What is FRACAS?

Failure Reporting Analysis and Corrective Action System (FRACAS) is an

excellent process that can be used to control or eliminate failures. This is
a process in which you identify any reports from your CMMS/EAM or a
specialized Reliability Software that can help you to eliminate, mitigate
or control failures. These reports could include cost variance, Mean Time
between Failure, Mean Time between Repair, dominant failure patterns
in your operation, common threads between failures such as lack of
lubrication (perhaps due to lubricator not using known industry
standards).

Figure 1 - FRACAS Loop

Seven Steps to a Working Failure Reporting System FRACAS

Youve gotten buy-in from the boss by showing him how much money
the organization can make from a good Failure Reporting Plan (FRACAS).
He said, Great idea! Now go make it happen. How many new ideas
have you seen come and go in your organization? I have seen many
through my career and I am sure you have as well. Failure Reporting
(FRACAS) is something that must be sustainable because it is the
continuous improvement process for your Maintenance Strategies for
each piece of equipment. In this chapter from FRACAS, Failure Reporting
Made Simple book, we are going to offer you a phased approach to
success, one step at a time.
FRACAS Step 1 Determine your end goal.

Know where you are going.

FRACAS Step 2 Create your data collection plan.

What measures will be used?

What data must be collected to create the measures?
How will the data be collected?
How will the data be analyzed?

FRACAS Step 3 Determine organizational roles, goals, and

responsibilities (RACI).

Who collects the data?

Who analyzes the data?
Who takes what action based on analysis results?

FRACAS Step 4 Create the FRACAS Policies and Procedures

Manual.

Create a manual that clearly delineates the items determined in

Steps 1, 2, and 3.

FRACAS Step 5 Develop and execute the FRACAS Training Plan.

Create a Training Plan based on the organizational roles, goals, and

responsibilities determined in Step 3.

FRACAS Step 6 Implement the FRACAS.

Hold required informational meetings.

Begin data collection on highest priority systems.
Analyze data and report results.
Create corrective actions based on results.

FRACAS Step 7 Monitor and adjust.

Monitor data quality and results.

Monitor corrective actions.
Adjust data collection plan and corrective action implementation
plan based on results of monitoring.

FRACAS Benefits

The basic benefit of a comprehensive, closed-loop FRACAS is the

contribution
identification

of

the

and

information
correction

of

that

it

design

contains

for

errors,

part

the

timely

problems,

workmanship defects and /or process errors.

An effective FRACAS results in saving of significant direct costs such as
factory rework, parts/materials crap, or warranty service, and even
greater indirect costs associated with dissatisfied customers.
An effective FRACAS can serve as a major contributor to reliability
growth, efficient maintenance, and continuous process improvement.
Continuous monitoring and tracking of data via the FRACAS provides and
assessment as to whether previous failures trends have been eliminated
through corrective action. In conclusion, the main benefits of an effective
FRACAS process are:

Saving of direct and indirect costs by the proper handling and

investigation of problems followed by appropriate corrective

action.
Visibility of reliability performance problems.
Initiation of continuous reliability improvement process.
Effectiveness of corrective actions controls and linkage to results.
Expedient engineering effort to resolve problems.
Root Cause Analysis
Knowledge base of a history of problems and lessons learned
helping to avoid similar occurrences.