Analyzing failures due to problems occurring on the equipment

Analyze Failures - By Problem Code

In this page, you can perform a failure analysis on the problems that occur on the equipment. Tell me more.

Select the “Problem Code Wise Analysis” link from the bottom of the “Select Equipment” page.

The “Analyze Failures - By Problem Code” page appears.

The system displays the following fields:

Failure Analysis No.	The number of the failure analysis carried out. The system generates this number automatically when you click the “Save” pushbutton.
Prepared On	The date and time at which the analysis is performed. The system displays the current date when you click the “Save” pushbutton.
Prepared By	The login ID of the user who performed the analysis. The system displays this field when you click the “Save” pushbutton.

Enter the following fields to specify the dates on which you wish to perform the analysis:

Analysis From	The date starting from which the analysis must be done (Date Format). Mandatory.
To	The date until which the analysis must be done (Date Format). Mandatory.

Note: Ensure that the date entered in the “Analysis From” field is earlier than the date entered in the “To” field.

If you wish to perform a failure analysis on the problems that occur on the equipment other than the equipment entered in the main page, enter the following field:

Eqp.	The equipment for which the problems must be analyzed (Alphanumeric, 30). Mandatory.

	Help facility available
	Press <Enter>. The system retrieves in the “Analysis Results” multiline, the problem codes of the equipment, for which severity, occurrence and detectability ratings have been defined in the “Define Failure Analysis Configuration” activity. The description of the equipment is displayed alongside.

Click the “Analyse” pushbutton to perform the failure analysis.

The system displays the results of the failure analysis performed on the problems of the selected equipment, in the “Analysis Results” multiline.

Problem Code	The problem code of the equipment, for which detectability ratings have been defined in the “Define Detectability” page of the “Define Failure Analysis Parameters” activity.
Desc.	The description of the problem code.
Severity	The severity rating of the problem. This indicates the severity of failure of the equipment, due to the occurrence of this problem.

Click here to learn about the calculation of severity rating for a specific problem that occurs on equipment.

Occurrence	The occurrence rating of the problem. The higher the occurrence rating, the greater the chances of equipment failure. The occurrence rating is calculated as follows:
	The period of failure analysis is calculated as the difference between the dates entered in the “Analysis From” and “To” fields.
	The number of closed work orders that have been raised on the equipment during the analysis period for solving the specific problem is ascertained. This indicates the number of occurrences of the problem on the equipment.
	The number of problem occurrences is then apportioned for the base period that has been defined for failure analysis in the “Define Failure Analysis Parameters” activity.
	The occurrence rating is then arrived at, based on the range in which the actual number of problem occurrences falls.
Detectability	The detectability rating of the problem as defined in the “Define Detectability” page of the “Define Failure Analysis Parameters” activity.
Risk Factor	The risk factor indicating the criticality of the equipment due to the occurrence of the problem. This field is calculated by multiplying the severity, occurrence and detectability ratings. The system leaves this field blank, if any of these ratings have not been assigned.

Enter the following field in the multiline:

Recommended Actions

Any remedial action that is to be taken for handling the impending failure of the equipment and to reduce the risk factor in future.

Click the box in the “Select” column of the multiline, to select for deletion those rows for which you do not wish to save the failure analysis performed on the problem.
Click the Delete icon in the toolbar above the multiline, to delete the selected problems.
Click the “Save” pushbutton to save the details of the analysis along with the remedial action.

Note: The system saves the results of the failure analysis. It also generates a unique number for the failure analysis and displays the number in the “Failure Analysis No.” field. The login ID of the current user is displayed in the “Prepared By” field and the current date and time are displayed in the “Prepared On” field.

To proceed, carry out the following

Select the “View Failure Analysis Configuration” link from the bottom of the page to view the details of failure analysis that is done.
Select the “View Detectability/Safety Ratings” link from the bottom of the page to view the detectability and safety ratings defined for the equipment.

Calculation of severity rating for the problems that occur on an equipment

The system calculates the severity rating as follows:

1. The period of failure analysis is calculated as the difference between the dates entered in the “Analysis From” and “To” fields.

2. The severity rating based on production down hours is calculated as follows:

The actual number of production affected down hours the equipment was down during the analysis period is ascertained from the closed work orders that have been raised on the equipment for the problem during the analysis period.
The number of production down hours is then apportioned for the base period that has been defined for failure analysis in the “Define Failure Analysis configuration” activity.
The range in which the actual production down hours of the equipment due to the specific problem falls is ascertained, by comparing this value with the ranges defined in the analysis configuration, and the severity rating assigned to this range is ascertained.
The rating, which is on a scale of 1 to 10, is further multiplied with the weightage that has been defined for production down hours in the “Option Settings” activity.

For example, if the rating is 8, and the weightage that has been defined for production down hours in the “Option Settings” activity is 30 %, the system does the following calculation:

Severity based on production down hours = 8 * 0.30 = 2.4

If no weightage is set for the production down hours in the “Option Settings” activity, the system calculates with a weightage of 34%.

3. Calculation of severity based on maintenance expenses

The maintenance expenses incurred on the equipment due to the occurrence of the specific problem, during the analysis period is ascertained from the closed work orders that have been raised on the equipment during the analysis period.
The maintenance expenses are then apportioned for the base period that has been defined for failure analysis in the “Define Failure Analysis Configuration” activity.
The range in which the actual maintenance expenses of the equipment falls is ascertained, and the severity rating assigned to this range is ascertained.
The rating, which is on a scale of 1 to 10, is further multiplied with the weightage that has been defined for maintenance expenses, in the “Option Settings” activity.

For example, if the rating is 7, and the weightage that has been defined for maintenance expenses in the “Option Settings” activity is 40 %, the system calculates following:

Severity based on maintenance expenses = 7 * 0.4 = 2.8

If no weightage is set for the maintenance expenses in the “Option Settings” activity, the system calculates using a weightage of 33%.

4. Calculation of safety rating

The actual safety rating that has been specified in the “Define Analysis Configuration” activity is multiplied into the weightage that is defined for safety ratings in the “Option Settings” activity.

For example, if the rating is 6, and the weightage that has been defined for safety rating in the “Option Settings” activity is 30 %, the system does the following calculation:

Severity based on safety rating = 6 * 0.3 = 1.8

If no weightage is set for the safety rating in the “Option Settings” activity, the system calculates using a weightage of 33%.

5. Severity rating for the problem is calculated as a sum of the ratings ascertained from steps 2 to 4. This severity rating is displayed in the “Severity” column in the multiline.

Analyze equipment failure due to a specific problem

You can analyze equipment failure for a specific period and for a specific problem, based on the severity, occurrence and detectability ratings that have been defined.

Enter the period for which analysis must be done in the “Analysis From” and the “To” fields.
Click the “Analyze” pushbutton to analyze equipment failure and to view the results of the analysis that is done.

Analyze Failures - By Problem Code – An overview

In this page, you can perform a failure analysis on the problems that occur on the equipment selected in the “Select Equipment” page. You can also directly enter an equipment code, other than the equipment selected in the main page and retrieve its problem codes for failure analysis. You must specify the period for which the failure analysis is to be performed. The system performs the failure analysis and displays the following results in the multiline:

The description of the problem code for which the analysis is done.
The severity rating of the problem code. This rating indicates the severity of the failure of the equipment, due to the occurrence of the problem. The severity is calculated taken into consideration the following aspects:

The actual number of production down hours calculated from the closed work orders. of the equipment during the analysis period due to the occurrence of the specific problem. i.e., from the work orders raised on the equipment that is being analyzed, with the specific problem as the major problem.

The maintenance expenses, calculated from the closed work orders that were incurred on the equipment for the occurrence of the problem during the analysis period.

The safety factor of the equipment, which is defined by the user.

The occurrence rating of the problem. This rating indicates the frequency of occurrence of the specific problem on the equipment. It is calculated based on the actual number of closed work orders that are raised on the equipment during the analysis period to solve the specific problem. A higher occurrence rating indicates that the problem occurs more frequently on the equipment, than the problem that has a lower occurrence rating.
The detectability rating of the problem as defined in the “Define Detectability Rating” page of the “Define Failure Analysis Configuration” activity. This rating indicates the probability of detecting the problem when it occurs on the equipment. A higher detectability rating indicates that the problem is difficult to detect on the equipment, whereas a lower detectability rate indicates that the problem can be easily detected on the equipment.
The risk factor of the problem. This risk factor is calculated by multiplying the severity, occurrence and the detectability ratings of the problem, and it lies between 1 and 1000. The risk factor indicates the risk of failure of the equipment due to the occurrence of the problem. A high risk factor indicates the criticality of the problem code in the equipment performance.

Based on the results of the failure analysis, you can suggest the remedial actions that can be taken for reducing the risk factor of the problem in future. You can also save the results of the failure analysis and the suggested remedial actions, for future retrieval. When you save the failure analysis, the system automatically generates a failure analysis number and stores the login ID of the current user along with the date and time at which the analysis is done.

Prerequisite

Create Equipment under the “Equipment Induction” business component.