Ot Chan DyTPM Team Leader

Simple and discipline process used to investigate, rectify and eliminate equipment failureMost effective when directed @ chronic breakdown/problemIt take you beyond just “why it is break”… It tell you what weakness in your management system

1. Reduction of chronic problem2. Increase MTBF (Mean Time Between Failure)3. Improve product quality & regulatory

compliance4. Better sensitive to machine problem5. Less NVA work and admin6. Fulfillment ISO system “Corrective Action”7. Very inexpensive way to save money for

company

1. Overall maintenance cost down: maintenance staffs can do more through proper planning and scheduling, rather than reactive

2. Investment on spear part down: save on carrying cost

3. Biggest saving: increase asset utilisation

Mostly, 80% of plant’s losses are represent by 20% Of failure events. This is call “Significant few”

PrioritPriority for y for RCFARCFA

1. Define a failure mode2. Information of failure3. Organization of analysis team4. Actual analysis5. Sharing the finding & making

recommendations6. Tracking result

Problem must be very specific, i.e:Bearing rusted NOT bearing damagedBeer under fill on filling head 16 NOT beer under fillAlways got “not close” alarm signal on valve v.0123 NOT alarm signal on valve v.0123

Engineering ReportTechnical Drawing (if available)Failure historyDamaged partsStandards and specifications

• Principal analyst – team leader: choose the one who no background in the problem but highly skill methodology and facilitate the process rather than guide team to a preconceived conclusion

• Process control leader

• Operator involve

• Maintenance engineers, highly knowledge in the system and process

• Go to the spot: place where failure happen• Touch/Examine objects• Check Fact & Figure (speak with data)

• 2 Questions ask repeatedly (use logic tree)• How can that happen?• Why did it happen?

Example of logic treeCircuit Breaker Overloaded of Circuit Breaker Overloaded of

Motor Screw ConveyorMotor Screw Conveyor

Current Intensity Current Intensity > 2.1A> 2.1A

Motor Conveyor Motor Conveyor take load > 2.5 take load > 2.5

t/hrt/hr

Motor coupling Motor coupling FailureFailure

Motor itself Motor itself FailureFailure

Gear Gear Reduction Reduction

FailureFailure

• 4 M categories => Root Causes => Solutions (objectively)

• Re-occurrence follow up table

• Out of your area of control or responsibility• Knowledge limited• Man (does not want to do it)

• All causes at the root of the problem have been identified

• Series of effective countermeasures have been implemented

• No re-occurrences

• Jump to conclusion• Attack symptoms not the causes• Not gathering enough evidences.• Problem is too large or general• Not involve relevant persons