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Copyright 2009 GPAllied

F.R.A.C.A.S.
Failure Reporting, Analysis and
Corrective Action System

Presented by: Andy Page

Copyright 2009 GPAllied


Phone is Listen Only
During the Webinar.email questions to

smithr@alliedreliability.com

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F.R.A.C.A.S. Webinar Objectives
What is it?
How do you use the results?
How do you set it up?
Biggest Challenges
Summary and Wrap up

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Definition
fracas: n. A noisy, disorderly fight or quarrel; a brawl

F.R.A.C.A.S.
A system for recording the nature of equipment failures,
analyzing the data for patterns and making business
decisions based on the conclusions drawn from the data

Predominantly talking about CMMS Failure Codes and how they


can be used.
Also, talking about the other failure characteristics

Mean Time to Repair

Work Request Sources

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What do you want to know?
# of Failures (56)
Equipment
Hierarchy
#2 Press (30)

Drive Motor (15)

Bearings (13)

Fatigue (12)
Work Order
Closing Codes Misalignment

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This is not a coincidence!

C
Failure Modes

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Failure Mode - Definition
Part
Bearing

Defect
Fatigued

Reason
Misalignment

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Part
The level at which work is performed

Examples:
Bearing
Breaker
Shaft

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Defect
Not just the Mode
Worn
Not descriptive enough

Has to include Failure Mechanism


When the mechanism is descriptive
Knowing the mechanism might change the
countermeasure (task)
Example: Adhesive Wear versus Abrasive Wear

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Reason
Describes the action or condition that was
physically responsible for the problem
Example: Improper Installation

NOT another failure


Cannot reference another failure mode as the
reason why this failure mode is present
These are called Secondary Effects
Example: Bearing Abrasive Wear Seal Failed

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For Reasonhow deep do I go?

Effect Bearing Defect

Physical Cause Shaft


Misalignment

Human Cause

Systemic Cause

Latent Cause

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We only need a few codes

What we What we
expected recorded
(Failure Modes) (Failure Codes)

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Real World Example

Failure Modes Failure Codes


Bearing Fatigued Age Pump - Stopped

Bearing Fatigued Imbalance Pump - Making Noise

Bearing Fatigued Misalignment Pump - Not Pumping

Bearing Abrasive Wear Contaminants Shaft Seized

Bearing Adhesive Wear - Age

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Work Order History Report
# of Failures (56)

#2 Press (30)

Drive Motor (15)

Bearings (13)

Fatigue (12)

Misalignment

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This is what you are looking for
# of Failure Code
Instances
78 Misalignment Improper Assembly
56 Bearing Fatigue Misalignment
32 Loose Connections Improper Assembly
22 Soft Foot Improper Assembly
8 Abrasive Wear Improper Lube Procedure
1 Turn-to-Turn Short Background Vibration
Contains the Failure Mode
Independent of Equipment Type
Shows the BIG picture

What would be the Corrective Action?

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LEAN Terminology
Yokoten (push to the side)

Take what you have learned on this machine and


apply it to other like machines

FRACAS
If it has happened to this machinehow many
other machines has it happened to as well?
Even more importantlyHow many other machines
is it about to happen to?

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Nowwe go deep

Effect Bearing Defect

Physical Cause Shaft


Misalignment

Human Cause Skills Deficiency Lack of Motivation Lack of Time

Systemic Cause No Training No Performance No Repair


Standard Standard Standard

Organizational Attitude
Latent Cause Towards The Value of
Precision Maintenance

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2 Un-pardonables for Reliability Engineers
1. To fix the same problem twice
This really means you never FIXED it the first time.
You most likely addressed the Symptom and not the
Problem

2. To know a problem is coming and not be prepared


to deal with it efficiently
Run-to-Fail is a perfectly valid strategy for some things
But to not be ready is unpardonable
Job Plans on File
Ready access to spare parts

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Strategy Adjustments
Changing the Equipment Maintenance Plan
Different PM Task
Different Inspection Task
Different Frequency
Different Operating Philosophy
70% of failures come from improper operation
30% of failures come from improper/inadequate maintenance

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Biggest Challenges
Crafts personnel or Supervision wont always know
the Part - Defect Reason in the field
If they simply Remove & ReplaceFRACAS will never
happen
Someone has to be responsible to perform the failure
analysis and get that data into the CMMS

For a while, you will constantly find that you need a


Failure Code that is not in the system
This means that you Failure Modes Library isnt complete
yet

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Implementation Plan Part 1
Start Small & Take It Slow
Critical Equipment Only (Top 20%)
Let work processes mature around the new
requirements

Trigger for next level


All Work Orders = Closing Codes
Take the next 20%

Work your way up to 100%

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Implementation Plan Part 2
Define your work control processes

Assign Goals, Roles and Responsibilities


Individual responsibilities for data entry and
analysis can be anyonesjust make sure it is
officially assigned

Institute a system for checking compliance


A system for addressing non-compliance

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Implementation Plan Part 3
Identify the Top 20% of your equipment
Identify Failure Modes
Populate CMMS with Failure Codes
Close Each Work Order for Critical
Equipment
On Scheduled Basisrun analysis reports
Analyze whole plant or areas
Not much deeper
Not by equipment types
Focus too smallyoull miss the big patterns

Copyright 2009 GPAllied


Summary
Powerful method for making the organization
a learning organization
Learn from mistakes

A different way of thinking about failure


analysis
No longer is itwhich MACHINE is giving us
trouble
It is nowwhat are our dominant issues across
the plant

Copyright 2009 GPAllied


Summary - continued
Everybody wants the benefits of FRACAS but
few people are willing to put forth the effort
to Feed the Beast
Not willing to put the work control processes in
place to make it a reality
Not willing to hold people accountable for non-
compliance

Copyright 2009 GPAllied

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