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This Failure Reporting Webex was focused around the first steps you may want to use.
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Copyright 2009 GPAllied©
Failure Reporting, Analysis, Corrective Action System
“FRACAS”Presented by: Ricky Smith, CMRPMarch 9, 2010
Copyright 2009 GPAllied©
Nowlan and Heap Study stated…“…Without a precise definition of what
condition represents a failure, there is no way to assess its consequences or to define the physical evidence for which to inspect. The term failure must, in fact, be given a far more explicit definition than “an inability to function” in order to clarify the basis of Reliability-Centered Maintenance.”
Copyright 2009 GPAllied©
Nowlan and Heap Study further stated…
“…A failure is an unsatisfactory condition. In other words, a failure is an identifiable deviation from the original condition which is unsatisfactory to a particular user.”
Copyright 2009 GPAllied©
What is a Failure?• “A functional failure is the inability of an item
(or the equipment containing it) to meet a specified performance standard and is usually identified by an operator”.
Copyright 2009 GPAllied©
What is a Failure?• “A potential failure is an identifiable physical
condition which indicates a functional failure is imminent and is usually identified by a Maintenance Technician using predictive or quantitative preventive maintenance”
Copyright 2009 GPAllied©
Potential Failures
Copyright 2009 GPAllied©
Functional Failure
Copyright 2009 GPAllied©
Our Goal
Copyright 2009 GPAllied©
Where do you start? With Baby Steps
Begin Measuring MTBF- Of you total operation- By area- By asset
Calculation: Time / Number of Failures
Example: 24 hours / 3 failures = MTBF of 8
Copyright 2009 GPAllied©
How many can Measure MTBF?• Send me your report please
• What are the barriers?
Copyright 2009 GPAllied©
Let’s define Roles and Responsibilities
Tasks Maintenance Supervisors
Maintenance Planner
Maintenance Technician
Maintenance Manager
Reliability Engineer
PdM Technician
Inputting Failure Data -CMMS/EAM
A I R C C
Work Order Close Out
R C R A R R
Validating Failure Data and Codes
C I C A R C
QA of Failure Data Input
I C A R C
Analyze Failure Reports
R I C R A/R R
Making Maintenance StrategyAdjustments
I I I A R C
Responsibility “the Doer”Accountable “the Buck stops hereConsulted “in the Loop”Informed “kept in the picture”
Copyright 2009 GPAllied©
The next step• Define your failure reports (outputs)
– Dominant Failure Pattern?
• Causes of Infant Mortality?– Lack of Lubrication– Bolts not torque to specifications– Electrical connections RTF (run to failure)
Copyright 2009 GPAllied©
Next Steps• Develop a Process which delivers the Report
you want.– Dominant Failure Pattern
Copyright 2009 GPAllied©
Other Reports• % of Assets with No Identifiable Defect
• Failure Rate for Specific ComponentsDrive Belt-Broken-Ageing Failure Rate
0 602.49 1205 1807.5 2410 3012.5 3614.9 4217.4 4819.9 5422.4 6024.9
Time
0
0.00010696
0.00021393
0.00032089
0.00042785
0.00053481
0.00064178
0.00074874
0.0008557
0.00096266
0.0010696
Failu
re Ra
te
Regionalised rate
Distribution rate
P0: 0%
B20: 3492
B15: 3208
B10: 2858
ε: 0.05664
ρ: 0.9781
γ: 0
β: 3.745
η: 5212
Median rank
2-parameterWeibull
Copyright 2009 GPAllied©
Comments“ Like the tortoise - slow and steady wins the
race!”Kim Hunt – Reliability Leader / Domtar
Copyright 2009 GPAllied©
What are your next steps?• ???
Copyright 2009 GPAllied©
Recommendation• Measure MTBF• Educate your leaders and followers
– If you want a private session, let me know• Join me a Reliability 2.0 Conference in April.http://maintenanceconference.com/reliability/
