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<strong>AMMJ</strong> What’s The FRACAS 24 new failure modes not covered by your strategy occur. You can now make a new failure code to track the new failure mode so additional failures can be tracked and managed when you review work order history. You can see this is a continuous improvement loop which never ends. Steps to Implementing an Effective FRACAS Let’s back up a little. The foundational elements of an effective FRACAS are an effective validated equipment hierarchy, criticality analysis, failure modes analysis, and equipment maintenance plans. FRACAS Checklist: • Equipment Hierarchy should be built and validated so that similar failures on like equipment can be identified across an organization. • Criticality Analysis is developed and validated so that equipment criticality is ranked based on Production Throughput, Asset Utilization, Cost, Environment, and Safety. • Failure Modes Analysis is completed on all critical equipment using FMA, FMEA, or RCM. • Equipment Maintenance Plans are developed on all critical equipment to prevent or predict a failure. Effective Equipment Hierarchy Asset Catalog or Equipment Hierarchy must be developed to provide the data required to manage a proactive maintenance program which includes failure reporting or FRACAS (Failure Reporting, Analysis and Corrective Action System). In order to eliminate failures, one needs to ensure this is a successful first step. Figure 3 displays the findings from a plant with 32 total “Part – Bearing” failures from different size electric motors (“Part” is identified from a CMMS/EAM Codes drop down screen). One type “Defect – Wear” occurred in 85% of the failures (“Defect” is identified from a CMMS Codes drop down screen). In 98% of the cases, “Cause” was found to be ”Inadequate Lubrication”. Now it is time to perform a Root Cause Failure Analysis on this common thread of failures. (“Cause” as identified on CMMS/EAM Codes drop down screen). Once the hierarchy is established you can find similar failures in one area of an operation or across the total operation. Validation of the equipment hierarchy is required against the organization’s established equipment hierarchy standard. We are looking for “Part” – “Defect” – “Cause”. Maintenance personnel may not have the training or ability to determine the “Defect” (Predictive Maintenance Technician could identify Defect) and “Cause” can be typically identified by a maintenance technician, maintenance engineer, reliability engineer, or predictive maintenance technician. After a thorough analysis you will find that most failures come from a small amount of equipment. The question is, “Which equipment?”. Figure 3 Reason for Equipment Hierarchy is Valiidated Figure 4 Intersept Model Vol 24 No 1
<strong>AMMJ</strong> Asset Criticality Analysis Everyone says they have identified their critical equipment. But, in many cases, equipment criticality could change based on how upset people are about an equipment problem or because people are confused about what consequences associate to failure and the probability it will occur if we manage equipment reliability effectively. The purpose of the Asset Criticality Analysis is to identify which equipment has the most serious potential consequences on business performance, if it fails. Consequences on the business can include: • Production Throughput or Equipment / Facility Utilization • Cost due to lost or reduced output • Environmental Issues • Safety Issues • Other The resulting Equipment Criticality Number is used to prioritize resources performing maintenance work. The Intercept Ranking Model illustrates this process (Figure 4). On the “Y” axis you see the asset criticality is listed from none to high. I like using a scale of 0-1000 because all assets are not necessarily equal. TEST & CONDITION MONITORING SERVICES High Voltage Equipment Power Transformers & HV Cables deteriorate with age and excessive stress, and can fail without warning at enormous cost. Our services will provide fingerprinting, trending, grading of the worst offenders and accurately pinpoint likely failure. Figure 5 “4 Way Prioritisation Model” ALL-TEST PRO TM PREDICTIVE MAINTENANCE The only Complete System for motor diagnostics Online and Offline For more information go to www.aptgroup.com.au or call 1300 700 002 25 EASY & SAFE MOTOR TESTING – fast, accurate and non destructive PREDICTIVE MAINTENANCE – early detection and time to failure estimates STATOR FAULTS – turn, coil, phase, ground and connection faults ROTOR FAULTS – casting void, mechanical and rotor bar faults POWER QUALITY – transformer, VSD, harmonics and cable fault detection POWERFUL SOFTWARE – trending, analysing, writing reports and work orders ASSET MANAGEMENT – motor database and energy efficiency calculations COST EFFECTIVE – optimise motor availability and production QUALITY ASSURANCE – motor faults quantified and repairs assured LOCAL SUPPORT – training and technical backup GREAT DEALS TO BUY OR LEASE Risk Management Part of the apt Group
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