Failure Reporting, Analysis, Corrective Action System: Presented By: Ricky Smith, CMRP

Failure Reporting, Analysis,
Corrective Action System
Presented by: Ricky Smith, CMRP
Copyright 2009 GPAllied
What is FRACAS?
A Failure Reporting, Analysis, and Corrective Action
System (FRACAS)
Process by which failures can be reported in a timely manner
Analyzed so that a Corrective Action System can be put in place
and eliminate or mitigate the recurrence of a failure.
The goal of FRACAS

Help an organization better understand failures
The reporting required to identify failures
Actions required to eliminate or mitigate failures
What is FRACAS?
Maintenances Objective
Mitigate Failures with an effective Maintenance Strategy
- Preventive Maintenance (quantitative inspection, restoration,
replace, replenish, etc.)
- Condition Monitoring (ID of a Failure early enough a failure
can be mitigated) also known as PdM
- Run-to-Failure
PF Curve
Priority 5
Failure Ultrasonic Energy
Vibration Analysis
Initiated
Detected
Fault Detection
Priority 4
P-F Curve
Oil Analysis
Detected
Hot to Touch
Condition
Mechanically
Loose
PRECISION
Ancillary
Damage
PREDICTIVE
PREVENTIVE
RUN TO FAILURE
Priority 1
Equipment Condition
Priority 2
Audible Noise
Catastrophic
Failure
Time
Proactive Maintenance
FRACAS? Issues?
A Proactive Reliability Process is a supply chain. If a step
in the process is skipped, or performed at a substandard
level, the process creates defects known as Failures.
The output of a healthy reliability process is optimal asset
reliability at optimal cost.
Ron Thomas, former Reliability Director at
Dofasco Steel, Hamilton, ON
Causes of Failures
No repeatable procedures
Not executing PM to specification
Not performing Corrective Maintenance to specification
Personnel not trained (skills, maintenance, reliability)
Parts not stored to specifications
Not using the right tools
Best Lubrication Practices unknown
RCA is not applied or not known
No auditing of Maintenance Activity or Work
Known Best Practice Data

15% of Maintenance Work is Execution of PM
15% is the results of the PM Execution
PM / PdM is a controlled Experiment
15% of Maintenance is Execution of PdM

35% is the results of PdM
Emergency Work Less than 2%
Planned Work 90%
Scheduled Compliance 80% (by day by week)
Failure Patterns
Initial Break-in period
Bathtub
Pattern D = 7%
Pattern A = 4%
Random
Pattern E = 14%
Wear Out
Pattern B = 2%
Why is infant mortality so high?

Maybe because we do not applyTime
the PF Curve Philosophy?
Time
Fatigue
Pattern C = 5%
Infant Mortality
Age Related = 11%
Random = 89%
Pattern F = 68%
Source: John Moubray, Nolan & Heap
PF Curve with Priorities

Identify defect, Plan and Schedule Work Zone
100% Reactive Work

Work Priority Distribution
PM
PdM
CPM CPdM
REQ
Priority 1 and 2 Work is Reactive

Priority 3, 4, and 5 Work is Proactive
PF Curve and Managing Proactive Maintenance

Point P
Point F
Work Priority Distribution a Few Simple Rules

EMERGENT work is anything
that is done as a Priority 1 or 2
CORRECTIVE work is
anything done as a result of
an inspection
CORRECTIVE work should
never be done as a P1 or P2
ROUTINE work is anything
done as a PRIORITY 3
CORRECTIVE work can be
done as Priority 3
CORRECTIVE work should be
done as a Priority 4 and 5
Most CORRECTIVE work
should be done as P4 or P5 if
you embrace P-F mentality
FRACAS Enables Success of an Organization
It isnt what you know that will kill you, it is

what you dont know that will
It is all about the Data
How do you know where are?

How do you know the Direction to reach you objective.?
Without good data we are lost!
Bad Data resulting in High Variation

- Variation in your Maintenance Process
PM Program not effective

Variation in PM Compliance
PM program not focused on specific Failure Modes
Repeatable Corrective Maintenance Procedures not
available or if available not used
- Storeroom is a deathtrap for parts, little or no PM
program on critical spares
Definition of Data Quality ISO 14224

Must have Confidence in the collected Reliability and
Maintenance data, and hence any analysis, is strongly
dependent on the quality of the data collected. High-quality
data is characterized by:
a) completeness of data in relation to specification;
b) compliance with definitions of reliability parameters,
data types and formats;
c) accurate input, transfer, handling and storage of
data (manually or electronic);
d) sufficient population and adequate surveillance
period to give statistical confidence;
e) relevance to the data users need.
The International Standard for Failure Data
Failure Data ISO 14224
ISO 14224 Maintenance Taxonomy Standard
ISO 14224 Maintenance Taxonomy Applied
Effects of Good Data Quality
KPI #1 Asset Health Report
Asset Health Metric - The percent of assets with no identifiable Defect
KPI #2 Mean Time Between Failure

Mean Time Between Failures (MTBF) is the average length of
operating time between failures for an asset or component.
(Definition extracted from Published SMRP Metrics)
MTBF is used primarily for repairable assets and components of
similar type. (Definition extracted from Published SMRP Metrics)
KPI #2 - MTBF Example / Reporting by Taxonomy
Area Level MTBF
Component Level MTBF
Equipment Taxonomy (ISO 14224)

Systematic classification of equipment into generic groups based on factors
possibly common to several of the items
KPI #3 MTBF / Equipment Condition Report
KPI #4 Equipment Condition Report / Equipment Detail
KPI #5 Route Compliance
Route Compliance Impact on Asset Health Report
KPI #6 Monthly Maintenance Cost % of RAV

Maintenance Cost
- Labor Cost
- Material Cost
- Contract Maintenance Cost
- Overtime Cost
Correlate Cost to Other KPIs
Data Accuracy Requirements

Process Map
Roles and Responsibilities Identified
The 7 Steps to a Successful FRACAS
Step 1 Determine your end goal.

The beginning of every journey starts with a destination
The beginning of the journey to an effective FRACAS is the same as
any other
You must have an end goal in mind
The goal of a FRACAS is not to gather data, but to eliminate failures
from the organization
Knowing this helps ensure that every policy, procedure, and activity in
the system is goal oriented
The roles, goals, and responsibilities of everyone involved with the
system can be focused toward that goal
Having the goal in mind allows you to build the shared vision and
values that will make the system work successfully for you
Step 2 Create the Data Collection Plan

1. Determine the measures you will use
MTBF
Mean Time Between Failures (MTBF) is the average length of operating time
between failures for an asset or component. MTBF is used primarily for
repairable assets and components of similar type.
MTTF
Mean Time to Failure (MTTF) is the average length of operating time to failure
of a non-repairable asset or component, i.e., light bulbs, rocket engines. A
related term, Mean Time Between Failures (MTBF), is the average length of
operating time between failures for an asset or component. Both terms are a
measure of asset reliability and are also known as Mean Life.
Continued
2. Determine what data needs to be collected to create the desired
measures
Continued
3. Determine how the data will be collected
- There are different types of data that need to be collected
- Determine how the data will be collected
- Failure data can be collected through the EAM/CMMS, automated process
data systems, or by using checklists
4. Determine how data will be analyzed

The best bet is probably to start with Pareto
Just make sure to remember that data analysis - where to apply methods
JDI, RCA and RCM
Do not fall victim to analysis paralysis. Analytical reports are nice, but no
statistic ever solved a problem
Keep it simple in the beginning
1st
# of Failure by
area
2nd
# of Failures by
Equipment
3rd
# of Failure by
Component or Part
Examples Dominant Failure Pattern

Cause Code
=
MTBF
Object Type
(Electric Motor)
# LOL = 5%
# MAERR = 10%
# LOP = 20%
# OPER = 65%
Failure
Pattern
Cause Code
=
# LOL
# MAERR
#LOP
# OPER
New Failure Pattern

Example Continues
% of Assets with No Identifiable Defect
Failure Rate for Specific Components

Drive Belt-Broken-Ageing Failure Rate
0.0010696
2-parameter
Weibull
Median rank
0.00096266
: 5212
0.0008557
: 3.745
: 0
0.00074874
: 0.9781
: 0.05664
Failure Rate
0.00064178
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
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?
Develop Process Map / Maps
Develop a RACI Chart for each Process Map

Decisions/
Functions
Maint.
Maint.
Manager Supervisor
Reliability
Engineer
Maint.
Planner
Maint.
Tech
Failure Data Entry
Data Accuracy
RCA Invalid Data
Analysis of Data
Actions Identified
Actions Taken
FRACAS Activated
Step 4 Create the FRACAS Policies and

Procedures Manual
Policies and Procedures Manual that will serve as the basis for
managing and administering the FRACAS system
This is a tedious step, but should not be skipped
This Manual will serve as the basis for developing:
Initial FRACAS Training for all key personnel
Ensuring that new employees understand and participate in
FRACAS effectively
Best to develop a FRACAS Management Manual and a pocket
size book that is easy for people to carry around and refer to as
required
What should be in the Manual?

Lets develop this together to insure we both agree on the content
The manual should have at the minimum
Definition of FRACAS
Benefits of FRACAS
Managements Guidance
Managements Expectations
Roles and Responsibilities by position
FRACAS reports
Key data which must be input to generate these reports
What these reports will do for the mine
Training Outline for each person based on RACI Charts
Step 5 Develop FRACAS Training Plan

Each person in the organization will need to be trained according to
their level of participation in the FRACAS
Use the Tasks Listed on all RACI Charts
Decision
Function
Maint.
Manager
Maint.
Supervisor
Reliability
Specialist
Maint.
Planner
Maint.
Tech
Failure Data Entry

Data Accuracy
RCA Invalid Data
Analysis of Data
Actions Taken
FRACAS Activated
Training Plan Requirements

-
Training Plan should consist of the following

Position : Maintenance Technician
Task: Close out a Work Order
Condition: Given 5 Completed Emergency Work Orders
Standard: Close out Work Orders to 100% Compliance
Method of Training: Lecture, Web, Reading, etc.
Method of Validation: Written Test, Web Test, Verbal Recall, etc.
Step 6 Implement FRACAS

Lets turn it on
Publish FRACAS Policies and Procedures Manual
Train required personnel
Hold required informational meetings
Begin data collection on highest priority area
Analyze data and report results on Public FRACAS Information
Board
Create corrective actions based on results.
Mitigation of Human Error
Changes to the current maintenance strategy
Changes to how production operates equipment
Resign Equipment
Step 7 Monitor, Show Success, and Adjust

Monitor data quality and results
Decision
Function
Maint.
Manager
Maint.
Supervisor
Reliability
Specialist
Maint.
Planner
Maint.
Tech
Failure Data Entry
Data Accuracy
RCA Invalid Data
Analysis of Data
Actions Taken
FRACAS Activated
Monitor and Adjust

Good data is the backbone of good decision making
It is important to monitor data quality
Make adjustments to either the data collection plan or the training
program
Insure data is consistent and informative
Many organizations believe they have good data only to find out
their data collection is inconsistent
Questions?

Failure Reporting, Analysis, Corrective Action System: Presented By: Ricky Smith, CMRP

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Failure Reporting, Analysis, Corrective Action System: Presented By: Ricky Smith, CMRP

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Failure Reporting, Analysis,

Corrective Action System

Presented by: Ricky Smith, CMRP

Copyright 2009 GPAllied

The goal of FRACAS

Copyright 2009 GPAllied

Copyright 2009 GPAllied

Copyright 2009 GPAllied

Copyright 2009 GPAllied

Copyright 2009 GPAllied

Copyright 2009 GPAllied

Copyright 2009 GPAllied

Known Best Practice Data

15% of Maintenance is Execution of PdM

Copyright 2009 GPAllied

Why is infant mortality so high?

Age Related = 11%

Source: John Moubray, Nolan & Heap

Copyright 2009 GPAllied

PF Curve with Priorities

100% Reactive Work

Work Priority Distribution

Priority 1 and 2 Work is Reactive

Copyright 2009 GPAllied

PF Curve and Managing Proactive Maintenance

Work Priority Distribution a Few Simple Rules

Copyright 2009 GPAllied

FRACAS Enables Success of an Organization

Copyright 2009 GPAllied

It isnt what you know that will kill you, it is

Copyright 2009 GPAllied

It is all about the Data

Copyright 2009 GPAllied

How do you know where are?

Copyright 2009 GPAllied

Without good data we are lost!

Copyright 2009 GPAllied

Bad Data resulting in High Variation

PM Program not effective

Definition of Data Quality ISO 14224

Copyright 2009 GPAllied

Copyright 2009 GPAllied

The International Standard for Failure Data

Copyright 2009 GPAllied

Failure Data ISO 14224

Copyright 2009 GPAllied

ISO 14224 Maintenance Taxonomy Standard

Copyright 2009 GPAllied

ISO 14224 Maintenance Taxonomy Applied

Copyright 2009 GPAllied

Effects of Good Data Quality

Copyright 2009 GPAllied

KPI #1 Asset Health Report

Asset Health Metric - The percent of assets with no identifiable Defect

Copyright 2009 GPAllied

KPI #2 Mean Time Between Failure

Copyright 2009 GPAllied

KPI #2 - MTBF Example / Reporting by Taxonomy

Area Level MTBF

Component Level MTBF

Equipment Taxonomy (ISO 14224)

Copyright 2009 GPAllied

KPI #3 MTBF / Equipment Condition Report