Engineering products go through 4 stages of lifecycle; design, production, use, and disposal. Engineers have developed tools for avoiding design flaws that cause troubles in the later stages. Accidents and malfunctions, however, still happen and some are even catastrophic. Once in the market, products require service. Whether scheduled, or unexpected, service is mostly carried out by subsidiaries of the manufacturer or sometimes unrelated specialists. When product troubles occur, service companies tend to seek solutions within their own organization without going back to the design stage. This approach may prove less costly, however, quick fixes may lead to disasters. Industries currently lack effective ways of feeding service information back to design. We analyzed some real accidents that took place in Japan where hard work in the use stage triggered the events. Information from the use stage to design will prevent accidents and also improve design to closely model reality.

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