Suspension ball joint failure analysis based on problem solving process

A methodology of a ball joint failure analysis has been developed in order to evaluate warranty return parts. The method consists of defining and specifying the issue and the failure mode, identifying and testing the cause to define the extension and solution. Based on the vehicle user complain and the technical information received from the dealer, the effects in vehicle performance were classified. According to each effect class, tests and functional analysis are defined to reproduce the effects seen in the vehicle and detect the possible causes. This methodology allows to identify the root cause after eliminating external agents that can interfere in the evaluation, such as damages caused during the vehicle disassembly or effects caused by other components.