1. Failure Code Quality Plan Implementation ALCOA NAPM MASSENA, NY

2. DRIVERS: Future demand for anodes to support new pot lines - Modernization Project Strained capacity of current anode production Need for Downtime and Equipment Failure reporting mechanism Available functionality of Oracle eAM Quality Failure Collection Plans to identify opportunities MJClemens

3. SOLUTION: Only events that affect OEE and actual Production will be captured in the DMS Downtime Reporting Tool (including Equipment Failures) Focus on Downtime MJClemens

4. SOLUTION: All Equipment Failures (whether or not they create process Downtime) will be captured on an Oracle Work Order through Failure Codes in a Quality Failure Collection Plan Focus on Failures MJClemens

5. OWNERSHIP: RELIABILITY ENGINEERING Providing the Tools, Analyzing the Results MJClemens

6. OWNERSHIP: MAINTENANCE EXECUTION Applying the Tools, Capturing the Data MJClemens

7. PROCESS: Review Equipment Work Order Histories by Asset Category (Description Fields and Spare Parts Usage) Capture Known Failure Modes Review Alcoa or external FMEA data if available Rely on personal experience and that of Plant personnel Create Quality Failure Collection Plan FOCUS ON PREDOMINANT FAILURE MODES OR THOSE MOST LIKELY TO OCURR MJClemens

8. PROCESS: CURRENT ALCOA QUALITY PLAN MODEL: YES/NO DAMAGE DESIGN FABRIC INSTALL MAINT MAT’L MISUSE LUBRCTN LIST BY CLASS/CATEGORY CONT OIL DIRT OIL IMP FILT INSUF OIL LOW PRESS PUMP FAIL PLUG LINE WRONG LUB MJClemens Order of entry confusing to many

9. PROCESS: Alcoa Standard Component Codes for Bridge Cranes MJClemens List of Components to choose from over five screens long, not always clear or applicable

10. PROCESS: PTC Model (2008) – Follows FMEA methodology, but all Codes become one string – must scroll through entire list to appropriate combination. MJClemens

11. PROCESS: MASSENA QUALITY PLAN MODEL: YES/NO Three levels of Failure Code Hierarchy, and Lubrication Codes rolled into Root Cause Codes MJClemens

12. PROCESS: MASSENA QUALITY PLAN MODEL: LEVEL 2 LEVEL 1 MJClemens

13. PROCESS: MASSENA QUALITY PLAN MODEL: LEVEL 3 Z_OTHER Allows for manual input; multiple inputs would clue the RE to add the code to the list MJClemens

14. ADVANTAGES: MASSENA QUALITY PLAN MODEL: Failure Code Hierarchy allows for fast “drilldown” Codes reflect FMEA or RCM methodology; “The Magnetic Separator Drive System Motor Bearing Failed due to under-lubrication” Quality Plan components can be configured and modified at the site level to reflect the granularity of the Asset Hierarchy (Today’s Components may be tomorrow’s Assets, and the codes must adjust) Quality Plan results can be extracted through Discoverer and Pareto Analyses conducted Quality Failure Code Plans are living tools – the Reliability Engineer has the ability to add or remove those Failure Codes (Failure Modes) that either surface or disappear from Proactive Maintenance. MJClemens

15. From the Work Order Screen, Select the Quality Tab and then “Enter Quality Results”

16. The “Enter Quality Results” screen is now enabled MJClemens

17. If a Failure occurred (Y), entering a “% ENTER” opens an LOV for Level 1 Z_OTHER, (listing a new code in Comments) is an option at every level MJClemens

18. Having Selected “BELT” at Level 1, entering “BE, ENTER” at Level 2 would make available only those codes for “BELT” This Smart Coding eliminates the need to scroll through the entire list of codes to select the most appropriate one.

19. Having Selected “BELT” at Level 1, and “BELT_DAMAGED” at Level 2, all 15 existing Root Causes would be available to select IF KNOWN

20. PARETO: MJClemens

21. Current Failure Collection Quality Plans Applied to 176 Assets in Green Anode MJClemens

22. “A well designed Failure Reporting, Analysis, and Corrective Action System (FRACAS) can be an important part of any continuous improvement effort. Failure codes developed using functional analysis of plant equipment greatly improve the ability of the Reliability Engineer to analyze failures and initiate changes in equipment design, maintenance strategies, and operating strategies. Simple, two-part failure codes for use in the CMMS/EAMS allow operators and maintainers to better record failure information for use in the FRACAS.” Bill Keeter, Allied Reliability MJClemens

23. Other Quality Plans …. Incorporates Oracle eAM “Specifications” in the Quality Plan MJClemens

24. Other Quality Plans …. MJClemens

25. Other Quality Plans …. MJClemens