Failure Reporting Systems
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Failure Reporting Systems Under GJB9001C
Failure Reporting Systems — formally known as FRACAS (Failure Reporting, Analysis, and Corrective Action Systems) — are a mandatory requirement under GJB9001C-2017. GJB9001C Clause 10.2 requires organizations to "establish and operate a product and service failure reporting and corrective action system in accordance with GJB 841."GJB 841-1990 《Fault reporting, analysis and corrective action system》 is the foundational military standard that specifies the general and detailed requirements for establishing and operating a FRACAS. The purpose of FRACAS is "to report product failures in a timely manner, analyze failure causes, formulate and implement effective corrective actions, to prevent recurrence of failures, and to improve reliability and maintainability."
For PCB manufacturers, a failure reporting system is essential for systematically capturing, analyzing, and correcting failures that occur during design, fabrication, assembly, testing, and field use. FRACAS utilizes the principle of "information feedback, closed-loop control" through a set of standardized procedures, ensuring that product failures are reported and corrected in a timely manner, thereby achieving reliability growth and meeting reliability and maintainability requirements. This guide provides a complete implementation roadmap covering the standard requirements, the FRACAS framework and process, PCB-specific applications, and audit preparation.
Engineering Summary
- FRACAS (Failure Reporting, Analysis, and Corrective Action Systems) is a mandatory requirement per GJB9001C Clause 10.2 and GJB 841.
- The purpose of FRACAS is to report product failures in a timely manner, analyze causes, formulate corrective actions, prevent recurrence, and improve reliability and maintainability.
- FRACAS applies to the development, production, and early use phases of military products.
- For PCB manufacturers, FRACAS covers failures in design, fabrication, assembly, testing, and field use.
- Key elements include failure reporting, failure verification, failure analysis, corrective action, and closed-loop management.
- FRACAS is the core tool for achieving "technical" and "management" problem closure — the "Double Five Return to Zero" (双五归零).
- GJB 841A-2024 (effective March 2025) has superseded GJB 841-1990, expanding the scope to "general quality characteristic issues."
1. What Auditors Check — A Quick Overview
| Audit Focus | What External Auditors Verify | Expected Evidence |
|---|---|---|
| FRACAS Establishment | Is a FRACAS established and documented per GJB 841? | FRACAS procedure, system documentation |
| Failure Reporting | Are failures reported in a timely manner with complete information? | Failure reports, report logs, timeliness records |
| Failure Analysis | Is root cause analysis conducted and documented? | Analysis reports, root cause identification records |
| Corrective Action | Are corrective actions implemented and verified effective? | Corrective action plans, verification records, closure reports |
| Closed-Loop Management | Is the FRACAS process a closed loop from reporting through verification? | Closed-loop tracking records, closure evidence |
| Documented Information | Are failure records, analysis, and corrective action records retained? | Documented information, failure files, summary reports |
| Customer Notification | Are quality-related issues and corrective actions reported to customers? | Customer notification records, communication logs |
KEY INSIGHT:
FRACAS is a critical audit focus area. Auditors will verify that a failure reporting system is established per GJB 841, that failures are reported and analyzed systematically, that corrective actions are implemented and verified, and that the system operates as a closed loop. Organizations without a documented FRACAS face significant audit findings.
2. Standard Requirements for Failure Reporting Systems
2.1 GJB9001C Clause 10.2 — Nonconformity and Corrective Action
GJB9001C-2017 Clause 10.2 establishes the foundational requirement for failure reporting systems:
"When product and service serious or major quality issues occur, the organization shall implement technical and managerial problem closure (technical and management 'Return to Zero'). When it is confirmed that the nonconformity is caused by an external provider, the organization shall require the external provider to take correction and corrective action and evaluate the effectiveness of the actions. The organization shall establish and operate a product and service failure reporting and corrective action system in accordance with GJB 841, and shall report quality-related issues concerning the final product and service, as well as corrective actions and their results, to the customer."
2.2 GJB 841 — Failure Reporting, Analysis, and Corrective Action Systems
GJB 841-1990 is the foundational standard for FRACAS. It was issued on March 22, 1990, and implemented on October 1, 1990.The standard:
- Purpose: To report product failures in a timely manner, analyze failure causes, formulate and implement effective corrective actions, to prevent recurrence of failures, and to improve reliability and maintainability
- Scope: Primarily applicable to the development phase of military products, and also applicable to the production phase and early use phase
- Relationship: FRACAS is GJB 450 Work Item 104
- Allowance: General and detailed requirements may be tailored when applying the standard
Note: GJB 841A-2024《General Quality Characteristics Problem Reporting, Analysis and Corrective Action System》was released on January 7, 2025, effective March 1, 2025, superseding GJB 841-1990. The new standard expands the scope from "failure" reporting to "general quality characteristic issues" reporting. Organizations should monitor this transition and plan for implementation of the updated standard.
2.3 GJB 841 — General Requirements
GJB 841 specifies the following general requirements:
- Contractor and Purchaser Responsibilities (3.1): The FRACAS shall be established by the contractor (and subcontractors) as early as possible, with the cooperation of the purchaser (user).The system shall ensure timely reporting, analysis, and correction of failures occurring during development and production phases.
- FRACAS Plan (3.2): The plan shall include procedures for failure reporting, failure analysis, corrective action feedback, flow charts for information transfer and failure handling, tracking and monitoring procedures, and the authority and responsibilities of the failure review board. The plan shall be approved by the purchaser.
- Failure Review Board (3.3): A failure review board shall be established (or an existing organization may perform this function) to review major failures, failure trends, and corrective actions.
- Failure Documentation (3.4): All failures, cause investigations, corrective actions and their effectiveness, and review activities shall be recorded and preserved.
2.4 GJB 841 — Detailed Requirements
The detailed requirements of GJB 841 cover the four core activities of FRACAS:
- Failure Reporting (4.1): All failures occurring in products at the contract-specified level shall be reported in a timely manner.
- Failure Verification (4.2): Reported failures shall be verified against actual conditions.
- Failure Analysis (4.3): Reported failures shall be analyzed to determine root causes.
- Corrective Action (4.4): After root causes are identified, the responsible organization shall formulate corrective actions, prepare documentation, and implement them.
- Failure Report Closure (4.5): Each reported failure shall be analyzed and corrected in a timely manner.
2.5 Relationship to "Double Five Return to Zero"
FRACAS is the core tool for achieving the "Double Five Return to Zero" required by GJB9001C for serious and major quality issues:
- Technical Return to Zero: Five requirements — accurate positioning, clear mechanism, problem reproduction, effective measures, and apply lessons learned
- Management Return to Zero: Five requirements — clear process, clear responsibility, measures implemented, serious handling, and improve regulations
3. FRACAS Framework — The Four Core Activities
FRACAS operates on the principle of "information feedback, closed-loop control" through four core activities.These activities form a continuous cycle that drives reliability growth.
3.1 The FRACAS Cycle
| Activity | Description | PCB Example |
|---|---|---|
| Failure Reporting | Timely reporting of failures with complete information — includes failure identification, conditions, and observations | Report impedance failure on PCB assembly from incoming inspection; document lot number, test conditions, and measurements |
| Failure Verification | Verify reported failures against actual conditions — confirm that the failure exists and is accurately described | Re-test failed PCB to confirm impedance out of specification; verify test setup and measurement accuracy |
| Failure Analysis | Determine root cause through systematic investigation — use 5 Whys, fishbone, or other structured methods | Conduct root cause analysis: identify that trace width variation during etching caused impedance deviation |
| Corrective Action & Verification | Formulate, implement, and verify corrective actions — document effectiveness and close the loop | Adjust etching process parameters; re-test subsequent batches; verify impedance within specification; close FRACAS item |
3.2 FRACAS Stakeholder Roles
GJB 841 defines the following stakeholder roles:
| Role | Responsibilities |
|---|---|
| Contractor | Establish FRACAS early; ensure timely reporting, analysis, and correction of failures; maintain failure documentation; implement corrective actions |
| Subcontractor | Summarize failure information from development and production phases; report to contractor's information system |
| Purchaser/User | Provide timely failure information feedback to FRACAS; participate in failure review board |
| Failure Review Board | Review major failures, failure trends, and corrective actions; composed of design, production, reliability, maintainability, safety, and quality representatives |
3.3 Failure Review Board Responsibilities
The failure review board has the following authorities and responsibilities:
- Regularly review failure information from development and production phases, including subcontractor and purchaser feedback
- Analyze and review failure trends and corrective action effectiveness
- Conduct timely analysis of major failures, frequent failures, and failures of reliability-critical and important components, and propose corrective recommendations
- Require subcontractors to investigate failures and review their corrective actions
- Investigate unresolved issues and propose recommendations; report to higher authorities when necessary
4. FRACAS Implementation Process — A Step-by-Step Approach
Implementing FRACAS requires a systematic approach that establishes the system, defines procedures, and ensures closed-loop operation.
4.1 The Implementation Process — Nine Steps
| Step | Activity | PCB Example |
|---|---|---|
| 1 | Establish FRACAS Plan — Develop a documented FRACAS plan per GJB 841 requirements. Define reporting procedures, analysis methods, corrective action processes, and tracking mechanisms. Obtain purchaser approval. | Document PCB FRACAS procedure; define failure report form, analysis methods (5 Whys), corrective action workflow, and tracking system; submit to customer for approval. |
| 2 | Establish Failure Review Board — Form a failure review board with representatives from design, production, reliability, quality, and other relevant functions. Include customer representatives when appropriate. | Form PCB FRACAS review board: Design Engineer, Process Engineer, Quality Manager, Reliability Engineer, and customer representative. |
| 3 | Define Failure Reporting Requirements — Specify what failures must be reported, reporting formats, and reporting timelines. Include failures from development, production, and early use phases. | Define PCB failure reporting: all impedance failures, soldering defects, and material nonconformances must be reported within 24 hours using standardized FRACAS form. |
| 4 | Implement Failure Reporting — When failures occur, report them in a timely manner. Capture all required information: failure identification, conditions, observations, and environment. | Report PCB impedance failure: document batch number, test conditions, measured values, and operator observations. |
| 5 | Conduct Failure Verification — Verify reported failures against actual conditions. Confirm the failure exists and is accurately described. | Verify PCB impedance failure: re-test using calibrated equipment; confirm impedance out of specification. |
| 6 | Perform Failure Analysis — Conduct systematic root cause analysis using 5 Whys, fishbone, or other structured methods. Document analysis findings. | Conduct root cause analysis: identify etching process parameter drift causing trace width variation; document findings. |
| 7 | Formulate Corrective Actions — Develop corrective actions to address root causes. Prepare documentation and obtain approval. | Develop corrective action: adjust etching parameters, implement daily process monitoring, and retrain operators; document and obtain approval. |
| 8 | Implement and Verify Corrective Actions — Execute corrective actions and verify effectiveness through re-test or analysis. Document verification results. | Implement etching process changes; re-test subsequent batches; verify impedance within specification; document results. |
| 9 | Close and Document — Close the FRACAS item after corrective action is verified effective. Retain all documentation. Report to customer as required. | Close FRACAS item; file all documentation; report corrective action and results to customer. |
4.2 FRACAS Documentation Requirements
GJB 841 requires the following documentation:
- Failure Report : Initial documentation of the failure with complete description and conditions
- Failure Analysis Report : Documentation of root cause analysis findings and conclusions
- Corrective Action Implementation Report : Documentation of corrective actions taken and verification results
- Failure Summary or Status Report : Periodic summary of failure status, trends, and corrective action status
5. PCB-Specific FRACAS Scenarios — Practical Examples
5.1 PCB Fabrication Failure — Impedance Nonconformance
| FRACAS Element | Description |
|---|---|
| Failure Report | Impedance out of specification (target 50Ω ±5%, measured 45Ω) on PCB lot #PCB-2026-045 during incoming inspection |
| Failure Verification | Re-test on calibrated equipment confirmed impedance values below specification; repeated on multiple samples |
| Root Cause Analysis (5 Whys) | Why? → Trace width too wide. Why? → Etching process under-etched. Why? → Etching solution concentration too low. Why? → Bath monitoring frequency insufficient. Why? → Process control plan incomplete — no daily bath testing |
| Corrective Action | Implement daily etching solution concentration testing; update process control plan; retrain operators; adjust etching parameters |
| Verification | Subsequent batch re-tested — impedance within specification (49.8Ω - 50.2Ω); 3 consecutive batches confirmed |
| Closure | FRACAS closed; documentation archived; customer notified; process control plan updated |
5.2 PCBA Assembly Failure — Solder Joint Defect
| FRACAS Element | Description |
|---|---|
| Failure Report | Solder joint voids (X-ray inspection) on BGA components in PCBA assembly #A-2026-089 during final inspection |
| Failure Verification | X-ray re-inspection confirmed voids > 25% of joint area per IPC-A-610 Class 3 criteria |
| Root Cause Analysis (Fishbone) | Methods: Reflow profile ramp rate too fast; Materials: Solder paste expired; Machines: Reflow oven temperature sensors out of calibration |
| Corrective Action | Calibrate reflow oven sensors; revise reflow profile; implement solder paste expiration monitoring; retrain operators |
| Verification | Next two production batches X-ray inspected — zero voids; soldering quality meets Class 3 requirements |
| Closure | FRACAS closed; documentation archived; process updates implemented; customer notified |
5.3 FRACAS Failure Report Form — Required Fields
| Field | Description | PCB Example |
|---|---|---|
| Report Number | Unique identifier for tracking | FRACAS-2026-045 |
| Failure Item Identification | Product/part identification | PCB Assembly #A-2026-089, Lot #PCB-2026-045 |
| Failure Description | Detailed description of failure | Impedance out of specification — 45Ω vs. 50Ω ±5% |
| Test Conditions | Environmental and test conditions | 25°C, 50% RH, TDR measurement at 1GHz |
| BIT/BIST Indication | Built-in test indications (if applicable) | N/A |
| Operating Time at Failure | Product operating time when failure occurred | 0 hours (incoming inspection) |
| Observer | Person who observed the failure | Zhang Wei, Quality Inspector |
| Environmental Conditions | Environmental conditions at time of failure | Standard laboratory conditions |
6. Key Control Points in PCB FRACAS Management
6.1 FRACAS Establishment and Planning
- Establish FRACAS as early as possible in the product lifecycle
- Document FRACAS plan with reporting, analysis, and corrective action procedures
- Obtain purchaser approval of the FRACAS plan
- Establish failure review board with appropriate representation
6.2 Failure Reporting
- Report all failures in a timely manner — including development, production, and early use phases
- Use standardized failure report forms with all required fields
- Include identification of failed item, failure description, test conditions, and environmental conditions
- Ensure failure reports are accurate and complete
6.3 Failure Analysis
- Verify all reported failures
- Conduct root cause analysis using structured methodologies (5 Whys, fishbone, etc.)
- Investigate failures from the appropriate hardware or software level
- Document analysis findings and conclusions
6.4 Corrective Action
- Formulate corrective actions by the responsible organization
- Follow engineering change procedures for corrective actions
- Implement corrective actions and verify effectiveness
- Close FRACAS items only after verification of effectiveness
6.5 Documentation and Records
- Record and preserve all failures, cause investigations, corrective actions, and review activities
- Maintain failure reports, analysis reports, and corrective action implementation reports
- Prepare failure summary or status reports periodically
- Report quality issues and corrective actions to customers
6.6 Customer and Subcontractor Integration
- Ensure subcontractors report failure information to the contractor's information system
- Provide timely failure information feedback from the purchaser
- Report final product quality issues and corrective actions to customers
- Include customer representatives in the failure review board as appropriate
7. Audit Preparation Checklist for PCB Manufacturers
| # | Check Item | Clause/Standard | Status | Notes |
|---|---|---|---|---|
| FRACAS Establishment | ||||
| 1 | FRACAS is established and documented per GJB 841 | 10.2 | ☐ | |
| 2 | FRACAS plan is documented and approved by purchaser | GJB 841 3.2 | ☐ | |
| 3 | Failure review board is established and functioning | GJB 841 3.3 | ☐ | |
| Failure Reporting | ||||
| 4 | Failures are reported in a timely manner | GJB 841 4.1 | ☐ | |
| 5 | Failure reports are complete and accurate | GJB 841 4.1 | ☐ | |
| Failure Analysis | ||||
| 6 | Failure verification is conducted | GJB 841 4.2 | ☐ | |
| 7 | Root cause analysis is conducted and documented | GJB 841 4.3 | ☐ | |
| Corrective Action | ||||
| 8 | Corrective actions are formulated and implemented | GJB 841 4.4 | ☐ | |
| 9 | Corrective action effectiveness is verified | 10.2 | ☐ | |
| Closed-Loop Management | ||||
| 10 | FRACAS items are closed only after verification | GJB 841 4.5 | ☐ | |
| 11 | Closed-loop tracking is maintained | GJB 841 | ☐ | |
| Documentation | ||||
| 12 | Failure reports, analysis reports, and corrective action records are retained | GJB 841 3.4 | ☐ | |
| 13 | Failure summary or status reports are prepared | GJB 841 3.4 | ☐ | |
| Customer Notification | ||||
| 14 | Quality issues and corrective actions are reported to customers | 10.2 | ☐ | |
| 15 | Customer notification records are retained | 10.2 | ☐ | |
8. Common Audit Findings and How to Avoid Them
| Finding | Why It Happens | How to Avoid |
|---|---|---|
| "No FRACAS established" | FRACAS not recognized as mandatory requirement | Establish FRACAS per GJB 841; document plan and obtain approval |
| "Failures not reported in a timely manner" | Reporting delays or informal handling | Implement timely reporting procedures; monitor report timeliness |
| "No root cause analysis" | Failures addressed without identifying root causes | Require root cause analysis using structured methodologies |
| "Corrective actions not verified" | Actions implemented but effectiveness not confirmed | Verify corrective action effectiveness before closure |
| "FRACAS not closed loop" | Items opened but never closed or tracked | Maintain closed-loop tracking; close items only after verification |
| "No failure documentation" | Records not retained or incomplete | Maintain complete failure files; retain all documentation |
| "Customer not notified" | Quality issues not communicated to customers | Report quality issues and corrective actions to customers |
| "No failure review board" | Review board not established or not functioning | Establish failure review board; hold regular meetings |
9. Frequently Asked Questions
What is FRACAS under GJB9001C?
FRACAS (Failure Reporting, Analysis, and Corrective Action Systems) is a mandatory requirement under GJB9001C Clause 10.2. It is a closed-loop system for reporting product failures, analyzing causes, formulating corrective actions, and preventing recurrence.
What is the purpose of FRACAS?
The purpose of FRACAS is "to report product failures in a timely manner, analyze failure causes, formulate and implement effective corrective actions, to prevent recurrence of failures, and to improve reliability and maintainability."
What does GJB 841 require?
GJB 841-1990 specifies the general and detailed requirements for establishing a FRACAS. It covers failure reporting, failure verification, failure analysis, corrective action, and closed-loop management. The standard applies to the development, production, and early use phases of military products.
What is the relationship between FRACAS and "Double Five Return to Zero"?
FRACAS is the core tool for achieving the "Double Five Return to Zero" required by GJB9001C for serious and major quality issues. It supports both technical return to zero and management return to zero.
When should FRACAS be established?
FRACAS should be established by the contractor (and subcontractors) as early as possible in the product lifecycle, with the cooperation of the purchaser.
What is the failure review board?
The failure review board is responsible for reviewing major failures, failure trends, and corrective actions. It is composed of representatives from design, production, reliability, maintainability, safety, and quality assurance.
What documentation is required for FRACAS?
Required documentation includes: failure reports, failure analysis reports, corrective action implementation reports, and failure summary or status reports. All failures, cause investigations, corrective actions, and review activities shall be recorded and preserved.
What is the status of GJB 841A-2024?
GJB 841A-2024《General Quality Characteristics Problem Reporting, Analysis and Corrective Action System》was released on January 7, 2025, and became effective on March 1, 2025, superseding GJB 841-1990. The new standard expands the scope from "failure" reporting to "general quality characteristic issues" reporting. Organizations should monitor this transition and plan for implementation of the updated standard.
Related Standards & Topics
PCB and PCBA Manufacturing for Military and Aerospace Programs
UltroNiu Electronics Group provides PCB and PCBA manufacturing services with GJB9001C-compliant failure reporting and corrective action systems (FRACAS). Contact our engineering team for program-specific FRACAS requirements and compliance support.
Request Engineering ReviewReferences: GJB9001C-2017 Clause 10.2 (Central Military Commission Equipment Development Department); GJB 841-1990 Failure Reporting, Analysis, and Corrective Action Systems; GJB 841A-2024 General Quality Characteristic Issue Reporting, Analysis, and Corrective Action Systems; GJB 450-2008 Equipment Reliability Work General Requirements. FRACAS definition and purpose sourced from GJB 841-1990 and GJB 450. General requirements (3.1-3.4) and detailed requirements (4.1-4.5) sourced from GJB 841-1990. "Double Five Return to Zero" requirements sourced from GJB9001C-2017 Clause 10.2 implementation guidance. PCB-specific FRACAS practices based on industry best practices for military and aerospace PCB manufacturing. Courtesy of UltroNiu Engineering Knowledge Center.
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