Root-Cause Isolation via Bidirectional Traceability in Industrial Automation
A manufacturer of industrial Variable Frequency Drives (VFDs) and power control modules produces high-voltage power conversion units for water treatment facilities and automated factory floors. Each drive undergoes rigorous end-of-line electrical testing before field installation.
Run on Anvaya · Traceability & Product Data
The challenge
A field failure is reported for an installed VFD (Serial # VFD-9021-X) that suffered a thermal power stage breakdown after 100 hours of operation.
Quality engineers must quickly determine whether the failure was caused by shop-floor assembly error, incorrect test parameters, or a defective vendor component lot.
Legacy traceability is strictly unidirectional; finding whether other active WIP jobs contain components from the same suspect batch requires opening hundreds of physical job jackets.
How Anvaya solves it
Backward Serial Traceability
Quality engineers input Serial # VFD-9021-X into Anvaya Bidirectional Traceability. The system instantly traces backward from the failed unit to identify the exact power MOSFET lot (Lot # MOSFET-441-A) used during assembly.
Vendor Defect Correlation
Cross-referencing component test data confirms Lot # MOSFET-441-A contains a latent silicon gate defect from the semiconductor vendor.
Forward Traceability to Active WIP
With a single click, engineers switch from backward to forward tracing starting from Lot # MOSFET-441-A. Anvaya instantly searches all active shop-floor work orders.
Inline WIP Identification
Anvaya flags three active production orders currently on the assembly line that contain MOSFETs from the identical defective batch.
Immediate Floor Containment
Quality supervisors halt the affected WIP orders directly from the platform, sending inline rework instructions to operator workstations before the drives undergo final potting and box- build.
The outcome
- investigation time from field failure report to root-cause
- 0 daysinvestigation time from field failure report to root-cause
- manufacturer submits an indisputable, data-backed warranty
- 0%manufacturer submits an indisputable, data-backed warranty
Investigation time from field failure report to root-cause isolation drops from 5 days to 20 minutes.
48 defective VFD units currently in production are intercepted and reworked before shipping to customer sites.
The manufacturer submits an indisputable, data-backed warranty claim to the semiconductor vendor, recovering 100% of material rework costs.
Representative scenario: a modelled industry situation showing how this accelerator applies. Figures are projections, not a named client result.
Capabilities used
Every accelerator is assembled from the same capability layer, so a workflow you adopt here shares its foundation with the rest of the portfolio.
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