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