Comprehensive Failure Assistance and Risk Assessment for Your Electronics Manufacturing
ZESTRON supports manufacturers of electronic assemblies and power modules with failure assistance in acute failure cases as well as with risk minimization before series release. We evaluate failure patterns, process risks and relevant influencing factors and derive concrete measures for quality assurance, delivery capability and process assurance.
failure Assistance & risk assessmentClarify Failure Causes and Minimize Risks at an Early Stage
Whether SMT electronic assembly, power module or manufacturing process: when failures occur, qualification tests are not passed or risks need to be assessed before series release, a traceable technical evaluation within the specific application and manufacturing context is required.
ZESTRON supports you with systematic failure assistance and risk minimization. We evaluate failure patterns, failure mechanisms, Technical Cleanliness, insulation risks and process-relevant influencing factors. Based on this, we derive suitable corrective actions, preventive measures or next steps for quality assurance, 8D, PPAP, series release and process assurance.
This creates a reliable basis for decision-making to address acute failures in a targeted manner, reduce potential risks at an early stage and safeguard the delivery capability of your electronics manufacturing
ABAssembled PCB Evaluate Failure Cases and Process Risks on SMT Electronic Assemblies
On assembled printed circuit boards, residues, corrosion, particulate contamination or narrow process windows can lead to qualification problems and field failures.
ZESTRON supports the technical evaluation of failure patterns and the derivation of suitable corrective actions.
Power Modules Assess Field Failures and Insulation Risks in Power Modules
In Power Modules, thermal stress, insulation risks, dendrite formation or abnormalities in the module structure can compromise reliability.
ZESTRON supports the evaluation of failure patterns and the derivation of next steps for quality, delivery capability and supplier communication.
How we support your successFrom Evaluation to Assurance
When failure cases occur or risks need to be assessed before series release, a traceable technical evaluation is essential. ZESTRON evaluates conspicuous failure patterns, critical influencing factors and potential risks within the respective application and manufacturing context.
Whether discoloration, residues, dendrite formation, insulation risks or abnormal process behavior: the aim is to provide a reliable basis for decision-making for failure assistance, risk minimization, quality assurance and process assurance.
Depending on your specific issue, ZESTRON supports you with targeted service modules — from failure evaluation to the preventive assurance of technical risks.
We evaluate failure mechanisms, distinguish between the immediate Cause and the underlying Root Cause, and narrow down relevant influencing factors in a traceable manner. The aim is to create a reliable basis for corrective actions, change management and technical assurance in communication with customers or suppliers.
We support you, among other things, with:
- Validation failures in the PPAP process, for example DV and PV, especially after climate stress tests in accordance with IEC 60068-2 as well as customer-specific OEM and factory standards in the automotive industry
- Dendrite formation, electrochemical migration, anodic migration, creepage corrosion, whiskers or particle-related failure risks
- Discoloration caused by corrosion, oxidation, contamination or polymer damage
We support you in the technical preparation of failure cases for 8D reports, customer communication and supplier coordination. The aim is to provide a traceable presentation of the failure mechanism, Cause, Root Cause and suitable corrective actions in order to reduce technical, quality-related and economic risks and safeguard your delivery capability.
We support you, among other things, with:
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Technical evaluation of failure patterns and influencing factors
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Traceable presentation of Cause and Root Cause
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Derivation of suitable containment, corrective and preventive actions
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Technical basis for customer communication, supplier dialogue and out-of-court clarification
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Evaluation of customer requirements, contractual conformity and complaint risks
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Reduction of potential consequential costs through traceable failure evaluation and clearly defined next steps
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Safeguarding delivery capability through reliable measures and technical decision-making bases
We support you in evaluating and implementing requirements for Technical Cleanliness and insulation coordination. The aim is to assess particle-related risks, pollution degree and electrical clearances at an early stage and to derive reliable requirements for development, manufacturing, drawings and specifications.
We support you, among other things, with:
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Implementation of VDA 19, the ZVEI guideline and IEC TR 61191-7 in the specific manufacturing environment
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Facility planning, equipment concepts, audits, risk assessments and training
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Development of TecSa management from strategy and concept through to operational implementation
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Creation of a reliable Component Cleanliness Code for drawings and specifications
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Compliance with the agreed pollution degree in accordance with IEC 60664-1 or IPC 2221
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Assurance of cleanliness requirements for qualification, series release and customer audits
We support you in identifying weaknesses in the product, prototype or manufacturing process at an early stage and in minimizing technical risks in a targeted manner. The aim is to create a reliable basis for process development, qualification, series release and stable manufacturing processes.
We support you, among other things, with:
- Analysis of product and prototype weaknesses using fast quality testing methods
- Evaluation of A-samples and B-samples before qualification or series release
- Technical classification of process risks in development and manufacturing
- Consulting and optimization of coating, potting, molding and embedding
- Support with sintering processes in power electronics
- Derivation of suitable measures for risk minimization and process assurance
practical insightsSolutions for Your Challenge
Our case studies and application examples demonstrate how we precisely analyze failure causes, implement practical solutions and sustainably optimize production processes to successfully overcome technical challenges.
Dendrites, Creepage Distances, and Deposits on Electronic Assemblies – All Consequences of Electrochemical Migration?
Assistance ModulesTargeted Support for the Next Step
When concrete measures need to be derived from a failure evaluation or risk assessment, ZESTRON’s Assistance Modules provide structured support for further action. They help to further classify technical interrelations and derive suitable next steps for development, manufacturing or quality assurance.
PartnershipsSpecialist Network for Reliable Assessments
Our network of industry associations, expert committees and research partners strengthens our technical evaluation of failure cases, process risks and current requirements in electronics manufacturing.
Get in TouchHave a Failure Case or Process Risk Assessed
Do you have an acute failure case, a qualification problem or would you like to minimize technical risks before series release, PPAP or process release? Talk to our experts about your specific issue.