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Root Causes Failure Analysis

by CHANDY OT on Nov 26, 2009

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Root Causes Failure Analysis — Presentation Transcript

Ot Chan Dy TPM Team Leader

Simple and discipline process used to investigate, rectify and eliminate equipment failure

Most effective when directed @ chronic breakdown/problem

It take you beyond just “why it is break”… It tell you what weakness in your management system

Reduction of chronic problem

Increase MTBF (Mean Time Between Failure)

Improve product quality & regulatory compliance

Better sensitive to machine problem

Less NVA work and admin

Fulfillment ISO system “Corrective Action”

Very inexpensive way to save money for company

Overall maintenance cost down: maintenance staffs can do more through proper planning and scheduling, rather than reactive

Investment on spear part down: save on carrying cost

Biggest saving: increase asset utilisation

Mostly, 80% of plant’s losses are represent by 20%

Of failure events. This is call “Significant few”

Priority for RCFA

Define a failure mode

Information of failure

Organization of analysis team

Actual analysis

Sharing the finding & making recommendations

Tracking result

Problem must be very specific, i.e:

Bearing rusted NOT bearing damaged

Beer under fill on filling head 16 NOT beer under fill

Always got “not close” alarm signal on valve v.0123 NOT alarm signal on valve v.0123

Engineering Report

Technical Drawing (if available)

Failure history

Damaged parts

Standards and specifications

Principal analyst – team leader: choose the one who no background in the problem but highly skill methodology and facilitate the process rather than guide team to a preconceived conclusion

Process control leader

Operator involve

Maintenance engineers, highly knowledge in the system and process

Go to the spot: place where failure happen

Touch/Examine objects

Check Fact & Figure (speak with data)

2 Questions ask repeatedly (use logic tree)

How can that happen?

Why did it happen?

Example of logic tree

Circuit Breaker Overloaded of Motor Screw Conveyor Current Intensity > 2.1A Motor Conveyor take load > 2.5 t/hr Motor coupling Failure Motor itself Failure Gear Reduction Failure

4 M categories => Root Causes => Solutions (objectively)

Re-occurrence follow up table

Out of your area of control or responsibility

Knowledge limited

Man (does not want to do it)

All causes at the root of the problem have been identified

Series of effective countermeasures have been implemented

No re-occurrences

Jump to conclusion

Attack symptoms not the causes

Not gathering enough evidences.

Problem is too large or general

Not involve relevant persons

Root Causes Failure Analysis

by CHANDY OT on Nov 26, 2009

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Root Causes Failure Analysis — Presentation Transcript