Chronic Failure Analysis Focuses on Worst Offenders

Definition

Chronic Failure Analysis (CFA) refers to recurring failures which by themselves are not noteworthy, i.e. requiring a root cause analysis. But because they are almost routine, their frequent occurrence impacts the bottom line. Thus, organizations should focus on ways to attack the worst offenders and eliminate the cause.

Create a Process to Address CFA

With a vision for excellence, you can create a purpose-built CMMS which reduces reactive maintenance and optimizes return on asset. (1) Capture failure mode on work order at job completion. (2) Reliability team meets monthly (3) Runs failure analytic to generate a Top 10 list. (4) Reviewing the list on screen, they choose the asset to analyze. (5) Drill down on failure mode (component, component problem, cause code). (6) Verify failure data from affected work orders with this asset failure mode. (7) Compare work order failure mode to the CMMS RCM Failure Mode application. (8) Talk with O&M staff to gain additional insights. (9) Take corrective action on asset.

BRE == business risk exposure (this is calculated on a tab within the Asset application)

CBT == condition based technologies

Also note: The RCM Failure Mode application was added to the base product, as well as the Risk-based Asset Criticality tab.

This is an advanced design which leverages the power of the CMMS once configured and supports on-going refinement of the CMMS PM-CBT application, as well as, updates to the RCM Failure Mode library. Chronic failure analysis, applied in this fashion, offers the greatest potential decrease in O&M costs.

Here is a graphic that I call the SAW-TOOTH. It states that condition based technology is great at identifying the potential defect point and preventing catastrophic failure (with follow-on CBM), but the root cause still needs to be eliminated.