Troubleshooting fatigue

Sunroof frame - warping at sub zero temperatures

Sunroof frame - warping at sub zero temperatures (Troubleshooting by M.TEC)

Test runs at sub-zero temperatures lead to thermal expansion, sunroof no longer closes – simulations reveal unfavourable fibre orientation, relocating the gate position solves problem while the part geometry remains unchanged

Vessel lid – crack at high pressure

Vessel lid – crack at high pressure (Troubleshooting by M.TEC)

Crack in series production component despite high glass-fibre content – simulations reveal unfavourable fibre orientation at local load peak; more stable component geometry determined using structural optimisation while preserving component weight

Blood glucose meter - Display damage during drop test

Blood glucose meter - Display damage during drop test (Troubleshooting by M.TEC)

Damaged corner of the display - multi-body simulation reveals cause, remedy by minor change to a single part (minor tool change)

Fighting fatigue – a design engineering process of its own

During the qualification of components or during the start of series production of manufacturing or production processes, unexpected problems often occur. For sustainable success, it is then usually crucial to understand troubleshooting as a process that should run in an orderly fashion. 

The causes for problems can be manifold:  

  • Component fault 
  • Tolerance problems 
  • Assembly error 
  • Problems in the injection molding process
  • Unsuitable material

Analysis of complex interactions 

Several causes in combination are often responsible for problems in series production start-up. M.TEC engineers are able to analyze complex problems in an orderly troubleshooting process and to eliminate the corresponding causes sustainably. We have made it our goal not only to work on the symptoms, but to get to the core of technical problems and thus to eliminate the problems sustainably. 

„As external, neutral experts, we have often been able to help our customers through our systematic and analytical approach to troubleshooting in order to solve their technical problems at the same time as organizing their internal processes and bringing them to a successful conclusion.“
Wolfgang Pelzer, Managing Director, M.TEC

Procedure in the troubleshooting process

How M.TEC typically proceeds in a troubleshooting process:

  • Problem identification
  • Cause analysis 
  • Revision of the requirements and specifications 
  • Solution-finding under consideration of all requirements 
  • Check of all relevant functions e.g. with simulation and calculation 
  • Tolerance check in a tolerance analysis 
  • Approval for revision


Phoenix Contact

Your contact

Andreas Büttgenbach
Andreas Büttgenbach
Team manager product development
+49 2407 9573-7361
+49 2407 9573-25
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