Failure Mapping

A New and Powerful Tool for Improving Reliability and Maintenance

Failure Mapping
A New and Powerful Tool for Improving Reliability and Maintenance

Daniel T. Daley


Note: There is no ebook version of this title.



Designed to be easy to read and perfect for busy people who have little time, unique Failure Mapping provides an introduction to the new concept of failure mapping by comparing typical functions in an organization which benefits from failure mapping to one without. Through examples it shows how individuals in different roles can have their effectiveness enhanced by having access to historical failure maps describing past failures.


While few of the individual concepts are new, the approach described ties established concepts together in a new and comprehensive manner. This resource describes the process used to create failure maps that connect malfunction reports (function - behavior) with failure modes (component - condition) to help users clearly understand the most likely final disposition based only on the initial report and the statistics produced by historical experience.


Failure Mapping is sure to be found useful by novice feliability engineers, maintenance and reliability managers, engineering managers, plant and corporate senior staff and executives looking for ways to enhance performance, and consultants who may want to enrich their portfolio by adding this tool.



  • Describes issues that are particularly important to creating Failure Maps that record failure histories in a manner that the records will be useful in the future.
  • Explains how Failure Maps can be used to improve reliability by identifying Failure Mechanisms while at work.
  • Details how Failure Maps can be used to improve reliability by identifying Defects before failures can occur.
  • Describes how Failure Maps can be used to increase the effectiveness of the diagnostic and troubleshooting process as a part of any help desk activity.
  • Explains how to use Failure Mapping as a tool to improve the effectiveness of "triage" as a part of failure response in high volume activities.
  • Includes several forms found useful in recording Failure Maps and creating reports.
  • Provides readers with tools needed to enhance and set up their own Failure Mapping program.
  • Offers both new and more experienced plant and shop personnel with a tool they can use to develop a consistent understanding of Failure Mapping, the roles in a Failure Mapping organization and the steps in implementing a Failure Mapping process.

Daniel T. Daley is from Omaha Nebraska and grew up in what was the packing house district of South Omaha. He attended the University of Nebraska and graduated in 1971 with a BS degree in Mechanical Engineering and a commission in the US Air Force. After serving a tour as an Air Force officer (in Selma Alabama and Osan Korea), he returned to school at the University of Missouri, Columbia. There he received a MS in Mechanical Engineering.


His career began with Shell Oil Company where he held a variety of positions in engineering, maintenance and operations, including Director of Maintenance and Reliability for several companies including Shell, OxyChem, Valero, and the Union Pacific railroad. He retired from the Union Pacific railroad, where he was the Director of Locomotive Engineering and Quality. He currently is providing consulting services through his company My Reliability Team, based on his books. Services in support of applying the concepts described in these books are available from My Reliability Team (


  • Introduction
  • Patterns and Relationships
  • The Path to Failure
  • Examples of Failure Mapping and Their Application
  • Naturally Occurring Elements that can be Enhanced by Failure Mapping
  • Structured Assessment
  • Characteristics Evaluated During a Failure Mapping Assessment
  • Assembling a Failure Mapping Process
  • Conclusion
  • Appendix
  • References for Further Reading
  • Index