Edwards Deming, PhD How good is your organization at identifying failures? Of course you see failures when they occur, but can you identify when recurring failures are creating serious equipment reliability issues? While this is not wrong, I prefer to either not see the failure in the first place, or at the least, to reduce the failures to a controllable level. One poll was conducted recently covering 80 large companies. Shockingly, none of these companies were capturing the data required to understand and control equipment failures.
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After all most organizations have a PM program and some form of a planning and scheduling program right? The key difference between those that do is their ability to use their failure data and systematically eliminate defects and issues from the processes and equipment.
To eliminate the defects and issues, the organization needs to collect meaningful data to analyze and act on. Typically it is to used to build a historical database of failures to drive reliability engineering work and equipment improvements.
So why is it that most organizations struggle with one? Also, the system may be overly complex. Start by following the suggestions below;.
Thankfully there are those who have taken the time to share their knowledge on this exact subject. ISO requirements. Well, it all starts with the asset hierarchy, which is a whole other topic. Assuming that the hierarchy is correct, the information that should be collected is as follows;. How effective is it? What are the issues you or your staff encountered when trying to record, analyze or act on the data? Remember, to find success; you must first solve the problem, then achieve the implementation of the solution, and finally sustain winning results.
Search for:. Phone: Info HPReliability. Previous Next. The failures related to a piece of equipment are reported through a standard form such as failure information in a work order. Analysis A. Is using the data to identify the cause of failure. This may be using a Pareto Analysis to identify the most important issue to address and then using other techniques to dive into the issue and determine the cause.
Corrective Actions CA. Once the cause has been identified, the corrective or preventative actions must be implemented to prevent the recurrence of the failure. Ideally, these are documented through a formal change management program to ensure the learnings are incorporated into new equipment designs. Start by following the suggestions below; Use a master library so that the number of overall codes is reduced, while only displaying codes relevant to the equipment in question Keep drop downs simple.
Ideally, they fit on a single screen with no scrolling Eliminate free text fields as much as possible for codes. Train your people. Train them on why the data needs to be collected, how it will be collected, how it will be used and most importantly, the benefits to them, Aligning Your FRACAS System to ISO Thankfully there are those who have taken the time to share their knowledge on this exact subject.
This could not be further from the truth. It is better to try to redesign out the failure or find a different solution. This will prevent nonvalue-added whether due to the nature of the failure mode or the cost effectiveness of the maintenance routine PM from being added to the maintenance program. Only collect the data that will be used. The people providing the data will realize that they are supplying data which is not used and as a result of that, they will stop supplying or worse, supplying incorrect data.
Make the data collection system easy. If it is not easy, it will not be used or will be gamed i. If you plan on recruiting Reliability Engineers in the future, setup the system to start collecting the data now. Related Posts. The Failure Mode Effect Analysis.
FRACAS: An Overview
FRACAS is a process that gives organizations a way to report, classify and analyze failures, as well as plan corrective reactions in response to those failures. A failure reporting, analysis and corrective action system FRACAS is a process that gives organizations a way to report, classify and analyze failures, as well as plan corrective reactions in response to those failures. Software is often used to implement a FRACAS system to help manage multiple failure reports and produce a history of failure with corresponding corrective actions, so recorded information from those past failures can be analyzed. The closed-loop process is a disciplined and focused approach that detects and solves issues in the design, development and production stages. It does this through multiple fundamental tasks, including recording and capturing data and information about failures; identifying and prioritizing failures; and determining, implementing and verifying corrective actions to prevent failure recurrence.
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Failure Reporting And Corrective Action System (FRACAS)
Although failure reporting, analysis, and corrective action system FRACAS has two management perspectives, its tasks and related information, the previous researches and applications mainly have focused on the data management. The development procedures are 1 to define the reporting and analysis tasks, 2 to define the information to be used at each task, and 3 to design a computerized business process model and set the attributes such as durations, rules, and document types. This computerized FRACAS process can be activated in a business process management system BPMS which employs the enactment functions, deliver tasks to the proper workers, provide the necessary information, and alarm the abnormal status of the tasks delay, incorrect delivery, cancellation. Through implementing the prototype system, improvements are found for automation of the tasks, prevention of disoperation, and real-time activity monitoring. Recently, the reliability of products or services is recognized as a key factor to accomplish the competitiveness of a company. Reliability refers to the ability of a system or a component to perform its required functions under the stated conditions for a specified period of time.