fracas, failure reporting analysis, corrective action system

Slide 1

Copyright 2009 GPAllied


F.R.A.C.A.S.Failure Reporting, Analysis andCorrective Action SystemPresented by: Andy Page


Phone is Listen OnlyDuring the Webinar.email questions to

[email protected]


F.R.A.C.A.S. Webinar ObjectivesWhat is it?How do you use the results?How do you set it up?Biggest ChallengesSummary and Wrap up


Definitionfracas: n. A noisy, disorderly fight or quarrel; a brawl

F.R.A.C.A.S. A system for recording the nature of equipment failures, analyzing the data for patterns and making business decisions based on the conclusions drawn from the data

Predominantly talking about CMMS Failure Codes and how they can be used.Also, talking about the other failure characteristics Mean Time to RepairWork Request Sources


What do you want to know?# of Failures(56)#2 Press(30)Drive Motor(15)Bearings(13)(12)FatigueMisalignment


This is not a coincidence!Failure ModesC



Failure Mode - DefinitionPartBearing

DefectFatigued

ReasonMisalignment


PartThe level at which work is performed

Examples:BearingBreakerShaft


DefectNot just the ModeWornNot descriptive enough

Has to include Failure MechanismWhen the mechanism is descriptiveKnowing the mechanism might change the countermeasure (task)Example: Adhesive Wear versus Abrasive Wear


ReasonDescribes the action or condition that was physically responsible for the problemExample: Improper Installation

NOT another failureCannot reference another failure mode as the reason why this failure mode is presentThese are called Secondary EffectsExample: Bearing Abrasive Wear Seal Failed


For Reasonhow deep do I go?Bearing DefectEffectPhysical CauseHuman CauseSystemic CauseLatent Cause



*We only need a few codesWhat we expected(Failure Modes)What we recorded(Failure Codes)


Real World ExampleFailure ModesBearing Fatigued AgeBearing Fatigued ImbalanceBearing Fatigued MisalignmentBearing Abrasive Wear ContaminantsBearing Adhesive Wear - AgeFailure CodesPump - StoppedPump - Making NoisePump - Not PumpingShaft Seized



Work Order History Report# of Failures(56)#2 Press(30)Drive Motor(15)Bearings(13)(12)FatigueMisalignment


This is what you are looking forContains the Failure ModeIndependent of Equipment TypeShows the BIG pictureWhat would be the Corrective Action?

# of InstancesFailure Code78Misalignment Improper Assembly56Bearing Fatigue Misalignment32Loose Connections Improper Assembly22Soft Foot Improper Assembly8Abrasive Wear Improper Lube Procedure1Turn-to-Turn Short Background Vibration


LEAN TerminologyYokoten (push to the side)

Take what you have learned on this machine and apply it to other like machines

FRACASIf it has happened to this machinehow many other machines has it happened to as well?Even more importantlyHow many other machines is it about to happen to?



Nowwe go deepBearing DefectEffectPhysical CauseHuman CauseSystemic CauseLatent Cause


2 Un-pardonables for Reliability EngineersTo fix the same problem twiceThis really means you never FIXED it the first time.You most likely addressed the Symptom and not the Problem

To know a problem is coming and not be prepared to deal with it efficiently Run-to-Fail is a perfectly valid strategy for some thingsBut to not be ready is unpardonableJob Plans on FileReady access to spare parts



Strategy AdjustmentsChanging the Equipment Maintenance PlanDifferent PM TaskDifferent Inspection TaskDifferent FrequencyDifferent Operating Philosophy70% of failures come from improper operation30% of failures come from improper/inadequate maintenance


Biggest ChallengesCrafts personnel or Supervision wont always know the Part - Defect Reason in the fieldIf they simply Remove & ReplaceFRACAS will never happenSomeone has to be responsible to perform the failure analysis and get that data into the CMMS

For a while, you will constantly find that you need a Failure Code that is not in the systemThis means that you Failure Modes Library isnt complete yet


Implementation Plan Part 1Start Small & Take It SlowCritical Equipment Only (Top 20%)Let work processes mature around the new requirements

Trigger for next levelAll Work Orders = Closing CodesTake the next 20%

Work your way up to 100%


Implementation Plan Part 2Define your work control processes

Assign Goals, Roles and ResponsibilitiesIndividual responsibilities for data entry and analysis can be anyonesjust make sure it is officially assigned

Institute a system for checking complianceA system for addressing non-compliance


Implementation Plan Part 3Identify the Top 20% of your equipmentIdentify Failure ModesPopulate CMMS with Failure CodesClose Each Work Order for Critical EquipmentOn Scheduled Basisrun analysis reportsAnalyze whole plant or areasNot much deeperNot by equipment typesFocus too smallyoull miss the big patterns


SummaryPowerful method for making the organization a learning organizationLearn from mistakes

A different way of thinking about failure analysisNo longer is itwhich MACHINE is giving us troubleIt is nowwhat are our dominant issues across the plant


Summary - continuedEverybody wants the benefits of FRACAS but few people are willing to put forth the effort to Feed the BeastNot willing to put the work control processes in place to make it a realityNot willing to hold people accountable for non-compliance

*****How do determine if your team shares a common vision?

Brainstorm at least 3 indicators that the team shares a common vision.***

fracas, failure reporting analysis, corrective action system

Technology

work control

failure mode

common vision

team shares

drive motor

copyright

work

system