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R-TRIZ on Telescoping Rail Failures

Howard C Cooper
Design for Reliability Engineer
General Dynamics Land System

Since 2003, occasional failure of a very expensive and mission critical ammunition handling system would fail. Over multiple failures the root cause always “boiled down” to the same one of eight “stops” on a telescoping rail support assembly. Yet, the same position “stop” on the opposite rail, serving the very same function was not failing, nor were any of the other seven “stops” on these two identical telescoping rails failing. Across 150 identical weapon systems in field test, when the failure would occur it was always the same stop, in that same right-hand mid-rail position. The left-hand rail never failed.

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