Analyze Failures - By Equipment

In this page, you can carry out equipment-wise failure analysis. Tell me more.

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

The “Analyze Failures - By Equipment” page appears.

The system displays the following fields:

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

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

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

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

• Click here to learn about the calculation of severity rating.

• Enter the following field in the multiline:

• Check the box in the “Select” column of the multiline, to select those equipment for which you do not wish to save the analysis that is done.

• Click the Delete icon in the toolbar above the multiline, to delete the selected equipment from the analysis.

• Click the “Save” pushbutton to save the details of the analysis along with the suggested 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 is 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

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 of the equipment during the analysis period is ascertained from the closed work orders that have been raised on the equipment 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 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 the production down hours in the “Option Settings” activity.

3. Calculation of severity based on maintenance expenses

• The maintenance expenses incurred on the equipment 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.

4. Calculation of safety rating

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

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

Analyze Failures - By Equipment – An overview

In this page, you can carry out equipment-wise failure analysis. You must specify the period for which the failure analysis must be done. The system performs the failure analysis and displays the following results in the multiline:

• The description of the equipment for which the analysis is done.

• The severity rating of the equipment. This rating indicates the severity of the failure of the equipment, which is calculated based on

• The occurrence rating of the equipment. This rating indicates the number of times problems have occurred on the equipment, which is counted based on the actual number of closed work orders that are raised on the equipment during the analysis period.

• The detectability rating of the equipment as defined by the user in the “Define Detectability Rating” page of the “Define Failure Analysis Parameters” activity. This rating indicates the probability of detecting problems when they occur on the equipment. A higher detectability rating indicates that the chance of detecting a failure in the equipment is difficult. A lower detectability rating indicates that it is easy to detect failure in equipment or the problems on the equipment. For example, if the operator of equipment gets an alarm indicating equipment failure, then the equipment has a lower detectability rating as compared to another equipment which does not have an alarm-raising facility.

• The risk factor of the equipment. This risk factor is computed by multiplying the severity, occurrence and the detectability ratings of the equipment and lies between 1 and 1000. Risk factor indicates the impact of the failure of equipment. This number is to be looked at as a relative number which helps one find out which equipment in a given set involves more risk. While selecting the set of equipment one should take equipment in a single process chain and find of out which equipment in this chain is the weakest link in that chain. For example, if you are doing an analysis on your boiler house and the boiler house has the equipment: ID Fan, FD Fan, PA Fan, Boiler Feed Pump, Furnace and  Fuel Feed pump, the risk factors that you get after the analysis for a period of 6 months would be as shown below:

In this case the boiler feed pump has more impact on the overall functioning of the boiler house and you may have to take some decisions like doing preventive maintenance more frequently on that pump, having online vibration analyzer on the pump or even changing that pump so as to improve the overall availability and functioning of the boiler house.

Similarly you can do an analysis on the different problem codes within equipment to assess which problem within the equipment has more impact on the performance of that equipment.

Based on the results of the failure analysis, you can suggest the remedial actions that can be taken for handling failure of the equipment. You can also save the results of the failure analysis and the suggested remedial actions, for future retrieval. On saving 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 on which the analysis is done.

Prerequisite

• Create Equipment of “Equipment Induction” business component

What you can do in this page

Analyze equipment failure

Analyze equipment failure

You can analyze equipment failure for a specific period, 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.