KPI Users Group - Failure Reports


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At the end of the year or month what reports would you like to see from your CMMS/EAM? Would you like a few failure reports? Check out this presentation. It may make your day.

KPI Users Group - Failure Reports

  1. 1. KPI Users Group “Failure Reports” Presented by: Ricky Smith CMRP November 30, 2009 Copyright 2009 GPAllied©
  2. 2. “It isn’t what you know that will kill you, It is what you don’t know that will” Copyright 2009 GPAllied©
  3. 3. The PF Curve – Objective: Identify “P” as Early as possible Copyright 2009 GPAllied©
  4. 4. The I-PF Curve – Objective: To Eliminate the Causes of Failures at Point “I” Copyright 2009 GPAllied©
  5. 5. 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? Copyright 2009 GPAllied©
  6. 6. 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 Copyright 2009 GPAllied©
  7. 7. 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 Copyright 2009 GPAllied©
  8. 8. 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 Copyright 2009 GPAllied©
  9. 9. 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) Copyright 2009 GPAllied©
  10. 10. 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” Copyright 2009 GPAllied©
  11. 11. Where do we start? 1st Step Copyright 2009 GPAllied©
  12. 12. 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. Copyright 2009 GPAllied©
  13. 13. A Managed System For Continuous Improvement for Asset Reliability Copyright 2009 GPAllied©
  14. 14. “A picture is worth a thousand words” - Napoleon Bonaparte Copyright 2009 GPAllied©
  15. 15. The Objective of Failure Reports • Identify root cause of frequent failures • Identify common threads between failures • Identify dominant failure patterns • Identify true bad actors • Plus many other reports FRACAS: A Managed System For Continuous Improvement Copyright 2009 GPAllied©
  16. 16. Simple Steps: Reports? • Identify the failure codes from failure modes of your equipment, not from a laundry list on the web Copyright 2009 GPAllied©
  17. 17. Simple Steps: Reports? • 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 68% 6% Infant Mortality Copyright 2009 GPAllied©
  18. 18. Simple Steps: Reports? • 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” Copyright 2009 GPAllied©
  19. 19. Root Cause Analysis Definition of insanity: “Doing the same thing over and over again and expecting a different result” Copyright 2009 GPAllied©
  20. 20. Simple Steps: Reports? • Changing how you prevent or predict specific failures • Making adjustments to your Maintenance Strategy • Making changes to your Equipment Criticality Ranking Copyright 2009 GPAllied©
  21. 21. 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 Copyright 2009 GPAllied©
  22. 22. Where do we start? “just a reminder” Copyright 2009 GPAllied©
  23. 23. 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 Copyright 2009 GPAllied©
  24. 24. 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 Copyright 2009 GPAllied©
  25. 25. Questions / Comments 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. Copyright 2009 GPAllied©