Failure Mode and Cause Code in SAP
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Transcript of Failure Mode and Cause Code in SAP
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Maintenance Excellence
Failure Modes
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Failure Modes Jan 08 2
Update status of Failure Mode Development
What are Failure Modes?
Why use Failure Modes?
How are they used in SAP
How are they used in PMO
SAP Reliability Reports
Review of Components, Parts and Damage
Cause Codes MPC approval to change SAP List
Where to next?
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Failure Modes Jan 08 3
Failure Mode Definition
What is a Failure Mode?
Any event that causes a 'Functional Failure' ie the asset is no longer able to perform its original function
Made of four sections
Component e.g. Gearbox
Part e.g. Bearing
Damage e.g. Worn
Cause e.g. Expected use, wear or tear
GEARBOX, Bearing worn due to expected use, wear or tear
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Failure Modes Jan 08 4
Failure Mode Benefits
Why use a Failure Mode?
Enter Reliability Data when completing a SAP Work Order listing failure mode and cause
Feedback from Tradesperson on what failed and why (To be read in conjunction with Work Description)
Basis for developing Maintenance strategy tasks to prevent failure modes which have happened in the past or that could happen and cause a hazard
PMs are then developed to efficiently plan and undertake these strategy tasks
Able to undertake review of all failure modes and strategy tasks against a particular functional location
In future able to use BW Reliability reports
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Failure Modes Jan 08 5
How we use Failure Modes in SAP
There are three main types of Notifications
M1 Maintenance Requests
M2 Malfunction Reports
M3 Activity Reports
Notifications initiate any request for maintenance
Notification contain the failure codes
Notifications capture the tradesmens feedback (text and codes)
Notifications are used to report all equipment failures and reliability information
Subsequent Notifications contain the maintenance plan number and are used to validate the Preventative Maintenance Activities.
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Failure Modes Jan 08 6
How we use Failure Modes in PMO
Develop Maintenance Strategy tasks aimed at preventing
Failure Modes
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Failure Modes Jan 08 7
SAP Reliability Report
Reliability Report for Maintainable Item 24/05/2005
Functional Location Floc1
Description X Cylinder System XYZ Plant W
Predicted Life (yrs) 5 Current Age (yrs) 1.1
Average life achieved (yrs) 2.9 Condition Assesment at last inspection Very Good
Std Dev (yrs) 2.2 Next Restoration based on predicted life Mar-09
Maximum Life (yrs) 4.7 Next Restoration based on average life Feb-07
Minimum Life (yrs) 0.4
Repa ir / Restora tion History
Date
Activity Code
Group
Description
Activity
Code
Description
T ime Since
Last
Restora tion
(yrs)
Cause Code Group
Description
Cause Code
Description
Fa ilure Mode
Description
Fa ilure Mode
Description Damage T ext
22/08/1995 Restoration On failure Normal ageing & usage Guide bush Worn
27/08/1995 Repair On condition 0.01 Material / Installation Problem Incorrect assy / installation Hose connection leaking
30/12/1995 Restoration On failure 0.36 Damage / Overload external force Mounting Broken Crane tore cylinder off mounting
16/07/1999 Restoration On failure 3.55 Damage / Overload unknown Rod Broken
12/03/2004 Restoration On failure 4.66 Damage / Overload external force Mounting Broken Crane tore cylinder off mounting
31/03/2004 Repair On condition 0.05 Material / Installation Problem Incorrect assy / installation Hose connection leaking
Reasons for Restoration
Normal ageing & usage
Damage / Overload
Distribution of Lives Achieved
0
1
2
3
0 - 1 yrs 1 - 2 yrs 2 - 3 yrs 3 - 4 yrs 4 - 5 yrs
Failure Mode Summary
0
1
2
3
Hose
connectio
n
leakin
g
Mountin
g
Bro
ken
Guid
e b
ush
Worn
Rod B
roken
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Failure Modes Jan 08 8
PMO and SAP Failure Mode Data Coordination
Aim - have the same pick lists for Failure Modes in PMO & SAP
Benefit facilitates comparison of actual failures with strategy to manage those failure modes
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Failure Modes Jan 08 9
PMO Structured Failure Mode Library
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Failure Modes Jan 08 10
3 Types SAP Reliability Data Codes
Based on the nature of the equipment (Object type) Used to capture the component that failed and the Mode of failure. The PMO strategy and identified failure modes will form the basis
of the failure Mode codes. Are equipment specific and will only be configured once a strategy
review for the equipment has been completed in PMO.
Common for all equipment. Used to describe the nature of the action taken in terms of its effect
on the item life cycle Restoration Repair Modification Not related to an installed item
Common for all equipment. Used to understand the nature of the failure Groupings are based on the Bath tub curves
Material or Installation Problem (Infant mortality)Damage / overload (Random)Normal ageing & usage (Wear out)Accelerated Deterioration (Wear Out)Not Failure Related
Failure Code
Cause Code
Activity Code
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Failure Modes Jan 08 11
SAP Reliability Data
Failure Code
Cause Code
Activity Code Able to add
Long Text
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Failure Modes Jan 08 12
Tradesperson Access to Failure, Cause & Activity Fields
2. Click on Edit
Job Notes
3. This opens Work/Breakdown
Details screen able to enter Description information
4. Open Reliability Data screen
able to enter Failure, Cause and Activity information
1. Highlight the job
after hours
entered and job
confirmed
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Failure Modes Jan 08 13
Component List Status
Components form Device level of Functional Locations e.g.NZ/153/H02/GBX002
Comparison made to PK
NZS and PK have variations of alpha/numeric coding
Further discussions needed with BSL sites to reach consensus on how to handle Component Lists. Either
Try and get commonality against BSL
Agree on variations able to be used
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Failure Modes Jan 08 14
Part List Status
Parts List reviewed to
Eliminate double ups
Bearing / Bearings
Incorrect items
Water cavities
Use generic term
Lining becomes Liner
Motor Bearing become Bearing
Lead Screw become Screw
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Failure Modes Jan 08 15
Damage List Staus
Damage List reviewed to
Rationalise items
Arc becomes arc damaged
Bent becomes damaged
Fouled becomes blocked
Eliminate double ups
Cracked and cracked weld
Depleted, empty and discharged
Become master list for SAP
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Failure Modes Jan 08 16
PMO Failure Mode - Cause List
Eg: pump bearing seized due to lack of lubrication
Note: used to be 45 causes, now rationalised down to just 12
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Failure Modes Jan 08 17
Compare PMO Causes to existing SAP Cause list
PMO Causes mapped to existing SAP Cause list
Showed that there were serious gaps need to change SAP list
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Failure Modes Jan 08 18
Recommend change SAP Cause list to:
MPC to approve change to SAP list
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Failure Modes Jan 08 19
Develop SAP Equipment Catalogues
Able to allocate Functional
Location Devices to a Failure
Mode Catalogue in SAP
Reduce selection when
allocating Failure and Cause
Codes in SAP
e.g NZ/153/H02/GBX001
Only see the following
Failure Modes in SAP
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Failure Modes Jan 08 20
Where to next
1. Distribute SAP Cause recommendations to MPC for review and comment
2. Complete PMO Part/Damage lists for review by MPC (These form Failure Mode list in SAP)
3. Load to SAP Test (BRT) for review
4. Communicate with PK and WP regarding our intentions
5. Load to BR0 and load
6. Continue to develop SAP Catalogues