[et_pb_section fb_built=”1″ admin_label=”section” module_class=”fpb0 table_of_content_sec” _builder_version=”4.27.4″ locked=”off” global_colors_info=”{}”][et_pb_row admin_label=”row” module_class=”fpt0 fpb0″ _builder_version=”4.27.4″ background_size=”initial” background_position=”top_left” background_repeat=”repeat” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.16″ custom_padding=”|||” global_colors_info=”{}” custom_padding__hover=”|||”][et_pb_code _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_code][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ _builder_version=”4.27.4″ _module_preset=”default” locked=”off” global_colors_info=”{}”][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”1″ module_id=”sectionscrollid1″ _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n
For quality managers, production managers, and process managers in the industrial sector, systematic failure analysis\u2014particularly through preventive methods such as FMEA\u2014lays the foundation for effectively resolving deviations and reducing costs in the long term. In industrial processes, undetected defects are not merely a nuisance; they pose a genuine risk to quality, production costs, and customer satisfaction. Often, even minor deviations in processes are enough to cause significant damage or even complete production shutdowns.<\/p>\n
The structured investigation of root causes therefore plays a central role in manufacturing. It is the tool that manufacturing companies use to systematically identify problems, implement effective corrective measures, and ensure the quality of products, processes, and services. If teams focus solely on treating symptoms and consequences when identifying defects, rather than uncovering the true root cause of a problem, disruptions will keep recurring.<\/p>\n
Best practices, digital tools, and a clearly structured approach form the ideal combination in practice for thoroughly identifying sources of error. Well-known methods such as root cause analysis, the Ishikawa diagram, and failure mode and effects analysis are valuable across all industries. In this article, you\u2019ll learn exactly how these techniques are applied and how modern technologies can support your team in practice.[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_image src=”https:\/\/tepcon.de\/wp-content\/uploads\/2025\/07\/Fehleranalyse-img.jpg” alt=”Manufacturing Defects” module_class=”img__radius” _builder_version=”4.27.6″ _module_preset=”default” hover_enabled=”0″ global_colors_info=”{}” sticky_enabled=”0″][\/et_pb_image][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”2″ module_id=”sectionscrollid2″ module_class=”checkmrk_list ” _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n
Product defects and disruptions in industrial processes can occur at many stages\u2014from incoming goods through actual production to distribution. In their analysis, experts distinguish between internal and external causes of defects.<\/p>\n
Internal causes arise directly within a company\u2019s own manufacturing or operations. A variety of factors can trigger problems here, for example:<\/p>\n
These causes can be directly addressed using internal resources and targeted measures. When internal factors are the cause, the desired efficiency improvements can usually be achieved quickly following a thorough investigation. For example, clear, digital checklists can prevent workers at the production line from overlooking important inspection steps.<\/p>\n
External causes of errors lie outside the company\u2019s direct sphere of influence. Common sources of defects in this context include:<\/p>\n
Even though external factors are more difficult to control, holistic quality management requires a comprehensive investigation. Only by understanding the exact impacts can a company, for example, switch suppliers or build up internal buffers to minimize the damage to its own project.[\/et_pb_text][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ admin_label=”Common_CTA” module_class=”wissen_cta_section” _builder_version=”4.27.4″ _module_preset=”default” use_background_color_gradient=”on” background_color_gradient_direction=”90deg” background_color_gradient_stops=”#2c333a 0%|#2c333a 52%|#532d3b 75%|#b61f3f 100%” background_image=”https:\/\/tepcon.de\/wp-content\/uploads\/2025\/10\/bg-element-3.svg” background_position=”top_center” locked=”off” collapsed=”off” global_colors_info=”{}”][et_pb_row column_structure=”2_3,1_3″ module_class=”vam_a980″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”2_3″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text module_class=”h2_class white_text anchor_link_class” _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n
[\/et_pb_text][\/et_pb_column][et_pb_column type=”1_3″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_button button_url=”\/en\/contact\/” button_text=”Contact” button_alignment=”right” module_class=”secondary_btn” _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_button][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ module_class=”checkmrk_list anchor_link_class” _builder_version=”4.27.6″ _module_preset=”default” locked=”off” collapsed=”off” global_colors_info=”{}”][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”12″ module_id=”sectionscrollid16″ module_class=”anchor_link_class ” _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n
The term \u201cfailure analysis\u201d describes a systematic procedure for identifying, documenting, and evaluating the causes of failures in industrial and business processes. The most important steps in failure analysis are failure data collection and root cause analysis. The purpose of this method is to lay the foundation for effective troubleshooting and long-term process optimization.<\/p>\n
The definition goes far beyond the mere detection of a defect: The goal is genuine error prevention for the future. In quality management, there are various established methods for conducting this process in a structured manner.[\/et_pb_text][et_pb_text admin_label=”12″ module_id=”sectionscrollid16″ module_class=”anchor_link_class ” _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n
To conduct failure analyses in a structured manner, companies rely on proven standards. The following five methods form the foundation of modern root cause analysis.[\/et_pb_text][et_pb_accordion admin_label=”Accordion” module_class=”custom_accrodian_toggle” _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”][et_pb_accordion_item title=”Failure Mode and Effects Analysis (FMEA)” open=”on” _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n
FMEA (Failure Mode and Effects Analysis) is a method for preventive failure avoidance. In practice, the term \u201cFMEA analysis\u201d has become established, even though, strictly speaking, the word \u201canalysis\u201d appears twice in it. It was developed by NASA in the 1960s and is ideally used during the development phase, before a product is even manufactured. FMEA promotes the cross-functional exchange of expertise. In a Failure Mode and Effects Analysis, an interdisciplinary team evaluates potential failures based on three criteria: the probability of their occurrence, their significance (severity) for the customer, and the probability of detection. The system calculates a risk priority number based on these factors. The Risk Priority Number (RPN) can have a maximum value of 1,000. This allows designers and planners to know exactly where the highest risk of costly product recalls lies. In the impact analysis, a distinction is made between different types of FMEA:<\/p>\n
[\/et_pb_accordion_item][et_pb_accordion_item title=”Root Cause Analysis” _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}” open=”off”]Root-cause analysis aims to identify the deepest root of a problem. Rather than simply replacing the defective component, this method seeks to determine the cause of the defect. Identifying the true root cause prevents the same error from recurring under similar conditions and thus provides an important foundation for developing more stable production processes.[\/et_pb_accordion_item][et_pb_accordion_item title=”The Ishikawa Diagram” _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}” open=”off”]The Ishikawa diagram, often referred to as a fishbone diagram, visualizes cause-and-effect relationships. The specific problem is located at the \u201chead\u201d of the diagram. The branching lines represent the main influencing factors, usually organized according to the classic M-categories: Man, Machine, Material, Method, Environment, and Measurement. This structure helps teams during brainstorming sessions to ensure that no potential causes are overlooked.[\/et_pb_accordion_item][et_pb_accordion_item title=”Q7, based on Kaoru Ishikawa” _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}” open=”off”]The Q7 comprises seven basic quality tools that assist with data collection and problem-solving. These include, among others, defect collection cards, histograms, Pareto charts, and quality control charts. They make defects visible and quantifiable, and prepare the data for in-depth risk analysis. The Pareto principle identifies the causes responsible for the majority of defects.[\/et_pb_accordion_item][et_pb_accordion_item title=”The 5 Whys Method” _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}” open=”off”]This simple yet effective method involves asking \u201cWhy?\u201d whenever a problem arises until the root cause is identified. Here\u2019s a brief example:<\/p>\n
Result:<\/strong> The corrective action is not \u201creplace the fuse,\u201d but rather \u201cimplement a maintenance schedule for the lubrication pump.\u201d[\/et_pb_accordion_item][\/et_pb_accordion][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”12″ module_id=”sectionscrollid16″ module_class=”anchor_link_class ” _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n As digitalization advances, the tools used for analysis have also evolved. Modern software solutions speed up the process of identifying root causes: The structured documentation of deviations, the automated identification of sources of error, and the tracking of corrective actions across the entire company can be accomplished much more reliably with a digital solution.<\/p>\n Applications that support if-then logic are particularly helpful: As soon as an employee records a specific error on the equipment, the system automatically displays relevant cause or corrective action fields. This creates a more dynamic process and reduces the time required. Every expert in the operation receives exactly the data they need for their analyses.<\/p>\n Furthermore, digital systems enable the integration of analyses with other areas of quality management\u2014such as quality assurance, auditing, or training administration. Data from various business units is consolidated, can be compared, and evaluated at the click of a button\u2014often in multiple languages or directly in German.[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_image src=”https:\/\/tepcon.de\/wp-content\/uploads\/2024\/11\/Fachkraeftemangel-entgegenwirken-2.jpg” alt=”Quality Management with Digital Tools: Reducing Error Rates with the tepcon instructor” module_class=”img__radius” _builder_version=”4.27.6″ _module_preset=”default” hover_enabled=”0″ global_colors_info=”{}” sticky_enabled=”0″][\/et_pb_image][\/et_pb_column][\/et_pb_row][et_pb_row module_class=”fpb0″ _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”12″ module_id=”sectionscrollid16″ module_class=”anchor_link_class ” _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n Whether used for service documentation, assembly instructions, or work instructions, our instructor software solution provides comprehensive support for production processes. With detailed step-by-step instructions, the tool guides independent workers through a wide variety of processes.<\/p>\n For error analysis, the system acts as a proactive measure: Thanks to the continuous documentation of all work steps, the tool automatically generates reliable data to transparently monitor production costs.<\/p>\n Furthermore, instructor plays a direct role in error resolution: Based on its if-then logic, the system can ask specific questions in forms when logging deviations and, if necessary, show or hide additional inspection steps. An integrated ticket system makes it possible to immediately log issues, notify all relevant parties, and analyze the effectiveness of implemented changes.<\/p>\n All information is available at any time, regardless of location. Process adjustments are implemented more quickly, as updated specifications are pushed digitally directly to the workstations. This significantly reduces the likelihood of errors, lowers manual labor costs, and increases overall productivity.<\/p>\n We\u2019d be happy to explain how you can optimize your quality management with the tepcon instructor:[\/et_pb_text][et_pb_button button_url=”\/en\/contakt\/” button_text=”Book a consultation here!” admin_label=”Button” module_class=”primary_btn pb0″ _builder_version=”4.27.6″ _module_preset=”default” locked=”off” global_colors_info=”{}”][\/et_pb_button][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.27.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text admin_label=”12″ module_id=”sectionscrollid16″ module_class=”anchor_link_class ” _builder_version=”4.27.6″ _module_preset=”default” global_colors_info=”{}”]<\/p>\n A thorough and targeted analysis is far more than a short-term Band-Aid solution\u2014it serves as a strategic tool in quality management. Using structured methods such as FMEA, the Ishikawa diagram, and modern tools, organizations identify weaknesses and eliminate them permanently.<\/p>\n Choosing the right techniques is key to success. Whether in process analysis, collaboration with suppliers, or fine-tuning internal workflows: Understanding sources of error paves the way for seamless production and more satisfied customers. Take advantage of modern software to learn from deviations and continuously improve\u2014directly benefiting your project, your products, and your company\u2019s overall performance.<\/p>\nDigital Tools as Part of Fault Analysis<\/h2>\n
Quality Management with Digital Tools: Reducing Error Rates with the tepcon instructor<\/h2>\n
Failure Analysis as a Strategic Success Factor in Quality Management<\/h2>\n