11.0 Failure Analysis

8/2/2019 11.0 Failure Analysis

http://slidepdf.com/reader/full/110-failure-analysis 1/7

November 15,

200911.0 FAILURE ANALYSIS

1.0 PURPOSE

This standard defines the process for performing Failure Analysis on assets at the Water Authority.

2.0 SCOPE

This standard applies to the Water Authority facilities and divisions involved in recording failure classes

and failure hierarchies on assets and workorders.

3.0 DEFINITIONS

3.1 Cause Code - Defines the CAUSE of the failure and/or Problem.

3.2 Failure Analysis - Failure analysis is the process by which you examine asset or location

failure history, reported over a significant period of time. Use any Asset or Location failure reports to

look for breakdown trends, average time between failures, and so on. By correlating this failureinformation with other data available to you, for instance, preventive maintenance schedules for an

Asset or Location, you can develop ways to reduce or limit equipment failures in the future. For

example, you might want to review your preventive maintenance schedule, or you might be able to

identify a branch of faulty inventory items.

3.3 Failure Reporting - Failure reporting is a long-term process where you gather data about

failures so that you can analyze trends and take steps to avoid problems in the future. For example, in

looking back over the failure reports for a pump, you might notice that the pump often breaks down

about one week before its monthly preventative maintenance check is scheduled. You might decide to

change the frequency of the PM checks to every other week, rather than every four weeks. You conduct

failure analyses to review histories of asset and location failures over time. Look for issues such as

breakdown trends or mean time between failures on printed reports. You can correlate this failureinformation with other data such as preventive maintenance (PM) schedules to develop ways to reduce

or limit asset failures in the future.

3.4 Failure Hierarchy - A failure hierarchy is an organized set of Problems, Causes, and Remedies

related to Asset and Location failures. The failure hierarchy is identified by its top-level component,

called a Failure Class. There must be an associated failure class for each Asset or Location that you want

to report failures for. Groups of data called failure codes are linked in parent-child relationships to

form a failure hierarchy.

3.5 Failed System – Defines the system where the failure occurred. This is tied to the type of

system (i.e. - Sewage, Gravity).

3.6 Failure Class - Defines where in the system the failure occurred. This is tied to the type of

Asset (i.e. - Meter, Pipe, Fire Hydrant).

3.6 Problem Code - Defines the PROBLEM of the failure. I.E. Leaks, Knocked Out, Blocked, Backed

Up, etc.

3.7 Remedy Code -Defines the REMEDY to fix the failure/problem.



November 15,


4.0 RESPONSIBILITIES

The following provides typical descriptions of responsibilities and accountabilities for implementing the

failure analysis process. Each Superintendent or Supervisor, as appropriate, should designate

responsibilities.

4.1 Superintendent - Responsible for the review and approval of workorder documentation,including the Failure Hierarchy.

4.2 Supervisor - Responsible for the review and approval of workorder documentation, including

the Failure Hierarchy.

4.3 Maintenance Technician – Responsible for performing the initial steps in completing the Failure

Analysis, which includes the proper recording of the Failure Class, Problem, Cause and Remedy.

4.4 Planner/Scheduler - Responsible for completing all workorders and ensuring that the workorder

is documented with the appropriate Failure Hierarchy.

5.0 INSTRUCTIONS

5.1 Unless required, the Failure Hierarchy need only be completed at the Parent level of the

working being performed. If the work being completed is not applicable to a failure hierarchy, then the

Failure Class will be noted as NA (Not Applicable), and the Problem, Cause and Remedy codes may be left

blank.

5.2 Any person authorized to create or modify workorders can document the Failure Hierarchy as

work progresses through the completion of a workorder and its tasks.

5.3 Levels of the hierarchy can be added at anytime. Changes to the failure hierarchy codes must be

requested through the Maximo Support team and will be immediately completed. These requests must conform to the definitions identified in this standard.

5.4 Unless it is not required, all workorders will be documented with a Failure Class as defined in

this standard. This will represent what asset class failed. If the asset itself has already been identified

with a failure class, the workorder will automatically have this completed once the workorder is

assigned an asset. Completion of the Failed System field is optional.

5.5 During the completion of the workorder, the Problem, Cause and Remedy of the workorder will

be documented. These items may change during the course of workorder completion as more

information is obtained during the work process.

5.6 Failure Hierarchy Completion: If possible, the person creating the workorder will identify theFailure Class and Problem. As the workorder progresses, it is responsibility of the Maintenance

Technician, Supervisor and Superintendent to perform a review of the Failure Hierarchy prior to

submitting the workorder for final completion. Additional notes related to the Problem, Cause and

Remedy will be noted on the workorder log.

5.7 The Planner/Scheduler has final approval on the Failure Hierarchy, or lack thereof. No

workorder will be marked with a status of COMPLETED until the Failure Hierarchy is final.



November 15,


6.0 APPENDICES

APPENDIX 11.0.A – Building a Failure Hierarchy – Maximo Example



November 15,


Appendix 11.0.A - Building a Failure Hierarchy – Maximo Example

Failure reporting lets you identify and track asset and location failures. Entering Failed System, Failure

Class and Problem Code data on work orders provides data that can be used for failure analysis. You usethe Failure Reporting subtab of the Quick Reporting application, and the Failure Reporting tab of the

Work Order Tracking application to record failure data.

Failure analysis is how you examine your failure history data, reported over a significant period of time.

You use asset or location failure reports to look for breakdown trends, average time between failures,

and so on.

By correlating this failure information with other data available to you, for instance, preventive

maintenance schedules for an asset or location, you can develop ways to reduce or limit future failures.

For example, you might want to review your preventive maintenance schedule, or you might be able to

identify a branch of faulty inventory items.

A failure hierarchy is a set of data on problems, causes, and remedies for asset and operating location

failures. Groups of data called failure codes are linked in parent-child relationships to form a failure

hierarchy. Each hierarchy is identified by its failure class.

Failure hierarchies are built from the top down. You navigate the failure hierarchy from top to bottom. A

failure hierarchy can be created all at once, or completed partially and added to later as necessary. You

can use existing failure codes and/or create new ones to build the hierarchy.

Maximo and Failure Hierarchies

You can select existing failure codes by clicking the Select Value icon next to the field used in Maximo for

recording Failure Hierarchies. You can create new failure codes by typing a value into the field. Maximo

will attempt to match the value you entered with an existing failure code value. If one already exists,

Maximo copies it into the field. If one does not exist, Maximo displays the Select Value dialog box. Click

Continue to accept the value.

NOTE: Failed System is a Water Authority custom field and has been added to the Failure Analysis

Program procedures. It is not a required field, but provides means to track failures at a “system” level

rather than the Failure Class level.

NOTE: Failure codes can be used at any level of the hierarchy. For example, jammed" could be both a

Problem and a Cause. The procedures for adding Problem, Cause, and Remedy level failure codes are the

same with one exception: selecting the parent for Causes and Remedies. All Problem failure codes are

children of the Failure Class, but note the labels for the Cause and Remedy tables, which indicate the

parent levels for the records in each table window. The Cause and Remedy table windows are both

paired table windows, their labels reflect the selected row in the table above.

CAUTION: Before entering Causes or Remedies, check that the table window label reflects the correct

parent for the failure code you are about to enter. To change the table label, click the appropriate row in

the parent table window.



November 15,


TIP: Using failure codes on work orders can help reduce the number of duplicate work orders that are

entered in the system. Maximo displays a message if a work order with the same Problem Code already

exists for the asset or location!

Failure Hierarchy Example

This example demonstrates the steps you could use to build a three-level failure code hierarchy named

PUMPS in the Failure Codes application. Click the links below to see how you build each level. The

following figure shows a failure hierarchy for a pump:

Failed System

To create a Failed System selection, a request must be submitted to the Maximo Support team with the

Failed System Code and Description. This information will be configured in the system and made

available via a drop down list.

Failure Class and Failure Codes

To create the failure class and first level failure code of the PUMPS failure hierarchy in the Failure Codesapplication:

1. On the Failure Codes tab of the Failure Codes application, click New Failure Code .

2. In the Failure Class field, enter PUMPS. In the Description field, you can enter a description; e.g.,

Pump failures.



November 15,


You have just created the top level of the failure hierarchy. Next, you will create three failure codes in the

top failure code type within this hierarchy.

Problems

The Problems table contains the top level failure codes in the hierarchy. Under the Problems table, click New Row.

1. In the Problem field, enter LOW PRES.

2. In the Description field, enter Low Pressure.

3. Repeat steps 3-5 to enter the following additional problems:

4. LOW VOL, Low Pressure, Problem

5. STOPPED, Stopped, Problem

6. Click Done, and then click Save Failure Code .

You have now identified three main problems that could put the pump out of service. These problems

are the first level of the failure hierarchy. You must save each level of the hierarchy before you can create

or add to another level of the hierarchy.

Causes

You are now ready to start building the second level of the PUMPS failure hierarchy in the Failure Codes

application. For every cause, or second level failure code that you create, you must first select its parent

from the first level of failure codes.

1. In the Problems table, click LOW PRES to select it as the problem to which you want to add a

cause.

2. Under the Causes table, click New Row.

3. In the Cause field, enter FITTING.

4. In the Description field, enter Fitting Leaking.

5. Repeat steps 2-4 to insert the following additional causes for the problem of low pressure:

6. HOUSING, Housing Leaking, Cause

7. SEAL, Seal Leaking, Cause

8. Click Done, and then click Save Failure Code.

You have just created three causes for the problem of low pressure in this failure hierarchy. Next, you

can enter remedies, or children, for these causes.



November 15,


Remedies

Take these steps to build the third and final level of the PUMPS failure hierarchy in the Failure Codes

application:

1. In the Causes table, click Fitting to select it as the cause to which you want to add a remedy.

2. Under the Remedies table, click New Row.

3. In the Remedy field, enter REPFIT.

4. In the Description field, enter Replace Fitting.

5. Repeat steps 2-4 to insert the following additional remedy for the cause Fitting:

6. TIGHT FIT, Tighten Fitting, Remedy

7. Click Done, and then click Save Failure Code.

You have completed building a failure hierarchy. You can add and delete problems, causes, and remediesto the failure hierarchy.

11.0 Failure Analysis

Documents

Transcript of 11.0 Failure Analysis