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-fact”, 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.