The document discusses Failure Reporting, Analysis, and Corrective Action System (FRACAS). It summarizes definitions of failure from previous studies. A failure is defined as an unsatisfactory condition or the inability to meet performance standards. Potential failures are identifiable physical conditions indicating imminent functional failure. The goal is to begin measuring Mean Time Between Failures to understand failure patterns and improve maintenance strategies. Next steps include defining failure reports and developing a process to deliver these reports.

1. Failure Reporting, Analysis,
Corrective Action System
“FRACAS”
Presented by: Ricky Smith, CMRP
March 9, 2010
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2. Nowlan and Heap Study stated…
“…Without a precise definition of what
condition represents a failure, there is no
way to assess its consequences or to define
the physical evidence for which to inspect.
The term failure must, in fact, be given a far
more explicit definition than “an inability to
function” in order to clarify the basis of
Reliability-Centered Maintenance.”
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3. Nowlan and Heap Study further stated…
“…A failure is an unsatisfactory condition. In
other words, a failure is an identifiable
deviation from the original condition which is
unsatisfactory to a particular user.”
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4. What is a Failure?
• “A functional failure is the inability of an item
(or the equipment containing it) to meet a
specified performance standard and is
usually identified by an operator”.
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5. What is a Failure?
• “A potential failure is an identifiable physical
condition which indicates a functional failure
is imminent and is usually identified by a
Maintenance Technician using predictive or
quantitative preventive maintenance”
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6. Potential Failures
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7. Functional Failure
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8. Our Goal
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9. Where do you start? With Baby Steps
Begin Measuring MTBF
- Of you total operation
- By area
- By asset
Calculation: Time / Number of Failures
Example: 24 hours / 3 failures = MTBF of 8
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10. How many can Measure MTBF?
• Send me your report please
• What are the barriers?
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11. Let’s define Roles and Responsibilities
Maintenance Maintenance Maintenance Maintenance Reliability PdM
Tasks Supervisors Planner Technician Manager Engineer Technician
Inputting Failure A I R C C
Data -
CMMS/EAM
Work Order R C R A R R
Close Out
Validating C I C A R C
Failure Data and
Codes
QA of Failure I C A R C
Data Input
Analyze Failure R I C R A/R R
Reports
Making I I I A R C
Maintenance
Strategy
Adjustments
Responsibility “the Doer”
Accountable “the Buck stops here
Consulted “in the Loop”
Informed “kept in the picture”
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12. The next step
• Define your failure reports (outputs)
– Dominant Failure Pattern?
• Causes of Infant Mortality?
– Lack of Lubrication
– Bolts not torque to specifications
– Electrical connections RTF (run to failure)
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13. Next Steps
• Develop a Process which delivers the Report
you want.
– Dominant Failure Pattern
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14. Other Reports
• % of Assets with No Identifiable Defect
• Failure Rate for Specific Components
Drive Belt-Broken-Ageing Failure Rate
0.0010696
2-parameter
Weibull
0.00096266 Median rank
η: 5212
0.0008557
β: 3.745
γ: 0
0.00074874
ρ: 0.9781
ε: 0.05664
0.00064178
Failure Rate
B10: 2858
0.00053481 B15: 3208
B20: 3492
0.00042785
P0: 0%
0.00032089
Distribution rate
Reg ionalised rate
0.00021393
0.00010696
0
0 602.49 1205 1807.5 2410 3012.5 3614.9 4217.4 4819.9 5422.4 6024.9
Time
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15. Comments
“ Like the tortoise - slow and steady wins the
race!”
Kim Hunt – Reliability Leader / Domtar
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16. What are your next steps?
• ???
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17. Recommendation
• Measure MTBF
• Educate your leaders and followers
– If you want a private session, let me know
• Join me a Reliability 2.0 Conference in April.
http://maintenanceconference.com/reliability/
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