ECE 3000 Engineering Seminar Engineering Failures ECE 3000

ECE 3000: Engineering Seminar Engineering Failures ECE 3000 Engineering Seminar Suketu Naik

1 2 0 1 6 p 1) Toyota Recalls (2009) Issue: Pedals trapped/stuck causing unintended acceleration or braking issues. p Impact: p ~20. 5 m 1 vehicles recalled ECE 3000 Engineering Seminar Suketu Naik

2 2 0 1 6 2) Hall of Shame: Samsung 2 https: //www. sammobile. com/2016/08/24/samsung-galaxy-note-7 -explodeswhile-charging-using-a-usb-type-c-converter/ ECE 3000 Engineering Seminar Suketu Naik

3 2 0 1 p 6 2) Samsung’s Galaxy Note 7 are on Fire! (2016) p 3 https: //www. extremetech. com/mobile/243198 -samsungreveals-root-cause-galaxy-note-7 -failures-fires Samsung’s version of the story: Battery had manufacturing defect – electrodes were prone to bending. > Causing short circuit and fire. p Recalled > Had 2 battery manufacturers- switched to only one> New batteries prone to welding defect causing positive and negative electrodes to short at welding point. p Second recall !! > Note 7 off market. p p Impact: $5. 3 billion cost to Samsung! p 96 battery overheating reports (per US Consumer Product Safety Commision) p Per Samsung: p p 13 report of Burns. p 47 reports of property damage. ECE 3000 Engineering Seminar Suketu Naik

4 2 0 1 p 6 4 2) Burnt Note 7 - Video http: //www. dailymail. co. uk/sciencetech/article 3774896/Samsung-DIDN-T-officially-recall-Galaxy -Note-7 -Consumer-Reports-slams-phonemakerfailing-make-exploding-battery-issue-official. html ECE 3000 Engineering Seminar Suketu Naik

5 2 0 1 p 6 p 3) Takata Airbags (2004? /2008 – 2017) 2019? ? 5 May shoot metal fragments, upon/during inflation! Impact: p p Chrysler, Honda, Toyota, Nissan, Ford, BMW, GM, Subaru, Volkswagen, Mercedes Benz, Ferrari, Mazda, Mitsubishi, Audi, Jaguar, Tesla. ~42 million vehicles affected in US Honda: 11 deaths & 184 injuries in US Interesting: Only 12% of recalled cars repaired in America, vs 70% recalled repaired in Japan (huge difference in the no. of cars? ) p Orbital testing results: “it was the combination of these three factors—the use of ammonium nitrate, the construction of Takata’s inflator assembly, and the exposure to heat and humidity—that made the inflators vulnerable to rupture. ” p p Cause: p p Improper storage of propellant causes increased pressure Humidity? Rust? Welding issue? DPM - High passing rate? ECE 3000 Engineering Seminar Suketu Naik

6 2 0 1 p 6 4) VW TDI Fiasco 6 Promise: clean Diesel, Failure: 40 x times NOx emissions! p Impact: p Public health and enviorment p Law enforcement and EPA p Bad publicity and failure for approval of future vehicles p Cause: p Activated ECU controls during testing to mask their true NOx emissions p In real-world driving, ECU controls were off p Corporate greed p Software realignment p Defeat device ECE 3000 Engineering Seminar Suketu Naik

7 2 0 1 Most 6 More engineering disasters 7 Famous p https: //10 mosttoday. com/10 -most-famous-engineering-disasters/ Architectural Failures p https: //www. youtube. com/watch? v=M 6 w. P 93 cvn. SA EE/ECE related Failures p https: //www. youtube. com/watch? v=qgus. Hew. RFg. A p https: //en. wikipedia. org/wiki/Capacitor_plague Learning from Failures (Technical issues) p https: //www. tms. org/Communities/FTAttachments/material_disa sters_Nik_Chawla. pdf p https: //www. journals. elsevier. com/engineering-failureanalysis/recent-articles ECE 3000 Engineering Seminar Suketu Naik

8 2 0 1 p 6 8 Assignment Please do a case study on an engineering failure that was reported in the past 5 years. p Summarize the event (what happened), what was the impact (on both customer and engineer/organization side) and how the organization responded to it (fix? ). p Share your thoughts on what was the cause of the failure. p What can be learnt from this failure and how can it be avoided in the future? ECE 3000 Engineering Seminar Suketu Naik

9 2 0 1 1. 6 2. 3. 4. 5. References 9 http: //www. engineering. com/Designer. Edge/water/Article. ID /5301/Five-Biggest-Engineering-Disasters. aspx https: //www. extremetech. com/mobile/243198 -samsungreveals-root-cause-galaxy-note-7 -failures-fires https: //www. usatoday. com/story/tech/2016/10/14/samsungnote-7 -recall-cost-least-53 -billion/92040942/ https: //blog. caranddriver. com/massive-takata-airbag-recalleverything-you-need-to-know-including-full-list-of-affected -vehicles/ https: //www. theatlantic. com/business/archive/2011/05/whowas-really-at-fault-for-the-toyota-recalls/238076/ ECE 3000 Engineering Seminar Suketu Naik