Using Early Field Failure Analysis (EFFA) to Prevent Product Disasters

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February 27, 2025 • 42 mins

In episode 259 of the podcast, host Adrian welcomes back special guest Andrew Amirnovin, a reliability expert, to explore Early Field Failure Analysis (EFFA) and why it's essential for manufacturers aiming to avoid costly recalls and reputation damage. They share real-world examples of what happens when EFFA is neglected—including major recalls from Tesla, Volkswagen, and Firestone.

Tune in to learn how to implement an effective EFFA program, reduce risk, and ensure product reliability before small issues snowball into catastrophic failures.

Show Sections

[00:00] Introduction & Guest Welcome
[01:20] What is Early Field Failure Analysis (EFFA)?
[06:45] Why EFFA Matters in Mass Production
[12:30] Implementing an Effective EFFA Program
[22:00] Real-World Case Study: Tesla’s Power Steering Recall
[27:00] Firestone & Ford Tire Failure Disaster
[31:45] Volkswagen Dieselgate: A Different Kind of Failure
[36:20] The Hidden Costs of Neglecting EFFA
[39:00] Key Takeaways & Final Advice

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.css-14f5ked{margin:0;word-break:break-word;display:-webkit-box;-webkit-box-orient:vertical;box-orient:vertical;-webkit-line-clamp:2;overflow:hidden;}Using Early Field Failure Analysis (EFFA) to Prevent Product Disasters