Asset Offender Report
Caution: You should not assume the OOB product has a failure analytic that you will like.
Every site should have at least one failure analytic which helps them drill-down on worst offenders. And, one of the key tenets of a maintenance & reliability program is failure analysis -- admittedly “after-the-factâ€, but still a valuable tool. And with the help of good “failure data†this type of review can help management focus on recurring problems. Using the power of SQL, the analyst (or reliability team) can then perform grouping to identify worst offenders.
Since most sites struggle to capture good failure data, it may help to explain some data elements. The objective is to select those work orders from work completions that have the following attributes:
Some Key Points:
- Failure Modes are important as a data element. But not all CMMS/AMS products easily capture failure mode. Therein it is my suggestion that you capture this in pieces (failed component + component problem + cause code) ..... and then compare to RCM Analysis failure modes.
- Some CMMS/AMS products also do not make it easy to capture asset downtime (due to high click-count). I suggest you make an “automatic calculator†which does this for the user with minimal input.
- The recording of the asset condition is also not a standard feature in most systems – but it can be easily captured. Simply make a business rule to record this data on every monthly PM.
Your system may permit dynamic selections as shown below:
Answer the prompt as to which column to emphasize (sort on). This could be number of failures, MTBF, asset condition, downtime, percent annual average cost / replacement cost, or age. Note: you may run this for each sort and record top asset.
Optionally select plant/facility/fleet system, or asset classification
Optionally select an asset criticality.
Once output is produced, record the top ASSET NUMBER for each of the above sorts.
Then hyperlink on that asset number to generate pie charts.
Click on the significant Failure Mode and then view Work Orders in a tabular listing. At this point you would review individual WO history and tex notes including Cause codes.
With all of the above data, the Reliability Team should begin asking a series of questions:
- Do we have the correct maintenance (PM/PdM) strategy?
- Was the PM performed correctly?
- Are key steps missing from the PM?
- Was the PM skipped?
- Was the last maintenance performed correctly?
- Was there an operational error?
- Is there a design flaw?
- Is there any maintenance technician feedback on the work orders?
- What were the entered cause codes?
- Should we continue with "repairs"?
Perhaps a root cause analysis is required, or a revised FMEA, or at a minimum, a plant system walk-down. Remember, it is important to find the "defect" - not just perform the repair.
Book author, CRL, CMM and CMMS champion.
9 å¹´thanks Kevin. ...a segue perhaps .... I was planning to make Repair/Replace the next posting. We are thinking alike.
Performance Analytics and Improvement Management Professional
9 å¹´Great article!!
Book author, CRL, CMM and CMMS champion.
9 å¹´thank you Eric Robinson @ Nissan Motor Corporation.
Book author, CRL, CMM and CMMS champion.
9 å¹´this is the $64k question - and one that many have. I don't have a magic pill, but here is my standard reply. I will use "BR" to mean business rule. 1) BR states that O&M staff involved with WOs must update the system at least once per shift. 2) BR states that at "job completion" and if this is a repair WO then certain data fields will be required. 3) Add new fields to screen to capture FAILED COMPONENT, COMPONENT PROBLEM, and CAUSE codes. Using electronically mandatory IF statements, I would make these fields required. {there are more details here so pls contact if needed} The combination of the above creates the FAILURE MODE. Some may say, "Hey, we are spending too much time at computer", ....but I say ... either we have an Asset Management System, or, we simply have a WO TICKET system (which adds minimal value to anyone). Evaluate where you are ... and where you have been.... and then ask, if we added value. If the "struggle" continues, then consider a new approach. Answer to your question: O&M Technician
Semi Retired; Contract Opportunities Considered
9 å¹´Hello John, As you mention: "Since most sites struggle to capture good failure data" how do we determine responsibility for failure data being entered as the work order moves through the system? The first couple of bullets should be entered by the creator of the W/O, but it's not clear who should be entering the data beyond that. In the past, we've had problems capturing this information because it does not impact those entering the W/O data. Consequently, we do not have the data to do the failure analysis.