the key to improving your availability is fracas
DESCRIPTION
A broad description of the major steps in a FRACAS for existing equipment.TRANSCRIPT
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by Jim Taylor
CRE, CPE, CPMM
Director of Operations, Machinery Management Solutions, Inc.
www.machineryhealthcare.comhttp://blog.machineryhealthcare.com
The Key to Improving Your Availability is FRACAS
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Key Takeaway: Effective root cause elimination can be done by
the average maintenance professional
michaelcardus
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You work in a facility or plant.
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You’re a Maintenance professional: A Crafts Person, a Planner, a Supervisor, a
Maintenance Manager, or an Engineer.
theakshay.
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Low availability and repeat failures on your equipment is affecting your production and
customer service.
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You want to find and eliminate these failures.
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To keep track of it all, you need a
system.
A Failure Reporting,
Analysis, and Corrective Action
System (FRACAS).
English106
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First, You must capture as much
information about the Event as you
can.
FSIFailure Scene
Investigation
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You must capture the details of the Event in enough detail to do effective failure analysis.
As found condition
Failed components
Operating parameters
Sequence of events
Fluid levels
Signs of over temperature or pressure
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You must capture the timeline of the Event in order to reconstruct the event.
T0 – time of eventT1 – time of trouble reportT2 – maintenance on sceneT3 – trouble shooting complete, parts orderedT4 – parts on siteT5 – repairs completeT6 – test completeT7 – system back on line
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The data you capture must be stored in a way to make analysis as easy as possible.
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Capture the event times and
forensics data.
We need them to calculate metrics such
as:
MTBF
MTTR
MLDT
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Use your DCS/SCADA/PLC to capture times, parameters, production information.
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Collect forensic data for later analysis.
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In the case of manual entry, you must hold people accountable!
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Capture it in a usable format.
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The operator & craftsman must be complete and accurate in their assessment
and narrative of the event.
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Do you like to write? Nether do I. Neither do our operators & craftsmen. So we have to teach
them to write in a simple, declarative sentences.
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Simple declarative sentences
Declarative sentences are used to convey information or to make statements:
David plays the piano. I hope you can come tomorrow. We've forgotten the milk.
This declarative sentence is spoken by Don Corleone (played by Marlon Brando) in the movie The Godfather (1972).
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Make data collection as
automatic & easy as possible.
A walk in the park.
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PDA’s, tablet’s, etc. are cheap. Strongly consider digital work orders
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You can use drop downs, radio buttons, pick lists, etc. to make it easy to collect
specific categories of data.
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Don’t allow work order closeout until all information is complete!
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Second: Conduct a Failure Analysis
to find the real reason for the
event.
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Your Primary Objective
Prevention, Not Blame!
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There are many available
techniques.
• Kepner-Tregoe
• 5 Whys
• Cause Mapping
• Apollo RCA
• Fault Tree Analysis
• Success Tree Analysis
• Failure Modes, Effects and
Criticality Analysis
• Management Oversight & Risk
Tree (MORT)• …
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A simple method
5 Whys
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A complex one
Fault Tree Analysis
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There is not usually one single
cause
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Types of Causes
Fire in paint tank
Ignition source
Oxygen in air
Lacquer (Flammable)
(Required by process?)
(yes)
(no)
(yes)
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Action and Condition causes
Fire in paint tank
Craftsperson drops non-
safe wrench.
Oxygen in air
Lacquer (Flammable)
(Condition)
(Action)
(Condition)
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Don’t stop too soon
Why was craftsperson using a non-safe wrench?
Is oxygen really required by the process?
Is a water-based lacquer required?
…
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Try to use two techniques to
confirm
Cause mapping
And/Or
Fault tree
And/Or
Kepner-Tregoe
And/Or
…
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I like back of the envelope calculations to make sure I’m talking reality.
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Third: develop a corrective action
plan.
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You can use the RCM decision
tree to decide on the correct procedure.
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As you can see, the decision tree is biased towards Condition Assessment.
Develop & scheduleCondition Monitoring
task.Develop & schedule
PM task.Redesign system
or accept risk. Run-to-Fail
Will the failure havea direct and adverseeffect on safety or
environment?Will the failure have a
direct and adverseeffect on operations(quantity or quality)?
Will the failure result inother economic loss(high cost damage tomachines or system)?Is there an effective
Condition Monitoringtechnology/approach?
Is there an effectivePreventive
Maintenance task?
No
No
No
No
No
Yes
YesYes
Yes
Yes
3tre
e.vs
dCandidate
For -
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You may find redesign is best option in some cases.
Develop & scheduleCondition Monitoring
task.Develop & schedule
PM task.Redesign system
or accept risk. Run-to-Fail
Will the failure havea direct and adverseeffect on safety or
environment?Will the failure have a
direct and adverseeffect on operations(quantity or quality)?
Will the failure result inother economic loss(high cost damage tomachines or system)?Is there an effective
Condition Monitoringtechnology/approach?
Is there an effectivePreventive
Maintenance task?
No
No
No
No
No
Yes
YesYes
Yes
Yes
3tre
e.vs
dCandidate
For -
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Make sure the procedure is both
effective and applicable.
Effective
and
Applicable
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An Applicable procedure
actually improves the situation.
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An Effective procedure
costs less to do the procedure
than to suffer the failure.
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Develop a corrective action plan in enough detail to enable
effective application.
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The Job plan should have step by step actions.
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You now have a Job Plan that should either eliminate the cause of the failures or give you
enough lead time to manage the failure.
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Forth: Implement a system of
accountability
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SMART Objective
S)pecificM)easurableA)cheviableR)ealisticT)ime limited
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Individual responsibility and authority
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Include on agenda of the weekly planning meeting
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So what has our FRACAS
accomplished
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We started with a piece of equipment that was causing problems.
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We did a Root Cause Analysis to find out what was causing the problems.
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Then we developed an Action Plan to eliminate the cause.
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We now must put that Plan into action and track the results.
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If we do this effectively, we should see an increase in Ao and a decrease in costs.
Goal
Managed
Avoided
Surprise Managed
Avoided
Surprise
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Key Takeaway:You can perform this kind of analysis.
theakshay.
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Do it and you’ll eliminate most failures, and you’ll have a happy customer.
Muffet
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Within the next week pick a recent Event:
Collect as much information about the Event as you can. Interview the operators and the craftsmen. Look at the replaced and/or the broken parts. Record the details on a computer (Excel).Perform a RCFA. Develop a way to manage that failure using RCM principles. Write and implement a Job Plan to correct the problem.
Give me a call if you have questions or want help.
Your Next Step (Homework)
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Questions?Comments?
Jim TaylorCRE, CPE, CPMM
Director of Operations, Machinery Management Solutions, Inc.
www.machineryhealthcare.comhttp://blog.machineryhealthcare.com
765-366-4285