Lost production of 44 hours and $2.4M in costs was caused by a bearing failure in the central processor's wet end. The bearing failed due to lack of lubrication after the grease was washed out by water entering through the worn labyrinth seal. This was caused by water pressure falling below minimum levels due to other production demands overloading the water supply's limited capacity.
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completely new product- smart coating, durable, environmental friendly, safe and easy using, protect your glass from limescale and keep self-clean over 1 year!
uality is one of the most important management principles for any organization regardless of industry. This is particularly true for the pharmaceutical sector: maintaining quality product standards is essential for the prevention and treatment of numerous medical disorders.
Although the pharmaceutical industry has been around for centuries, in recent years we have experienced an increase in the number of drugs being launched in the market. As a result of this increase, the need for quality assurance and quality control measures has risen. For instance, drug manufacturers must follow strict guidelines to get their drugs approved by the FDA (Food and Drug Administration) in the United States. Such guidelines include requirements for testing, manufacturing, labelling, packaging, storing and distributing pharmaceuticals.
Quality Management
Quality management is a crucial component of any successful organization as it ensures that products and services are produced and distributed consistently and effectively.
Good Manufacturing Practice (GMP) is the element of quality management that ensures goods are produced and controlled according to the quality standards of their intended use and that they meet the requirements specified by the marketing authorization or product specification. Additionally, it ensures that manufactured goods are safe, of high quality, and effective. For pharmaceutical companies, GMP entails the monitoring of procedures, apparatuses, employees, and environments.
Quality planning, quality control, and quality assurance are all important aspects of quality management too. We’ll look at what quality management is, why it’s important, and the main components and principles of quality management in this article.
Quality planning
Quality planning refers to the process of defining the quality requirements and standards of a product or service and identifying the resources needed to meet such requirements and standards. The planning phase is the first stage in establishing a good quality management system. It is in this phase that companies define their baseline quality objectives. Once goals have been set, organizations must determine what is required to achieve these objectives and what procedures should be implemented to ensure their success. During this stage of the quality management process, it is important to keep in mind the following considerations:
The organization’s definition of success
How often procedures and processes will be evaluated for improvement
If the stakeholders have any quality-related priorities, goals, or ambitions
If there are any legal procedures or standards that must be followed in order to achieve the desired quality level
Quality Control
Quality control is the next step in the quality management process. At this stage, companies assess through physical inspection and testing whether their plan is achievable.
This presentation was given at the EPA’s National Water Event 2019, which took place on 29 and 30 May 2019 in Galway. This presentation by Michael Goss from Irish Water is on addressing the challenges related to wastewater networks.
An investigation into the cause of loss of containment from the supply of min...Turlough Guerin GAICD FGIA
An Intermediate Bulk Container (IBC) was punctured during its handling, releasing oil onto soil at an environmentally-sensitive region of Australia. The telehandler did not pierce the plastic of the IBC directly (as was expected) but rather one of the tynes had caught on the underside of the metal base plate, despite numerous controls being in place at time of spill, revealing a previously unreported mechanism for a fluid spill from handling of petroleum hydrocarbons. The diverse investigation team used a root cause analysis (RCA) technique to identify the underlying cause: the inspection process was inadequate with contributing
factors of not using a spotter and design of IBC did not anticipate conditions. Engineering controls were put in place as part of the change management process to help prevent spills
from occurring from piercing from telehandler tynes on the current project site.
Eliminating Critical Quality Defects at a Component ManufacturerAnirban Mazumdar
An engagement where our team could help the client improve quality performance significantly within a short period. On some critical components, Zero Defect conditions were also achieved. Use of right tools, some creative techniques like Generation-Defect analysis and effective implementation of countermeasures was the key to success.
Ami Adini & Associates - Southern California Environmental Firmamiadini.
This presentation explores about CA based Ami Adini & Associates specialized in environmental site assessments and remediation and the design and construction of petroleum and chemical UST facilities.
uality is one of the most important management principles for any organization regardless of industry. This is particularly true for the pharmaceutical sector: maintaining quality product standards is essential for the prevention and treatment of numerous medical disorders.
Although the pharmaceutical industry has been around for centuries, in recent years we have experienced an increase in the number of drugs being launched in the market. As a result of this increase, the need for quality assurance and quality control measures has risen. For instance, drug manufacturers must follow strict guidelines to get their drugs approved by the FDA (Food and Drug Administration) in the United States. Such guidelines include requirements for testing, manufacturing, labelling, packaging, storing and distributing pharmaceuticals.
Quality Management
Quality management is a crucial component of any successful organization as it ensures that products and services are produced and distributed consistently and effectively.
Good Manufacturing Practice (GMP) is the element of quality management that ensures goods are produced and controlled according to the quality standards of their intended use and that they meet the requirements specified by the marketing authorization or product specification. Additionally, it ensures that manufactured goods are safe, of high quality, and effective. For pharmaceutical companies, GMP entails the monitoring of procedures, apparatuses, employees, and environments.
Quality planning, quality control, and quality assurance are all important aspects of quality management too. We’ll look at what quality management is, why it’s important, and the main components and principles of quality management in this article.
Quality planning
Quality planning refers to the process of defining the quality requirements and standards of a product or service and identifying the resources needed to meet such requirements and standards. The planning phase is the first stage in establishing a good quality management system. It is in this phase that companies define their baseline quality objectives. Once goals have been set, organizations must determine what is required to achieve these objectives and what procedures should be implemented to ensure their success. During this stage of the quality management process, it is important to keep in mind the following considerations:
The organization’s definition of success
How often procedures and processes will be evaluated for improvement
If the stakeholders have any quality-related priorities, goals, or ambitions
If there are any legal procedures or standards that must be followed in order to achieve the desired quality level
Quality Control
Quality control is the next step in the quality management process. At this stage, companies assess through physical inspection and testing whether their plan is achievable.
This presentation was given at the EPA’s National Water Event 2019, which took place on 29 and 30 May 2019 in Galway. This presentation by Michael Goss from Irish Water is on addressing the challenges related to wastewater networks.
An investigation into the cause of loss of containment from the supply of min...Turlough Guerin GAICD FGIA
An Intermediate Bulk Container (IBC) was punctured during its handling, releasing oil onto soil at an environmentally-sensitive region of Australia. The telehandler did not pierce the plastic of the IBC directly (as was expected) but rather one of the tynes had caught on the underside of the metal base plate, despite numerous controls being in place at time of spill, revealing a previously unreported mechanism for a fluid spill from handling of petroleum hydrocarbons. The diverse investigation team used a root cause analysis (RCA) technique to identify the underlying cause: the inspection process was inadequate with contributing
factors of not using a spotter and design of IBC did not anticipate conditions. Engineering controls were put in place as part of the change management process to help prevent spills
from occurring from piercing from telehandler tynes on the current project site.
Eliminating Critical Quality Defects at a Component ManufacturerAnirban Mazumdar
An engagement where our team could help the client improve quality performance significantly within a short period. On some critical components, Zero Defect conditions were also achieved. Use of right tools, some creative techniques like Generation-Defect analysis and effective implementation of countermeasures was the key to success.
Ami Adini & Associates - Southern California Environmental Firmamiadini.
This presentation explores about CA based Ami Adini & Associates specialized in environmental site assessments and remediation and the design and construction of petroleum and chemical UST facilities.
Similar to 292089 rca report---mining-lost-production (20)
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Empowering the Data Analytics Ecosystem: A Laser Focus on Value
The data analytics ecosystem thrives when every component functions at its peak, unlocking the true potential of data. Here's a laser focus on key areas for an empowered ecosystem:
1. Democratize Access, Not Data:
Granular Access Controls: Provide users with self-service tools tailored to their specific needs, preventing data overload and misuse.
Data Catalogs: Implement robust data catalogs for easy discovery and understanding of available data sources.
2. Foster Collaboration with Clear Roles:
Data Mesh Architecture: Break down data silos by creating a distributed data ownership model with clear ownership and responsibilities.
Collaborative Workspaces: Utilize interactive platforms where data scientists, analysts, and domain experts can work seamlessly together.
3. Leverage Advanced Analytics Strategically:
AI-powered Automation: Automate repetitive tasks like data cleaning and feature engineering, freeing up data talent for higher-level analysis.
Right-Tool Selection: Strategically choose the most effective advanced analytics techniques (e.g., AI, ML) based on specific business problems.
4. Prioritize Data Quality with Automation:
Automated Data Validation: Implement automated data quality checks to identify and rectify errors at the source, minimizing downstream issues.
Data Lineage Tracking: Track the flow of data throughout the ecosystem, ensuring transparency and facilitating root cause analysis for errors.
5. Cultivate a Data-Driven Mindset:
Metrics-Driven Performance Management: Align KPIs and performance metrics with data-driven insights to ensure actionable decision making.
Data Storytelling Workshops: Equip stakeholders with the skills to translate complex data findings into compelling narratives that drive action.
Benefits of a Precise Ecosystem:
Sharpened Focus: Precise access and clear roles ensure everyone works with the most relevant data, maximizing efficiency.
Actionable Insights: Strategic analytics and automated quality checks lead to more reliable and actionable data insights.
Continuous Improvement: Data-driven performance management fosters a culture of learning and continuous improvement.
Sustainable Growth: Empowered by data, organizations can make informed decisions to drive sustainable growth and innovation.
By focusing on these precise actions, organizations can create an empowered data analytics ecosystem that delivers real value by driving data-driven decisions and maximizing the return on their data investment.
Levelwise PageRank with Loop-Based Dead End Handling Strategy : SHORT REPORT ...Subhajit Sahu
Abstract — Levelwise PageRank is an alternative method of PageRank computation which decomposes the input graph into a directed acyclic block-graph of strongly connected components, and processes them in topological order, one level at a time. This enables calculation for ranks in a distributed fashion without per-iteration communication, unlike the standard method where all vertices are processed in each iteration. It however comes with a precondition of the absence of dead ends in the input graph. Here, the native non-distributed performance of Levelwise PageRank was compared against Monolithic PageRank on a CPU as well as a GPU. To ensure a fair comparison, Monolithic PageRank was also performed on a graph where vertices were split by components. Results indicate that Levelwise PageRank is about as fast as Monolithic PageRank on the CPU, but quite a bit slower on the GPU. Slowdown on the GPU is likely caused by a large submission of small workloads, and expected to be non-issue when the computation is performed on massive graphs.
1. Page 1 of 3
I. Problem Definition
What: Lost Production
When: December 18, 2013
Where: USA
Facility: Central 3
System: Processor
Significance: High
Safety: Minimal impact – increased exposure to lifted loads and slippery
conditions
Environment: No Impact
Revenue: Downtime 44 Hours
Cost: $2.4M
Frequency: First 1
II. Report Summary
Lost production was caused by the CHP having to be shut down when the wet end bearing failed.
This bearing failed because of metal-to-metal contact due to the bearing lubrication becoming
ineffective because the grease was washed and contamination was present.
The grease was washed out because the wet end labyrinth seal failed and allowed the entry
of gland water. Excessive wear occurred in the end cover and the labyrinth seal because the
lubricant supply ran out.
The contamination was caused by the failure of the screen filtration system due to the self-
cleaning system not operating and the subsequent blockage not being identified. The self-
cleaning system failure was caused by the water pressure falling below the minimum because
of demands on the water supply elsewhere on the site. This, in turn, was caused by new planned
production arrangements and the limited capacity of the water storage.
LOST PRODUCTION
Purpose: To prevent recurrence, not place blame.
Report Date: 12-12-2013
Start Date: 03-12-2013
Report Number: NC23-0351
2. Page 2 of 3
III. Solutions
Causes Solutions Solution Owner Due Date
Water pressure fell
below 25 psi
Install uprated pump to
ensure supply
Phil Sager 03-02-2014
Blockage not identified
Increase inspections of
screens to weekly
Stirling Maus 25-12-2013
Lubricant supply
exhausted
Double capacity of lube
supply
Nando Alonso 14-02-2014
Lubricant supply
exhausted
Schedule weekly
inspections of supply
Stirling Mice 25-12-2013
IV. Team Members
Name Email Member Info
Phil Sager psage@somewhere.com Reliability Superintendent
Roy Davies rdavies@somewhere.com Defect Elimination Officer
Nando Alonso nalonso@somewhere.com Plant Mechanical Engineer
Stirling Maus smaus@somewhere.com Plant Maintenance Supervisor
Bryson Fittipaldi bfittipaldi@somewhere.com Condition Monitoring Co-ordinator
Merv Shews mshews@somewhere.com Condition Monitoring Technician
Les Gibston lgibson@everywhere.com Facilitator Reliability Engineer
V. Notes
1. Realitychart Status: The Realitychart and Incident Report have been finalized.
2. Rules Check Status: Missing Causes Resolved.
3. Rules Check Status: Conjunctions Resolved.
VI. References
1. Photo # 17
2. mining development plan at 23.01.2014
3. photo # 13
3. Page 3 of 3
Action
METAL TO METAL
CONTACT
Condition
HIGH INJECTION
FREQUENCY
Root Cause (A)
LUBRICANT
SUPPLY
EXHAUSTED
Action
SELF-CLEANING
SYSTEM FAILED
Action
METAL TO METAL
CONTACT
Primary Effect
LOST
PRODUCTION
Action
SELF-CLEANING
SYSTEM FAILED
Condition
MIN PRESSURE IS
25 PSI
Other Cause Paths More
Productive
ORIGINAL DESIGN
Condition
PUMP ROTATING
Desired Condition
Action
BEARING GREASE
WASHED OUT
Desired Condition
Root Cause (A)
WATER
PRESSURE FELL
BELOW 25 PSI
Desired Condition
Condition
MIN PRESSURE IS
25 PSI
Condition
FEED PUMP
REQUIRED FOR
PROCESS
Other Cause Paths More
Productive
Condition
CONTAMINANTS
COMPROMISE
PERFORMANCE
Condition
SINGLE POINT
LUBE INJECTION
SYSTEM
Condition
SYSTEM
PRESSURISED
Action
BEARING GREASE
WASHED OUT
Action
GLAND WATER
ENTERED
Action
SUPPLY NOT
REPLENISHED
New Primary Effect
Action
WET END
BEARING SEIZED
Condition
25 PSI IS MINIMUM
REQUIREMENT
Condition
BEARING
PERMITS
ROTATION
Desired Condition
Condition
LUBRICANT
PREVENTS WEAR
Condition
HIGH INJECTION
FREQUENCY
Root Cause (A)
WET END
LABYRINTH WORN
Condition
COVER PROVIDES
PROTECTION
Condition
PUMP ROTATING
Condition
COVER PROVIDES
PROTECTION
Desired Condition
New Primary Effect
Action
GLAND WATER
ENTERED
Condition
CLEANING
INHIBITS
CONTAMINATION
Action
OTHER
PRODUCTION
REQUIREMENTS
PREVAILED
Action
EXCESSIVE WEAR
OCCURRED IN
END COVER
Lack Of Control
Action
SUPPLY NOT
REPLENISHED
Root Cause (A)
WET END
LABYRINTH WORN
Condition
LUBRICANT
FAILURE
Action
LUBRICANT
CONTAMINATED
Action
COARSE FEED
PUMP STOPPED
Desired Condition
Desired Condition
Condition
LUBRICANT
PREVENTS WEAR
Action
EXCESSIVE WEAR
OCCURRED IN
END COVER
Root Cause (A)
LUBRICANT
SUPPLY
EXHAUSTED
Desired Condition
Action
OTHER
PRODUCTION
REQUIREMENTS
PREVAILED
Action
WET END
BEARING SEIZED
Condition
LABYRINTH SEAL
PREVENTS
WATER ENTRY
Desired Condition
Condition
SINGLE POINT
LUBE INJECTION
SYSTEM
Action
LUBRICANT
CONTAMINATEDPrimary Effect
LOST
PRODUCTION
Condition
LABYRINTH SEAL
PREVENTS
WATER ENTRY
Condition
FEED PUMP
REQUIRED FOR
PROCESS
Condition
CLEANING
INHIBITS
CONTAMINATION
Condition
25 PSI IS MINIMUM
REQUIREMENT
Condition
SYSTEM
PRESSURISED
Action
COARSE FEED
PUMP STOPPED
Condition
CONTAMINANTS
COMPROMISE
PERFORMANCE
Condition
LUBRICANT
FAILURE
Condition
BEARING
PERMITS
ROTATION
Root Cause (A)
WATER
PRESSURE FELL
BELOW 25 PSI
