The Challenge
Unexpected Component Failure Disrupts Production
An energy industry integrated service provider experienced a significant production issue when several film resistors encountered open circuit failures, halting their manufacturing process. This disruption posed a risk to both timelines and product quality, and the customer needed to quickly identify the root cause to restore smooth operations.
The Solution
In-Depth Failure Analysis Pinpoints Electrical Overstress (EOS)
White Horse Labs conducted a comprehensive failure analysis to diagnose the issue. Our tests included External Visual Inspection (EVI), X-ray imaging, electrical testing, and cross-section analysis. The results revealed that the resistors were damaged due to burning and melting of the resistance material, which pointed to Electrical Overstress (EOS)—a condition where the resistors were subjected to excessive voltage or current, causing thermal damage.
The Benefit
Improved Production Reliability and Supply Chain Protection
Thanks to White Horse Lab’s precise failure analysis, the customer was able to trace the root cause of the resistor failures. This insight allowed them to prevent further defective components from being used in production, safeguarding the integrity of their supply chain. As a result, they not only resumed smooth operations but also strengthened the overall reliability of their products, protecting their reputation and ensuring future production success.
