Eliminating Failures thru Accurate Data

Eliminating Failures thru Accurate Data

 Eliminating Failures thru Accurate Data

 
Maintenance leaders are always looking for ways/methods to optimizing their equipment reliability through improvement of their maintenance processes. 
In my experience "Accurate Work Order Close Out" is critical to ensuring decisions are made targeting the "root causes of equipment reliability and maintenance process problems" in order to "optimize asset reliability at optimal cost". 

One cannot obtain "optimal asset reliability at optimal cost is the maintenance process without discipline and repeatability.

"The objective of accurate data collection is to assist management in making the right decisions at the right time"

Here are a few General Rules (based on my experience):
> ALL WORK MUST BE COVERED BY A WORK ORDER 
> All Work Orders should have at the minimum the: 
- Correct action codes (breakdown (1), urgent (2), etc.) 
- Correct equipment number, at the right level 
- Maintenance person’s total time worked on W.O. 
 - Start time and completion time of W.O. 
- Comments from the maintenance person as to: 
- Work Performed 
- Recommendation to changes to maintenance strategy or plan 
- Parts used whether from the storeroom or not. 
- The maintenance technicians signature.
Without the above information one cannot determine:
- Actual maintenance cost for specific assets 
- Mean Time Between Failure (MTBF) (SMRP Metric - 3.5.1 Mean Time Between Failures)
- Mean Time To Repair (MTTR) (SMRP Metric - 3.5.2 Mean Time to Repair or Replace)
- Mean Time Between Repairs
- Rework (SMRP Metric - 4.1 Rework)
- If a PM Procedure is effective or not
-If a specific type repair is effective 
- If a maintenance strategy meets the intent of the end user 
- A dominant failure pattern 
- A dominant failure thread 
> Repair or Corrective Work orders should contain the following: 
- Component Code
- Failure code - Cause codes - Action Codes

There is process which was created by US Department of Defense to mitigate and control failures and it is called FRACAS, Failure Reporting Analysis and Corrective Action System. 

A Failure Reporting, Analysis, and Corrective Action System (FRACAS) is a system, sometimes carried out using software, that provides a process for reporting, classifying, analyzing failures, and planning corrective actions in response to those failures. 
It is typically used in an industrial environment to collect data, record and analyze System Failures. A FRACAS system may attempt to manage multiple failure reports and produces a history of failure and corrective actions. FRACAS records the problems related to a product or process and their associated root causes and failure analyses to assist in identifying and implementing corrective actions.es and it is called: FRACAS, Failure Reporting, Analysis, Corrective Action System.

Just my thoughts, if you have questions please contact me.


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