Engine Failure Investigation and Analysis C1344

Topics: Powertrain & Propulsion

Engine failures can occur in a variety of equipment, vehicles, and applications. On occasion, a single vehicle type or equipment family will even experience multiple engine failures leading to the inevitable need to determine what the most likely cause of one or all of those failures was. This comprehensive seminar introduces participants to the methods and techniques used to understand the types of variables and inputs that can affect engine reliability and then determine the most likely cause of an individual engine or group of engine failures in the field.

The seminar begins with a discussion of customer expectations and experiences and how any disconnect between the two can affect the customer\'s overall perception of an engine\'s performance and reliability. The seminar then focuses on the concepts of uncertainty and deterministic design, what is a failure, and how a combination of factors from design inputs to supplier variability can affect the reliability of all or just a portion of an engine population. This is followed by a review of the investigative process and analytical methods required to arrive at an objective and thoroughly developed conclusion as to the nature and cause of the failures at issue. The seminar finishes with a review of case studies that involve customer related issues and failures arising due to a variety of inputs including design, manufacturing, duty cycle, and maintenance.

Learning Objectives

By attending this seminar, you will be able to:

  • Analyze engine failure claim narratives and how they relate to the customer experience
  • Explain the concept of uncertainty and how it relates to failures and complaints attributed to an engine system
  • Analyze and interpret engine and/or vehicle warranty data
  • Reconcile the physical evidence with the narrative and warranty evidence
  • Determine the most likely cause of engine failure based on the available evidence
  • Reconcile any disconnect between customer expectations and experience and determine what if any corrective actions are required

Who Should Attend

This course has been developed for engineers and technical professionals in all fields related to the investigation, analysis, and root cause determination of engine failures in various types of vehicles and equipment used in both on-road and of- road applications. In addition, this course can be valuable to individuals involved with handling and processing customer warranty and insurance claims for engine related issues.

Individuals directly involved in the investigation of engine failure and failure related issues will benefit most from this material. Please note that this course is not intended to provide an in depth discussion of individual component failure modes within the engine. The focus of the course is to understand the fundamental types and sources of inputs that contribute to engine failures and the process and methods used to identify them and determine what, if any, type of corrective actions should be implemented.


  • Professional technical certification or 2 year technical degree is highly recommended
  • Bachelors degree in Mechanical Engineering is recommended
  • A basic knowledge of and familiarity with engine operation, design, and vehicle installations is required
  • A basic knowledge of vehicle operational environments and duty cycles is recommended

You must complete all course contact hours and successfully pass the learning assessment to obtain CEUs.

  • The Customer Experience
    • Expectations
    • Perceptions
    • Experiences
    • Metrics
  • Uncertainty in Design and Development
    • Design
    • Development
    • Design Entropy
  • Engine Characteristics
    • Creation
    • Components
    • Production
    • Integration
  • Contributing Factors
    • Contributors
    • Inputs
    • Controlling Uncertainties
  • Investigative Process
    • Goals
    • Evidence
    • Collecting Information
  • Analytical Method
    • Analysis Steps
    • Population Identification
    • Analysis Methods
  • Selected Case Studies
    • Competing Requirements
    • Oil Consumption
    • Customer Maintenance
    • Engine Integration & Duty Cycle
    • Development Quirks
Robert Kuhn

Mr. Kuhn currently manages a technical consultancy for a variety of clients including automotive OEM\'s and their Tier suppliers. His experience includes single failures, multiple failures, class action suits, and individual engine operational and reliability issues. Prior to becoming a consultant, Mr. Kuhn worked for both Ford and Chrysler in a variety of positions that included engine testing and development, fleet testing of prototype engines, vehicle chassis and engine packaging, and overall vehicle platform development including engine systems. He holds a B.S. in Mechanical Engineering from Carnegie Mellon University and an M.S. in Automotive Systems Engineering from the University of Michigan Dearborn and is also a licensed Professional Engineer in the State of Michigan.

Duration: 2 Days
CEUs: 1.3

Fees: $1299.00

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