The bottom line? A happy customer. And isn’t that what we want?I thank you for your attention. The invitation from GlobalSpec to do this short course, and their support in producing it was much appreciated.
The key to improving your availability is fracas
The Key to Improving Your Availability is FRACAS by Jim Taylor CRE, CPE, CPMM Director of Operations, Machinery Management Solutions, Inc. www.machineryhealthcare.com http://blog.machineryhealthcare.com
Key Takeaway:Effective root cause elimination can be done by the average maintenance professional michaelcardus
To keep track of it all, you need a system. AFailure Reporting, Analysis, andCorrective Action System (FRACAS). English106
First, You must capture as muchinformation about FSI the Event as you Failure can. Scene Investigation
You must capture the details of the Event inenough detail to do effective failure analysis. As found condition Failed components Operating parameters Sequence of events Fluid levels Signs of over temperature or pressure
You must capture the timeline of the Event in order to reconstruct the event. T0 – time of event T1 – time of trouble report T2 – maintenance on scene T3 – trouble shooting complete, parts ordered T4 – parts on site T5 – repairs complete T6 – test complete T7 – system back on line
The data you capture must be stored in a way to make analysis as easy as possible.
We need themCapture the event to calculate times and metrics such as: forensics data. MTBF MTTR MLDT
Use your DCS/SCADA/PLC to capture times, parameters, production information.
The operator & craftsman must becomplete and accurate in their assessment and narrative of the event.
Do you like to write? Nether do I. Neither do our operators & craftsmen. So we have to teachthem to write in a simple, declarative sentences.
Simple declarative sentencesDeclarative sentences are used toconvey information or to makestatements: David plays the piano. I hope you can come tomorrow. Weve forgotten the milk. This declarative sentence is spoken by Don Corleone (played by Marlon Brando) in the movie The Godfather (1972).
Make data collection asautomatic & easy as possible. A walk in the park.
PDA’s, tablet’s, etc. are cheap.Strongly consider digital work orders
You can use drop downs, radio buttons,pick lists, etc. to make it easy to collect specific categories of data.
Don’t allow work order closeout until all information is complete!
Second: Conducta Failure Analysis to find the real reason for the event.
• Kepner-Tregoe • 5 Whys • Cause Mapping • Apollo RCAThere are many • Fault Tree Analysis available • Success Tree Analysis techniques. • Failure Modes, Effects and Criticality Analysis • Management Oversight & Risk Tree (MORT) • …
You can use the RCM decisiontree to decide on the correct procedure.
As you can see, the decision tree is biased towards Condition Assessment.Will the failure havea direct and adverse No effect on safety or environment? Will the failure have a Yes direct and adverse No Yes effect on operations (quantity or quality)? Will the failure result in other economic loss Yes (high cost damage to Is there an effective No machines or system)? Condition Monitoring No atetechnology/approach? Yes Is there an effective No ndid - Ca or Preventive F 3tree.vsd Maintenance task? YesDevelop & schedule Develop & schedule Redesign systemCondition Monitoring PM task. or accept risk. Run-to-Fail task.
You may find redesign is best option in some cases.Will the failure havea direct and adverse No effect on safety or environment? Will the failure have a Yes direct and adverse No Yes effect on operations (quantity or quality)? Will the failure result in other economic loss Yes (high cost damage to Is there an effective No machines or system)? Condition Monitoring No atetechnology/approach? Yes Is there an effective No ndid - Ca or Preventive F 3tree.vsd Maintenance task? YesDevelop & schedule Develop & schedule Redesign systemCondition Monitoring PM task. or accept risk. Run-to-Fail task.
Make sure theprocedure is both effective and Effective applicable. and Applicable
An Applicable procedureactually improves the situation.
An Effective procedurecosts less to do the procedure than to suffer the failure.
Develop acorrective action plan in enough detail to enable effective application.
The Job plan should have step by step actions.
You now have a Job Plan that should eithereliminate the cause of the failures or give you enough lead time to manage the failure.
We started with a piece of equipment that was causing problems.
We did a Root Cause Analysis to find out what was causing the problems.
Then we developed an Action Plan to eliminate the cause.
We now must put that Plan into action and track the results.
If we do this effectively, we should see an increase in Ao and a decrease in costs. Goal Avoided AvoidedManaged Surprise Managed Surprise
Key Takeaway:You can perform this kind of analysis. theakshay.
Do it and you’ll eliminate most failures, and you’ll have a happy customer. Muffet
Your Next Step (Homework)Within the next week pick a recent Event:Collect as much information about the Event as you can.Interview the operators and the craftsmen. Look at the replacedand/or the broken parts. Record the details on a computer(Excel).Perform a RCFA.Develop a way to manage that failure using RCM principles.Write and implement a Job Plan to correct the problem.Give me a call if you have questions or want help.
Questions? Comments? Jim Taylor CRE, CPE, CPMM Director of Operations,Machinery Management Solutions, Inc. www.machineryhealthcare.com http://blog.machineryhealthcare.com 765-366-4285
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