KPI Users Group - Failure Reports

Copyright 2009 GPAlliedCopyright 2009 GPAllied©©

KPI Users GroupKPI Users Group

““Failure ReportsFailure Reports””

Presented by: Ricky Smith CMRP

November 30, 2009


“It isn’t what you know that will kill you, It is

what you don’t know that will”


The PF Curve – Objective:

Identify “P” as Early as possible


The I-PF Curve – Objective:

To Eliminate the Causes of Failures at Point “I”


Risk to the Business

What does a complete plant shutdown cost?

What does a shutdown of a production line or area cost?

What does a system shutdown cost?

What does a component failure cost?


What is it you want to know about Failures?

• What equipment is giving me the biggest losses 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


Key Points to Know!

• If you are managing to “P” on the PF Curve you get rid

of most of your catastrophic or total function failure

• If you are managing to “I”, your are managing the

causes of failures and thus eliminate failures and

optimize reliability

• The best person to identify the “Defect or Problem” and

“Cause” of the failure is your Predictive Maintenance

Technician


Why?

• Why would the Predictive Maintenance Technician be

the best person to identify the cause of a failure?

– Because when a catastrophic failure occurs (most of the

time) the true root cause is very difficult to identify

Example: Catastrophic Bearing Failure


KPI Users Group Questionnaire

1. What is your number one report for tracking and identifying failures in your organization?

– Downtime– Severity of defect– Failure Codes Report (equipment level)

2. What metric or report do you use to identify your bad actors?• 2 failures in 6 month• Pareto – downtime to a component – 8 weeks• Pareto – MTBF of assets

3. What trigger do you use for an RCA to be executed?• $200,000 or greater• 4hrs of downtime or 40 tons of product loss• 1 hr of downtime

4. Can you identify the most frequent failure mode in your organization for a specific component or asset? (example: component – bearing, asset: Hydraulic System)


What is the Cause of a component failure?

• Not enough time to repair equipment back to standard?

• Not enough people to perform all the work?

• Not knowing when a failure will occur?

• Not having skilled workers?

• Not having effective work procedures?

• Not having an effective PM program?

• Not having an effective PdM Program?

• No standards or specifications followed?

• Very little results from Root Cause Analysis?

“Do not accept excuses, just viable solutions”


Where do we start?

1st Step


Wikipedia Defines…

• FRACAS is a system, sometimes carried out using

software, that provides a process for reporting,

classifying, and analyzing failures, and planning

corrective actions in response to those failures.


A Managed System For Continuous

Improvement for Asset Reliability


“A picture is worth a thousand words”

- Napoleon Bonaparte


The Objective of Failure Reports

FRACAS: A Managed System For Continuous Improvement

• Identify root cause of frequent failures

• Identify common threads between failures

• Identify dominant failure patterns

• Identify true bad actors

• Plus many other reports


Simple Steps: Reports?

• Identify the failure codes from failure modes of your

equipment, not from a laundry list on the web



• Part Code plus Failure Code plus Cause Code exposes problems (part > problem (or defect) > reason)

• Bad Actors Report

– Most Cost plus

– Most Failures plus

– Most frequency

• Bad Actors Report

– Repeat Component Failures

on different equipment

with same failure code

• Dominant Failure Pattern Exposed

Infant Mortality

68% �� 6%



• Elimination of the same failure cause on multiple

equipment (focused on true root cause)

• Reduction of dominant failure pattern by attacking

causes of failures

• “Spending time

on the right thing at

the right time”


Root Cause Analysis

Definition of insanity:

“Doing the same thing over and over again and

expecting a different result”



• Changing how you prevent or predict specific failures

• Making adjustments to your Maintenance Strategy

• Making changes to your Equipment Criticality Ranking


Simple Steps – The Objective of Failure Reports

• To identify where you have most losses, location of losses, dollars, labor hours,

• To identify the most dominant failure mode and eliminate / control it

• To identify the most dominant failure pattern across an organization

• To identify where your PM or Predictive Maintenance program is effective is if not where to make changes

• To identify where Root Cause Analysis will make the most impact


Where do we start? “just a reminder”


Steps to Success• More training and education for your staff

– Proactive Maintenance

– Failure Reports

– FRACAS

– RACI Models

– Facilitation

• Develop a model for the reports you want

– Use your staff to assist working as team• Maintenance Techs - Facilitator• Reliability Engineers• Planner• Maintenance Supervisor

• Develop a plan of action with timelines

• Develop a RACI Chart for all tasks

• Execute


Challenge

• Who is willing to accept the challenge?

• Develop a model for the reports you want

• Develop a plan of action with timelines

• Develop a RACI Chart for all tasks


Questions / Comments

[email protected]

If you are interested in joining the

KPI Users Group

Send an email to the above address.

We meet monthly for one hour on the web.

Documents

KPI Users Group - Failure Reports