FRACAS – anatomy of a failure

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Describes failure from the initial event through restoration. Discusses the type of data available and how to collect it.

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FRACAS – anatomy of a failure

  1. 1. byJim TaylorCRE, CPE, CPMMDirector of Operations,Machinery Management Solutions, Inc.www.machineryhealthcare.comhttp://blog.machineryhealthcare.comFRACASAnatomy of a failure
  2. 2. If we make an effortand have a plan,we can capture the informationneeded for good failure analysisKey Takeaway
  3. 3. 3 other presentations on this subjectAll available on SlideShare.com
  4. 4. Today Iwant to talkabout howthe failureoccurs andwhat datais availablefor capture.
  5. 5. You work in a small to mediumsize facility or plant.California Cthulhu
  6. 6. You’re a Maintenance professional:an Engineer, a Maintenance Manager,Supervisor, Planner, or Crafts Person.michaelcardus
  7. 7. You’d like to do good failure analyses when youhave an equipment failure but you find you justdon’t have the right information to do it.
  8. 8. The needed information isavailableby Jorge Franganillo
  9. 9. But you must develop a plan tocapture it
  10. 10. Event dataFirst we needto understandhow the eventandrestorationproceeds
  11. 11. A failureoccurs
  12. 12. The operator observes the eventby rachel_titiriga
  13. 13. Operator in initiates trouble call –capture complaint codeby danielfoster437
  14. 14. Craftsperson dispatchedby Mauropm
  15. 15. Craftspersonarrives
  16. 16. She begins troubleshooting
  17. 17. Diagnoses Completecapture failure codeby brendan.wood
  18. 18. CP initiates parts procurementby Iwan Gabovitch
  19. 19. Logisticsdelay
  20. 20. First you have to find the partsby Mackmyra Svensk Whisky AB
  21. 21. Or maybe you have to have themdeliveredzyphbear
  22. 22. Then they must be delivered to themachineby toolstop
  23. 23. Repair &restoration
  24. 24. CP completes repairby Official U.S. Navy Imagery
  25. 25. Capture Repair Code
  26. 26. Test satisfactorily completed
  27. 27. Process satisfactory and stable.
  28. 28. Time dataWhen thevarious eventsoccur isimportantinformation
  29. 29. CaptureEvent time &Responsetimes
  30. 30. Event timeActual time ofevent as recordedby DCS, etc.
  31. 31. Reaction time
  32. 32. Notification time
  33. 33. Response time
  34. 34. Logistics delaytime
  35. 35. Admin & ordering time
  36. 36. Waiting time
  37. 37. Repair&Restorationtimes
  38. 38. Started diagnosis
  39. 39. Completed diagnosis
  40. 40. Started repair
  41. 41. Started test
  42. 42. Back in service
  43. 43. As foundconditionsTry to determinethe equipmentconditionsimmediately beforeand after the failure
  44. 44. EquipmentCondition
  45. 45. Operating conditionsRPMTemperaturesPressuresFlow ratesLevelsEtc.
  46. 46. Product conditionsQualityRateFinishSizeEtc.
  47. 47. CodesComplaint codeAs found codeCause codeFailure codeEffect codeetc.
  48. 48. NarrativeObservations
  49. 49. Interview the OperatorsWhat did they:hearseefeelsmelldofind by Dplanet::
  50. 50. Interview the Crafts PersonsWhat did they:hearseefeelsmelldofind
  51. 51. Interview any others who may haveinformationby DaveFayram
  52. 52. CollectPhysicalEvidence
  53. 53. Broken parts
  54. 54. Damaged productby rileyporter
  55. 55. Any other physical evidencePhotosMeasurementsLeakagePartsEnvironmental conditionsEtc.by U. S. Fish and Wildlife Service - Northeast Region
  56. 56. Will this give us all theinformation we need toperform an effectivefailure analysis?
  57. 57. Lack of good failure analysismeans we’ll continue to looseproductivity and profitabilitybecause we’ll be fighting samefailures over and over.
  58. 58. Develop a plan to capture the rightinformation
  59. 59. With the right information, you can doeffective failure analysis
  60. 60. The key to an effective failureanalysis is having the rightinformation765-366-4285Jim.taylor@machineryhealthcare.comwww.machineryhealthcare.comhttp://blog.machineryhealthcare.com

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