22/09/2025
Reliability Case Study: Turning Structured Problem Solving into Race Winning Performance
Success on track begins long before the lights go out. In preparation for the latest race weekend, the team applied a structured reliability engineering approach to address recurring technical issues that had previously limited performance. A full inspection of the car identified inconsistencies in both the fuel and water-methanol injection systems. Using a root cause analysis methodology, the team discovered that the ethanol-petrol fuel mix was degrading system components when left standing after race weekends, and that the water-methanol mixture caused sediment build-up if not properly flushed. Corrective actions included redesigning the fuel system with braided piping, installing an adjustable racing fuel regulator, and programming a dual fuel map to allow safe running on pump fuel between events. In parallel, new maintenance tactics were introduced, requiring both the fuel and water-methanol systems to be drained and flushed after each event.
These interventions delivered immediate results: stable fuel pressure above 5 bar under full load, consistently low intake temperatures below 25°C, and a highly reliable power unit across all sessions. The car went on to perform faultlessly, securing back to-back wins from pole position, with best laps of 1:10.9 and 1:10.8 respectively.
The key lesson was clear: focusing on root causes rather than symptoms transforms reliability into performance. By combining engineering discipline with meticulous preparation, the team unlocked the car’s full potential. Going forward, the recommendation is to embed this structured approach into every preparation cycle, ensuring consistency, preventing repeat failures, and keeping the team competitive at the front of the grid.
Special thanks to Verlen Racing for technical support, Marie Brits for the endless encouragement, and Pragma for their continued sponsorship and belief in engineering excellence driving race-winning outcomes.
