Crustbreaker kaizen & sfmea

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Crustbreaker SFMEA

SFMEA

Simplified Failure Mode

Effects Analysis

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An Optimal Approach

Condition

Old

Definition

of Failure

There is a Science to defining

> The Right Work

> At the Right Time

Time

Detectable

Change in

Condition Intervention Window

P

Potential

Failure

Large Business

Consequences!

Too Much, Too EarlyF

Functionally Failed

or Equipment not

performing intended

function

New definition

of failure

Too Little, Too Late

CO

ST

S

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HelixPLAN

Idea Generation – General Rules

For all ideas that come to mind, print them on cards.

• 1 idea per card, but no limit on the number of ideas (cards).

• Don’t judge you ideas. Be freewheeling in your thinking.

• Go for lots of ideas.

• Make sure your statement has a verb. This improves clarity.

• Try to express each idea in 7 words or less.

– More than 7 words usually means you are trying to express multiple ideas on one card.

– Watch out for ANDs & ORs (2 ideas).

– Use the black flip-chart marker pen to print your ideas.

PLEASE PRINT

LARGE BLOCK

LETTERS LIKE

THIS.

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Note the Asset (green card) column headings.

Please print up any component failures you have that fit under any of the assets. (Note the components listed for each asset on the hierarchy handout)

One Failure per card. Failures Based On Past History or Potential

Once you have printed your first three ideas, go and post them under the appropriate column(s).

• Read what others have posted. This may stimulate additional ideas, and it may save you from duplicating ideas already posted.

• Print up three more ideas.

• Post them.

• Read what others have posted.

• Continue until you have no more ideas.

WHAT ARE THE FUNCTIONAL FAILURES OF CRUSTBREAKER

COMPONENTS?

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What are the frequency and duration of each of these

functional failures?

Print the frequency and duration of each failure on the Green cards posted

under the peach failure card.

• Read what others have written

• If someone has written a frequency &/or duration that you do not

agree with, print your opinion under theirs

• Continue under there is a frequency and duration listed under every

failure in each column

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What actions would eliminate or lesson the downtime

due to these functional failures?

Note the potential actions listed on violet cards and on the next slide.

• Print the alphabetical heading of the appropriate action or actions

on the Green cards posted to the right of the corresponding failure

mode.

• Review each failure mode for the actions posted and add any you

believe may have been missed.

• Continue under there is an action listed for every failure mode

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Possible Actions to Eliminate or

Lesson Downtime:

A. Add to Operator Checklist

B. Add to PM

C. Add to Critical Parts List

D. Adjust Stores Quantity

E. Replace on Timed Basis

F. Do Oil Analysis

G. Do Vibration Analysis

H. Do Infrared Inspection

I. Possible Modification

J. Training Needed

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To what extent ...

You have one rating dot (vote) for each item.

Rate each item using the following scale:

5 = Definitely

4 = To a large extent

3 = To some extent

2 = Only slightly

1 = Not at all

Each item should receive exactly 1 vote.

5 4 3 2 1

Item 1

Item 2

Item 3

Item 4

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