Have you ever encountered seemingly random failures of your fielded products? No failure is random, but it takes a fundamental understanding of materials to understand it. For many products the root cause failure is a complex interplay between material structure, processing, and environment. This presentation will first discuss common errors that design engineers make during the material selection process. This will include considering the environment the material experiences throughout its lifecycle, as well as material property deviations from technical data sheet values. Next, a depiction of the interplay between material structure, processing, and environment will be used to illustrate examples of the complexity of fielded product failures. Finally, the strategies that were implemented to fix the real-world failures and manufacture a more robust product will be discussed.