrical property | Capacitance high | - | A higher than expected amount of electrical charge. | - | Electrical |
| Manufacturing | Electrical property | Capacitance low | - | A lower than expected amount of electrical charge. | - | Electrical |
| Manufacturing | Electrical property | Dielectric strength high | - | Able to transmit a large amount of electric force without conduction. | - | Electrical |
| Manufacturing | Electrical property | Dielectric strength low | - | Only able to transmit a small amount of electric force without conduction. | - | Electrical |
| Manufacturing | Electrical property | Electrical potential high | - | A larger than expected amount of electric field potential. | - | Electrical |
| Manufacturing | Electrical property | Electrical potential low | - | A smaller than expected amount of electric field potential. | - | Electrical |
| Manufacturing | Electrical property | Electrical resistance high | Electrical conductivity high | The measure of opposition to current is higher than expected. | - | Electrical |
| Manufacturing | Electrical property | Electrical resistance low | Electrical conductivity low | The measure of opposition to current is lower than expected. | - | Electrical |
| Manufacturing | Electrical property | Impedance mismatch | - | The input impedance of a signal substantially differs to the output signal. | - | Electrical, Software |
| Manufacturing | Electrical property | Junction defects | - | There are flaws present between the connections of electrical parts. | Incorrect junction depth. | Electrical |
| Manufacturing | Electrical property | Line defects | - | There are flaws present in the cables or lines of an item. | Incorrect line width. | Electrical |
| Manufacturing | Electrical property | Open circuit | - | A scenario in a circuit where the normal path of current has been disconnected or interrupted. | - | Electrical |
| Manufacturing | Electrical property | Parasitic capacitance | Stray capacitance | The presence of unavoidable and unwanted capacitance between two items due to proximity. | - | Electrical |
| Manufacturing | Electrical property | Short circuit | - | A scenario in a circuit where the current is allowed to flow along an unintended path or with very low impedance. | - | Electrical |
| Manufacturing | Environmental protection | Insufficient surface protection | Insufficient insulation | A lack of or inadequate exterior preservation for an item. | - | Electrical, Mechanical, Plastics |
| Manufacturing | Geometry | Dynamic imbalance | - | An imbalance caused by the center of mass being out of alignment with the center of rotation. | - | Mechanical |
| Manufacturing | Geometry | Excessive clearances | - | A gap that allows relative movement and is larger then needed. | - | Mechanical |
| Manufacturing | Geometry | Inappropriate flow geometry | - | The geometric design of the system does not allow the ideal flow. | Poor flow geometry can cause excessive turbulence. | Mechanical |
| Manufacturing | Geometry | Incorrect size | - | The item sizing is to large or to small for intended purpose. | Excessively long columns are prone to buckling or creep buckling. | Electrical, Mechanical, Plastics |
| Manufacturing | Geometry | Insufficient clearances | - | An item that is unsecured or can move about freely. | - | Mechanical, Plastics |
| Manufacturing | Geometry | Possesive curvature | - | An item has been designed with more curvature than is necessary. | Curvature of load bearing members generates different loadings. | Mechanical |
| Manufacturing | Geometry | Stress concentrations | Geometric discontinuities, stress raisers. | A localization and amplification of stress at a particular point of an item. | - | Mechanical, Plastics |
| Manufacturing | Humidity | High humidity | - | An excessive amount of moisture. | - | Electrical, Mechanical |
| Manufacturing | Material quality | Crystal defects | - | Issues with crystalline structure of an item, impacting on the properties of the material. | - | Electrical |
| Manufacturing | Material quality | Excessive material defects | - | An unacceptable amount of deformities in an item. | Defects in alloys can cause precipitation of alloying elements at the grain boundary. | Electrical, Mechanical, Plastics |
| Manufacturing | Material quality | Incorrect material composition | - | The materials selected have an inaccurate formation for intended purpose. | - | Electrical, Mechanical, Plastics |
| Manufacturing | Material quality | Material contains inclusions | - | The presence of small foreign items that alter the material quality. | Impurities in metallic alloys renders them vulnerable to different types of corrosion and voiding. | Electrical, Mechanical, Plastics |
| Manufacturing | Material quality | Porous surface | - | The occurrence of small interstices on the exterior of an item, potentially allowing liquid or air to enter. | - | Electrical, Mechanical, Plastics |
| Manufacturing | Material quality | Presence of voids | - | The occurrence of small interstices on the interior of an item, potentially altering the material properties. | Voids may promote material cracking or crazing. | Electrical, Mechanical, Plastics |
| Manufacturing | Material quality | Rough surface | - | The exterior of an item is coarse or ridged. | - | Mechanical, Plastics |
| Manufacturing | Material quality | Surface surface | - | The exterior of an item is continuous or invariable. | - | Mechanical, Plastics |
| Manufacturing | Mechanical loading | Residual stresses | - | A stress present in an object that was caused by a previous loading or process. | Residual stresses render an item vulnerable to overstress under normal applied loading conditions. | Electrical, Mechanical, Plastics |
| Manufacturing | Mechanical property | Brittle material | - | The tendency to break without significant deformation. | Brittle surface materials vulnerable to cracking, fatigue or impact damage. | Mechanical, Plastics |
| Manufacturing | Mechanical property | Hardness mismatch | - | The ability to resist plastic deformation substantially differs between two connected items. | A hardness mismatch of mating surfaces causes yielding of the softer surface. | Electrical, Mechanical, Plastics |
| Manufacturing | Mechanical property | Insufficient stiffness | - | An item has inadequate or poor rigidity. | Items with insufficient stiffness can undergo torsion. | Mechanical, Plastics |
| Manufacturing | Mechanical property | Soft material | - | An item is susceptible to being deformed by external loads. | - | Mechanical, Plastics |
| Manufacturing | Mechanical property | Stiffness mismatch | - | The rigidity substantially differs between two connected items. | - | Mechanical, Plastics |
| Manufacturing | Mechanical property | Weak material | - | The material has a lower yield strength than its operating load. | - | Mechanical, Plastics |
| Manufacturing | Mechanical property | Wrong coefficient of thermal expansion | - | The incorrect correlation between geometry and thermal temperature of an item. | - | Electrical, Mechanical |
| Manufacturing | Metallization defect | Etching defects | - | A coating is performed leaving impression flaws on the item. | - | Electrical |
| Manufacturing | Metallization defect | Inadequate step coverage | - | A coating is performed in poor vacuum resulting in non-uniform trends. | - | Electrical |
| Manufacturing | Metallization defect | Incorrect alignment | - | A coating is performed at an incorrect angle or orientation. | - | Electrical |
| Manufacturing | Metallization defect | Incorrect composition | - | A coating is performed with inaccurate material constituents. | - | Electrical |
| Manufacturing | Metallization defect | Incorrect thickness | - | A coating is performed of inaccurate depth. | - | Electrical |
| Manufacturing | Metallization defect | Line width | - | A coating is performed with inaccurate width. | - | Electrical |
| Manufacturing | Metallization defect | Poor adhesion | - | A coating is performed with an insufficient bond strength. | - | Electrical |
| Manufacturing | Metallization defect | Scratching | Bridging | A coating is performed resulting in abrasive flaws on the item. | - | Electrical |
| Manufacturing | Metallization defect | Thin oxide layer | - | A coating is performed with an inaccurate oxide layer depth. | - | Electrical |
| Manufacturing | Metallization defect | Voids in oxides | - | The presence of gaps in the oxide layer of a coating. | - | Electrical |
| Manufacturing | PCB assembly defects | Bond line thicness error | - | An incorrect dimension of adhesive on a PCB. | - | Electrical |
| Manufacturing | PCB assembly defects | Bond overhang | - | A metal plating build up that can cause short circuits within the PCB. | - | Electrical |
| Manufacturing | PCB assembly defects | Bond pad contamination | - | Impurities within the conducting pads causing flaws within the PCB. | - | Electrical |
| Manufacturing | PCB assembly defects | Bond wire to substrate short | - | The distance between the wire and substrate on the PCB is too short. | - | Electrical |
| Manufacturing | PCB assembly defects | Bond-induced cracks | - | The presence of cracks caused by the connection between two items. | - | Electrical |
| Manufacturing | PCB assembly defects | Bonding overpressure | - | The pressurized environment used to form the bond is not at the ideal pressure. | - | Electrical |
| Manufacturing | PCB assembly defects | Solder balling | - | A clump of solder that forms due to poor manufacturing process. | - | Electrical |
| Manufacturing | Radiation | Electromagnetic inteference | EMI | A disturbance generated by an external source that affects an electrical circuit by electromagnetic induction. | - | Electrical, Mechanical |
| Manufacturing | Radiation | Electromagnetic pulse | EMP | A short burst of electromagnetic energy. | - | Electrical, Mechanical |
| Manufacturing | Radiation | Electromagnetic radiation | EMR | The emission of visible light, radio waves, gamma rays, and x-rays in which electric and magnetic fields vary simultaneously. | - | Electrical, Mechanical |
| Manufacturing | Radiation | Nuclear radiation | - | An emission of energy particles or rays from a radioactive element. | - | Electrical, Mechanical |
| Operation | Ambient pressure | High pressure | - | The ambient pressure is higher than expected. | - | Electrical, Mechanical, Plastics |
| Operation | Ambient pressure | Low Pressure | - | The ambient pressure is lower than expected. | - | Electrical, Mechanical, Plastics |
| Operation | Ambient pressure | Pressure differential | - | The range between maximum and minimum pressure experienced is different to expected. | - | Electrical, Mechanical, Plastics |
| Operation | Ambient pressure | Pressure fluctuations | - | Variations in ambient pressure that effect an item. | - | Electrical, Mechanical, Plastics |
| Operation | Ambient temperature | High temperature | - | The ambient temperature is higher then expected. | - | Electrical, Mechanical, Plastics |
| Operation | Ambient temperature | Low temperature | - | The ambient temperature is lower then expected. | - | Electrical, Mechanical, Plastics |
| Operation | Ambient temperature | Temperature differential | - | The range between maximum and minimum temperature experienced is different to expected. | - | Electrical, Mechanical, Plastics |
| Operation | Ambient temperature | Temperature fluctuations | - | Variations in ambient pressure that effect an item. | - | Electrical, Mechanical, Plastics |
| Operation | Contamination | Biological contaminant | - | A living organism that can degrade or consume a substance or component. | - | Electrical, Mechanical, Plastics |
| Operation | Contamination | Chemically reactive contaminant | - | An impurity that results in a substance or components to undergo a chemical change. | - | Electrical, Mechanical, Plastics |
| Operation | Contamination | Corrosive contaminant | - | An impurity that can degrade or consume a substance or component. | - | Electrical, Mechanical, Plastics |
| Operation | Contamination | Exposure to acid | - | The introduction of an item to a substance or gas that can cause corrosion. | - | Electrical, Mechanical, Plastics |
| Operation | Contamination | Gaseous contaminant | - | A vapor impurity that causes a substance or component to alter. | - | Electrical, Mechanical, Plastics |
| Operation | Contamination | Liquid contaminant | - | A liquid impurity that causes a substance or component to alter. | - | Electrical, Mechanical, Plastics |
| Operation | Contamination | Solid particle contaminants | - | A solid portion of matter that causes a substance or component to alter. | - | Electrical, Mechanical, Plastics |
| Operation | Electrical loading | Over-current | - | Current in excess of the normal operating limits of a device or circuit. | - | Electrical |
| Operation | Electrical loading | Over-voltage | - | Voltage in excess of the normal operating voltage of a device or circuit. | - | Electrical |
| Operation | Electrical loading | Transient electrical loads | Random electrical loads | Short lived bursts of random electrical loads. | - | Electrical |
| Operation | Electrical property | Electrical resistance high | Electrical conductivity high | The measure of opposition to current is higher than expected. | - | Electrical |
| Operation | Electrical property | Electrical resistance low | Electrical conductivity low | The measure of opposition to current is lower than expected. | - | Electrical |
| Operation | Environmental protection | Damaged surface protection | - | The outer preservation or layer of an item is compromised. | - | Electrical, Mechanical, Plastics |
| Operation | Hydraulic loading | Cyclic hydraulic loads | - | A series of repeated pressure changes in a hydraulic flow. | - | Mechanical |
| Operation | Hydraulic loading | High hydraulic load | - | A liquid that is generating a higher than expected pressure or rate. | - | Mechanical, Plastics |
| Operation | Hydraulic loading | Low hydraulic loads | - | A liquid that is generating a lower than expected pressure or rate. | - | Mechanical, Plastics |
| Operation | Hydraulic loading | Transient hydraulic loads | Random hydraulic loads | Short lived bursts of random hydraulic loads. | - | Mechanical |
| Operation | Input | Aerated liquid input | - | A material inlet flow is made effervescent by being charged with carbon dioxide or other gas. | - | Mechanical |
| Operation | Input | Contaminated input flow | - | An incoming flow is compromised by impurity. | - | Mechanical, Plastics |
| Operation | Input | High pressure input flow | - | An incoming flow that is generating a higher than expected pressure. | - | Mechanical |
| Operation | Input | Incorrect timing of input flow | - | An incoming flow has an incorrect or different pacing to what was expected. | - | Electrical, Mechanical |
| Operation | Input | Input flow too fast | - | An incoming flow has a higher than expected rate of flow. | - | Mechanical |
| Operation | Input | Input flow too slow | - | An incoming flow has a lower than expected rate of flow. | - | Mechanical |
| Operation | Input | Input temperature too high | - | An input that is generating a higher than expected temperature. | - | Mechanical, Plastics |
| Operation | Input | Input temperature too low | - | An input that is generating a lower than expected temperature. | - | Mechanical, Plastics |
| Operation | Input | Low pressure input flow | - | An incoming flow that is generating a lower than expected pressure. | - | Mechanical |
| Operation | Input | Moist input flow | - | An incoming flow has a high humidity. | - | Mechanical |
| Operation | Input | Unforseen user input | User error | The developer has not foreseen the potential input from a user. | - | Software |
| Operation | Mechanical loading | Acceleration | - | An increase in speed or rate. | - | Mechanical |
| Operation | Mechanical loading | Cyclic mechanical loads | - | A series of repeated forces or loadings. | - | Mechanical |
| Operation | Mechanical loading | High mechanical load | Overpressure | A higher than expected mechanical force is exerted on an item. | - | Mechanical |
| Operation | Mechanical loading | Imbalanced mechanical loads | Off-axis mechanical loads | A scenario where incoming forces occur out of alignment with the item geometry. | - | Mechanical |
| Operation | Mechanical loading | Impact loads | - | A force exerted on an item that is generated by a moving object. | A bird strike during flight. | Mechanical |
| Operation | Mechanical loading | Low mechanical load | - | A lower than expected mechanical force is exerted on an item. | - | Mechanical |
| Operation | Mechanical loading | Mechanical shock | Operating loads shock | A sudden acceleration due to impact. | - | Mechanical |
| Operation | Mechanical loading | Transient mechanical loads | Random mechanical loads | Short lived bursts of random mechanical loads. | - | Electrical, Mechanical, Plastics |
| Operation | Mechanical loading | Vibration loading | - | A continual and oscillating loading on an item. | - | Electrical, Mechanical, Plastics |
| Operation | Operating procedure | Dry start | - | An item is operated without proper priming or lubrication. | - | Mechanical, Plastics |
| Operation | Operating procedure | Shut-down procedures breached | - | The end of operation process is performed incorrectly. | - | Electrical, Mechanical, Plastics |
| Operation | Operating procedure | Start-up procedures breached | - | The beginning of operation process is performed incorrectly. | - | Electrical, Mechanical, Plastics |
| Operation | Operating speed | High operating speed | - | The operating speed of an item is higher than expected. | - | Mechanical |
| Operation | Operating speed | Low operating speed | - | The operating speed of an item is lower than expected. | - | Mechanical |
| Operation | Operating time | Item life-span exceeded | - | The long term item life expectancy has been surpassed. | - | Electrical, Mechanical, Plastics |
| Operation | Operating time | Maximum continuous use time exceeded | - | The short term usage time for an item has been surpassed. | - | Electrical, Mechanical, Plastics |
| Operation | Pneumatic loading | Cyclic Pneumatic loads | - | A series of repeated pressure changes in a pneumatic flow. | - | Mechanical, Plastics |
| Operation | Pneumatic loading | High pneumatic loads | - | A gas that is generating a higher than expected pressure or rate. | - | Mechanical, Plastics |
| Operation | Pneumatic loading | Low pneumatic loads | - | A gas that is generating a lower than expected pressure or rate. | - | Mechanical, Plastics |
| Operation | Radiation | Transient pneumatic loads | - | Short lived bursts of random pneumatic loads. | - | Mechanical |
| Operation | Radiation | Electromagnetic interference | EMI | A disturbance generated by an external source that affects an electrical circuit by electromagnetic induction. | - | Electrical, Mechanical |
| Operation | Radiation | Electromagnetic pulse | EMP | A short burst of electromagnetic energy. | - | Electrical, Mechanical |
| Operation | Radiation | Electromagnetic radiation | EMP | The emission of visible light, radio waves, gamma rays, and x-rays in which electric and magnetic fields vary simultaneously. | - | Electrical, Mechanical |
| Operation | Radiation | Nuclear radiation | - | An emission of energy particles or rays from a radioactive element. | - | Electrical, Mechanical |
| Transportation | Contamination | Biological contamination | - | A living organism that can degrade or consume a substance or component. | - | Electrical, Mechanical, Plastics |
| Transportation | Contamination | Chemically reactive contaminant | - | An impurity that results in a substance or components to undergo a chemical change. | - | Electrical, Mechanical, Plastics |
| Transportation | Contamination | Corrosive contaminant | - | An impurity that can degrade or consume a substance or component. | - | Electrical, Mechanical, Plastics |
| Transportation | Contamination | Exposure to acid | - | The introduction of an item to a substance or gas that can cause corrosion. | - | Electrical, Mechanical, Plastics |
| Transportation | Contamination | Gaseous contaminant | - | A vapor impurity that causes a substance or component to alter. | - | Electrical, Mechanical, Plastics |
| Transportation | Contamination | Ionic contaminant | - | A residue or harmful material that is left behind during a manufacturing process. | - | Electrical |
| Transportation | Contamination | Liquid contaminant | - | A liquid impurity that causes a substance or component to alter. | - | Electrical, Mechanical, Plastics |
| Transportation | Contamination | Saline contaminant | - | An impurity consisting of salt that causes a substance or component to alter. | - | Electrical, Mechanical, Plastics |
| Transportation | Contamination | Solid particle contaminants | - | A solid portion of matter that causes a substance or component to alter. | - | Electrical, Mechanical, Plastics |
| Transportation | Environmental Protection | Damaged surface protection | - | The outer preservation or layer of an item is compromised. | - | Electrical, Mechanical, Plastics |
| Transportation | Humidity | High humidity | - | An excessive amount of moisture. | - | Electrical, Mechanical |
| Transportation | Material quality | Surface damage | - | The exterior destruction of an item. | - | Electrical, Mechanical, Plastics |
| Transportation | Mechanical loading | Impact loads | - | A force exerted on an item that is generated by a moving object. | A car accident during transportation of an item. | Mechanical |
| Transportation | Mechanical loading | Vibration loading | - | A continual and oscillating loading on an item. | - | Electrical, Mechanical, Plastics |
| Transportation | Radiation | Electromagnetic interference | EMI | A disturbance generated by an external source that affects an electrical circuit by electromagnetic induction. | - | Electrical, Mechanical |
| Transportation | Radiation | Electomagnetic pulse | EMP | A short burst of electromagnetic energy. | - | Electrical, Mechanical |
| Transportation | Radiation | Electromagnetic radiation | EMR | The emission of visible light, radio waves, gamma rays, and x-rays in which electric and magnetic fields vary simultaneously. | - | Electrical, Mechanical |
| Transportation | Radiation | Nuclear radation | - | An emission of energy particles or rays from a radioactive element. | - | Electrical, Mechanical |
Source: Local MADE 3.9.1 installation: com.phm.made.help.plugin/documents/help/html/MADeHelp/03-Modelling/03-04-FailureDiagram/03-04-03-FailureConcepts/03-04-03-01-Causes.html · retrieved 2026-07-09