Fracas – anatomy of a failure

by Jim TaylorCRE, CPE, CPMM

Director of Operations, Machinery Management Solutions, Inc.

www.machineryhealthcare.comhttp://blog.machineryhealthcare.com

FRACASAnatomy of a failure

If we make an effort and have a plan,

we can capture the information needed for good

failure analysis

Key Takeaway

3 other presentations on this subject

All available on SlideShare.com

Today I want to

talk about how the failure

occurs and what data is available for capture.

You work in a small to medium size facility or plant.

California Cthulhu

You’re a Maintenance professional: an Engineer, a Maintenance Manager,

Supervisor, Planner, or Crafts Person.

michaelcardus

You’d like to do good failure analyses when you have an equipment failure but you find you just

don’t have the right information to do it.

?

??

?

?

?

The needed information is available

  by  Jorge Franganillo 

But you must develop a plan to capture it

Event dataFirst we need to understand how the event

and restoration proceeds

A failure occurs

The operator observes the event

by  rachel_titiriga 

Operator in initiates trouble call – capture complaint code

by  danielfoster437 

Craftsperson dispatched

by  Mauropm 

Crafts person arrives

She begins troubleshooting

Diagnoses Completecapture failure code

by  brendan.wood 

CP initiates parts procurement

by  Iwan Gabovitch 

Logistics delay

First you have to find the parts

 by  Mackmyra Svensk Whisky AB 

Or maybe you have to have them delivered

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Then they must be delivered to the machine

by  toolstop 

Repair & restoration

CP completes repair

 by  Official U.S. Navy Imagery 

Capture Repair Code

Test satisfactorily completed

Process satisfactory and stable.

Time data

When the various events

occur is important

information

Capture Event time & Response

times

Event time

Actual time of event as recorded

by DCS, etc.

Reaction time

Notification time

Response time

Logistics delay time

Admin & ordering time

Waiting time

Repair &

Restoration times

Started diagnosis

Completed diagnosis

Started repair

Started test

Back in service

As found conditions

Try to determine the equipment

conditions immediately before and after the failure

Equipment Condition

Operating conditions

RPM

Temperatures

Pressures

Flow rates

Levels

Etc.

Product conditions

Quality

Rate

Finish

Size

Etc.

Codes

Complaint code

As found code

Cause code

Failure code

Effect code

etc.

Narrative Observation

s

Interview the Operators

What did they:

hear

see

feel

smell

do

find by  Dplanet:: 

Interview the Crafts Persons

What did they:

hear

see

feel

smell

do

find

Interview any others who may have information

by  DaveFayram 

Collect Physical Evidence

Broken parts

Damaged product

by  rileyporter 

Any other physical evidence

Photos

Measurements

Leakage

Parts

Environmental conditions

Etc.by  U. S. Fish and Wildlife Service - Northeast Region 

Will this give us all the information we need to perform an effective

failure analysis?

Lack of good failure analysis means we’ll continue to loose productivity and profitability because we’ll be fighting same failures over and over.

Develop a plan to capture the right information

With the right information, you can do effective failure analysis

The key to an effective failure analysis is having the right

information

[email protected]

www.machineryhealthcare.comhttp://blog.machineryhealthcare.com