KPI Users Group - Failure Reports

KPI Users Group
“Failure Reports”

Presented by: Ricky Smith CMRP
November 30, 2009

Copyright 2009 GPAllied©

“It isn’t what you know that will kill you, It is
what you don’t know that will”


The PF Curve – Objective:
Identify “P” as Early as possible


The I-PF Curve – Objective:
To Eliminate the Causes of Failures at Point “I”


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?


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


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


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


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)


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”


Where do we start?
1st Step


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.


A Managed System For Continuous
Improvement for Asset Reliability


“A picture is worth a thousand words”

- Napoleon Bonaparte


The Objective of Failure Reports
• Identify root cause of frequent failures
• Identify common threads between failures
• Identify dominant failure patterns
• Identify true bad actors
• Plus many other reports

FRACAS: A Managed System For Continuous Improvement


Simple Steps: Reports?
• Identify the failure codes from failure modes of your
equipment, not from a laundry list on the web


• 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

68% 6%

Infant Mortality


• 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”


Root Cause Analysis

Definition of insanity:

“Doing the same thing over and over again and
expecting a different result”


• Changing how you prevent or predict specific failures
• Making adjustments to your Maintenance Strategy
• Making changes to your Equipment Criticality Ranking


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


Where do we start? “just a reminder”


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


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


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.


KPI Users Group - Failure Reports

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