KPI Users Group- Failure Reports, Session 2_Dec09 Ajc[1]

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Copyright 2005 Allied Services Group

KPI Users GroupKPI Users GroupKPI Users GroupKPI Users Group

“Failure Reports“Failure Reports””Session 2Session 2

Copyright Copyright 2009 2009 GPGPAlliedAllied

Presented by: Ricky Smith CMRPDecember 16, 2009

“It Isn’t What You Know That Will Kill You, It Is What You Don’t Know That Will”


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The PF Curve – Objective: Identify “P” as Early as Possible


The I-PF Curve – Objective: To Eliminate Causes of Failures at Point “I”


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What Do You Need to Know About Failures?

• What equipment is giving me the biggest losses and why?

• What component is failing the most and why?• What component is failing the most and why?

• Where should you focus your RCA efforts?

• Frequency of a failure mode – decrease?

“Part”: Bearing – 27x


“Defect”: Misalignment

“Cause”: No Alignment Specs

What Is Root Cause Analysis (RCA)?

• It’s a systematic, analytical work process that:– Alters manufacturing work environment to focus on

eliminating defects rather than repairing failuresg p g

– Engages operations workforce to incrementally and continuously improve plant and business performance

– Enhances connections between operations improvements and technologies

– Increases safety environmental performance and


– Increases safety , environmental performance and business profits

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• Proactive– Performed on processes and systems prior to a

failure

What Is Root Cause Analysis (RCA)?

– Looks to identify actions that will prevent specific undesirable conditions or situations from ever happening

– When performed on equipment (versus processes and systems), it’s called Reliability-Centered Maintenance (RCM)


Maintenance (RCM)

• Reactive– A failure or incident has occurred in a process, a

t hi

What Is Root Cause Failure Analysis (RCFA)?

system or a machine

– In the case of chronic problems, many similar failures have occurred

– Looks to identify the causes and implement solutions that will prevent, or at least reduce, recurrences


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Why Do RCA?

• To Eliminate Defects– Any undesirable condition

• Defects in manufacturing processes• Defects in manufacturing processes create:– Underperforming machines

– Broken machines

– Operations bottlenecks

– Frustration


ust at o

– Lower morale

Why Do RCA?, cont’d

• Defects lead to:– Lost production opportunities

– Product wasteProduct waste

– Lower revenues

– Injuries

– Environmental incidents


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6 Sources Of Defects

• Defects Come into Processes from 6 Sources1. Equipment operation

2 Equipment design2. Equipment design

3. Spare/Repair parts

4. Maintenance workmanship

5. Marginal (sub-optimal) equipment

6. Raw materials


Three Common Causes

1. Not Measuring the Right Thing

2. RCAs are executed on the “problem of the day”day

3. RCA results are not implemented


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Not Measuring the Right Thing

• What is the value of the RCA?

• Did you achieve the expected results from RCA?RCA?– MTBF

– Rework

– Defect elimination


RCAs are Executed on the “Problem of the Day”


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Triggers

• There are at least 5 key areas for consideration when deciding to use RCA– Safety (an incident or a trend)Safety (an incident or a trend)

– Environmental (an incident or trend)

– Manufacturing (yields, throughput, availability, etc.)

– Cost (unit cost, overshot budget, etc.)

– Customer satisfaction (quality, delivery, value, etc.)

– Other?


Reactive or Proactive Triggers

• Triggers can be either proactive or reactive

• Proactive triggers might include• Proactive triggers might include responding to leading indicators or conducting FMEAs


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Reactive Triggers

• Reactive triggers can show up in metrics such as: – Personnel metricsPersonnel metrics

• Recordable injury rate exceeds a predefined target

• Lost workday injury

– Environmental metrics• Environmental incident score exceeds a target number

– Production metrics• Availability throughput or yields fall below target


• Availability, throughput or yields fall below target

• Planning or scheduling effectiveness is below goal

• A significant downtime incident occurs

Proactive Triggers

• Leading indicators– Investigate minor injuries to uncover

underlying dangerous behavior patternsy g g p

– Document and investigate ‘near misses’

– Monitor and respond to trends in equipment availability, throughput and yields

– Monitor and respond to trends in % emergency work, schedule compliance or rework rate


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Proactive Triggers, cont’d

• Conduct FMEAs– Determine the effects of “hidden” chronic

equipment failuresq p

– Identify and prevent what could go wrong but hasn’t yet


RCA Results Not Implemented

• Changes to Maintenance Strategy?

• Changes to Operating Strategy?

Training?• Training?

• Procedures?

Why is it so hard?


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Simple Steps to Success

1. Establish quantifiable triggers • Potential Loss of production throughput at a cost $100,000 –

$1,000,000

– One Reliability Engineer to lead effort, Predictive Maintenance Technician, Maintenance Technician, Operator, and others as needed

• Potential Loss of throughput at a cost $1,000,000 – $5,000,000

– Two Reliability Engineers, Predictive Maintenance Technician, two Maintenance Technicians, Operator or Operators as needed


• Potential Loss of production throughput at a cost $5,000,000 plus

– Two Senior Reliability Engineers Fulltime, Predictive Maintenance Expert (possibly a consultant), RCM Expert (possibly a consultant)

Triggers

• There are at least 5 key areas for consideration when deciding to use RCA– Safety (an incident or a trend)Safety (an incident or a trend)

– Environmental (an incident or trend)

– Manufacturing (yields, throughput, availability, etc.)

– Cost (unit cost, overshot budget, etc.)

– Customer satisfaction (quality, delivery, value, etc.)

– Other?


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Ensuring Success?

2. Defining roles and responsibilities in the

Root Cause Analysis Process


Develop a Tracking System

• Develop Leading Indicators – Execute RCA before a failure occurs

• Ensure measuring success of RCA• Ensure measuring success of RCA


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Questions?


Documents

KPI Users Group- Failure Reports, Session 2_Dec09 Ajc[1]