Introduction to FRACAS: Develop the Tools to Build an Effective Failure Reporting and Corrective Action System
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This document describes a two-day training course on developing and implementing a Failure Reporting, Analysis, and Corrective Action System (FRACAS). The course will teach maintenance and operations personnel how to build the basic elements of an effective FRACAS, including developing a data collection plan, failure codes, roles and responsibilities, and procedures. Participants will practice analyzing sample failure data and developing corrective actions. The goal is to provide attendees with the skills to start building their organization's FRACAS.
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Introduction to FRACAS: Develop the Tools to Build an Effective Failure Reporting and Corrective Action System
- 1. BK Reliability 465 Bella Vista Drive Titusville, FL 32780 BK Reliability 465 Bella Vista Drive Titusville, FL 32780 Phone: +1 321-202-1717 Email: bill@billkeeter.com Introduction to FRACAS Level: Foundational Element DURATION 2 Days DESIGNED FOR Maintenance and Operations personnel who will be involved in the implementation of a Failure Reporting, Analysis, and Corrective Action System (FRACAS) ABOUT THE COURSE This course is designed to provide attendees with the basic skills and knowledge to begin implementation of a Failure Reporting, Analysis, and Corrective Action System (FRACAS). WHAT YOU WILL LEARN • What a FRACAS is • The definition of failure • The basic elements of a FRACAS • How to develop failure codes for a FRACAS • How to develop a failure data collection plan • How to manage FRACAS responsibilities • How to analyze FRACAS data • How to Develop FRACAS KPIs • How to monitor Corrective Actions WHAT YOU WILL DO • Build an outline for a FRACAS policy manual for your organization • Build a FRACAS data collection plan • Build a set of failure codes for an item of equipment • Build a RAS(C)I for a FRACAS • Build a set of criteria for selecting a corrective action • Build a basic set of FRACAS KPIs
- 2. BK Reliability 465 Bella Vista Drive Titusville, FL 32780 BK Reliability 465 Bella Vista Drive Titusville, FL 32780 Phone: +1 321-202-1717 Email: bill@billkeeter.com OVERVIEW Oil, Mining, and Chemical industry incidents over the past several years have focused new light on the need for improved Asset Integrity Management practices. PAS55 and ISO55000 have been developed to provide a top down approach to managing physical assets throughout their life-cycle in a way that ensures reliability, availability, and maintainability levels that are sustainable, and that provide maximized return on a company’s investment. Failure Reporting, Analysis, and Corrective Action Systems (FRACAS) are an essential element in continuously improving asset performance by eliminating recurrence of failures. This course focuses on developing and managing an effective FRACAS. WHY YOU SHOULD ATTEND THIS COURSE This course is designed to give you the basic tools you need to build an effective FRACAS for your organization. You will create a basic outline of your FRACAS policy, develop roles, goals and responsibilities for members of your organization, create a RAS/CI to capture organizational responsibilities within the FRACAS, and learn how to incorporate Root Cause Analysis (RCA) management into your FRACAS. KEY BENEFITS OF ATTENDING • Understanding how to develop and effective FRACAS • Creating a data collection plan • Creating a basic outline for your FRACAS policies and procedures manual • Understanding the role of FRACAS in improving system performance • Creating an initial set of Roles, Goals, and Responsibilities for your FRACAS • Creating a basic training plan for implementation • Understanding what a Corrective Action really is. DAY 1-2 Session 1: What is FRACAS Definitions of the terms within FRACAS have significant implications about what needs to be included in a FRACAS. This session focuses on understanding the definitions and how they may impact what is included in your FRACAS. • What is a failure? • What is a corrective action? • What is a system? • How does FRACAS fit with Asset Integrity Management (AIM), PAS55, and ISO55000
- 3. BK Reliability 465 Bella Vista Drive Titusville, FL 32780 BK Reliability 465 Bella Vista Drive Titusville, FL 32780 Phone: +1 321-202-1717 Email: bill@billkeeter.com Session 2: Data collection plans It is important to understand what data should be collected in the FRACAS. In this session you will develop an outline of a data collection plan for use in helping develop a FRACAS for your organization. • Determining which data needs to be collected • Understanding how your organizational goals drive data needs • Understanding the relationship of equipment criticality and data collection • Developing a data collection plan Session 3: Failure Codes for FRACAS Good failure codes are essential to being able to analyze failure data to look for patterns of failure across the organization. In this session you will work with failure modes analysis to develop an example set of failure codes for use by your organization. • Understanding what a failure mode is • Understanding how to develop easy to use failure codes • Understanding how to deploy failure codes in your data collection system Session 4: Organizational Roles in FRACAS Every member of the organization has a role within the FRACAS. In this session you will work through determining which members of your organization will have key roles in the development and deployment of your FRACAS • Understanding the role of the boss • Understanding the role of the champion • Understanding the role of operators and crafts people • Understanding the role of various engineering staff Session 5: Developing FRACAS Policies and Procedures Sustaining a FRACAS requires that it become part of organizational policy. Developing a policy and procedures manual is an essential step in helping establish and sustain the system. In this session you will create a basic outline for your FRACAS Policies and Procedures Manual. • Understanding the importance of a FRACAS policy statement • Developing data collection procedures • Developing data analysis procedures • Developing Corrective Action management procedures
- 4. BK Reliability 465 Bella Vista Drive Titusville, FL 32780 BK Reliability 465 Bella Vista Drive Titusville, FL 32780 Phone: +1 321-202-1717 Email: bill@billkeeter.com Session 6: Developing the RAS/CI Matrix Various individuals within the organization have varying responsibilities depending upon their role in the organization. A RAS/CI is an effective tool for helping individuals understand what their FRACAS roles and responsibilities will be. In this session you will develop a RAS/CI matrix for your FRACAS based on the job titles within your organization. • Understanding the job of the Responsible person • Understanding the job of the Accountable person • Understanding the job of the Supporter/Consultant • Understanding the importance of informing others • Developing the organizational task list Session 7: Deploying the FRACAS Deploying a FRACAS is not as simple as announcing that your organization is going to begin collecting failure data. Deployment requires extensive communication and training in order to provide the best chance of getting data recorded for further analysis. In this session you will develop an initial communication and training plan for deploying a FRACAS. • Developing the basic communication structure • Creating a training matrix based on organizational need • Creating training responsibilities • Understanding how to handle training for new employees Session 8: Analyzing FRACAS Data Analyzing collected data is the first step in understanding system failure patterns. In this session you will learn about different ways to turn FRACAS data into information for decision making. You will work with a sample data set to determine failure patterns. • Understanding the impact of repetitive failures • Using Pareto Analysis to prioritize work • Using Weibull Analysis to understand common failure threads
- 5. BK Reliability 465 Bella Vista Drive Titusville, FL 32780 BK Reliability 465 Bella Vista Drive Titusville, FL 32780 Phone: +1 321-202-1717 Email: bill@billkeeter.com Session 9: Generating Corrective Actions Understanding failure patterns and frequencies is not the end goal of a FRACAS. In this session you will learn the different ways of creating corrective actions, and how to analyze whether or not the potential corrective actions are in line with business goals. • Understanding failure analysis • Knowing when to use Root Cause Analysis (RCA) • Knowing when to use Reliability-Centered Maintenance (RCM) Methods Section 10: Measuring FRACAS Effectiveness Keeping score is an important part of everyday business practice. Key Performance Indicators help organizations understand the health and effectiveness of various programs. In this session you will develop a set of KPIs designed to help your organization understand whether or not the FRACAS is being used, and whether or not the corrective actions are being effective. • Understanding the importance of simple leading indicators • Measuring whether basic FRACAS activities are occurring • Measuring whether Corrective Actions are being implemented • Measuring Corrective Action effectiveness Session 11: Picking a Software System Picking the correct software for recording FRACAS data is an important step. In this session you will develop criteria for understanding which type of software package you will want for implementing your FRACAS. • Understanding the basic components required in the data collection software • Understanding the basic data elements that need to be recorded