Project Details

Reducing product returns with comprehensive product testing.

Working with one of the largest aerospace and defense suppliers, our team appreciates the importance of ensuring the safety and reliability of the products we supply to our customers. That is why Compass Electronics Solutions’ manufacturing team goes beyond ensuring quality to preempt potential defects before they occur. When the customer returned test failures stating there were defective components, our team investigated the root cause. After performing a complete failure analysis we found that a simple design fix could solve the problem and reduce the number of returns dramatically. In addition to replacing defective components, our team preempted issues in future products.


Aerospace and defense products are some of the most technically complex and rigorously tested items on the market today. Components are tested numerous times and at numerous stages in development. This is essential to ensure that the products that make it to market are safe, reliable and meet regulatory standards. As a trusted partner to one of the largest global suppliers of aerospace and defense products, we are used to meeting the stringent testing requirements set by the customer and regulatory bodies.  We utilize comprehensive tests to the board assemblies before sending them to the customer to integrate into their aerospace products. The customer then performs their own functional testing after the board assemblies and other components have been integrated during production.  When we noticed that a specific assembly was being sent back after failing the customer’s functional test, the manufacturing team sought to investigate the source of the problem.


Rather than simply replacing the part and sending the board back to the customer, our manufacturing team decided to determine and fix the root cause of the board issue to reduce product returns. The team first worked with the customer to gather details of their functional test so we could perform a complete failure analysis.

The first step in failure analysis is to recreate the problem and duplicate the customer’s test results. After successfully repeating their process, our manufacturing team investigated all circuits to determine what was causing the diode to fail during the functional test. The team found that the root problem was not a defective part, but a flaw in the design of the product. By slightly altering the product design, the manufacturing team found that the diode no longer failed during the test phase.


The results of the complete failure analysis were presented to the customer.  After verifying that the tests were accurate, the customer initiated the change in design to update their product. Following the product update, our manufacturing team received a verification from the customer that all of the boards being sent were passing their functional test and no further defects were found. Our continued relationship with the customer has helped to perfect to create this and other aerospace and defense products.


This Fortune 500 customer is one of the largest global suppliers of aerospace and defense products worldwide. The company designs, develops and manufactures systems and components for aircraft, UAVs and other military vehicles.


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  • Project Name Complete Failure Analysis