Failure analysis is very crucial to overall success of any material and engineering business. We have been involved in failure analysis and testing of a wide array of surface coatings during the last one decade. Using systematic investigations, performing failure analysis, and tracking of product failure claims, we have reduced the cost of payouts by over 75% during the last one decade. We have been utilizing myriad of physical, analytical and surface techniques and methods to determine the root cause of failures in the coating industry. In this presentation, we will report recent case studies of failure analysis related to aerospace, automotive, wood and other coatings. Overall, failure analysis is not only providing us the technical inside details of the failure but also helping us in several areas including (i) reducing cost of payments against failed parts, (ii) improve the quality of products, and (iv) increasing customer confidence and satisfaction.