Define Failure Analysis Configuration

In this page, you can define the failure analysis configuration. Tell me more.

• Select the “Define Failure Analysis Configuration” link under the “Trouble Shooting Guide” business component.

The “Define Failure Analysis Configuration” page appears.

The system displays the following fields:

• Enter the following field:

• Enter the following fields in the “Severity Ratings” multiline, to define severity ratings based on production down hours:

Note: When you click the “Submit Configuration” pushbutton, the system fills in this field with the value entered in the “Production Down Hrs (Max.)” field in the previous row of the multiline.

• Enter the following field:

Note: This field should be entered in an ascending order in the multiline. You must enter the first nine rows in the multiline and leave the last row blank to indicate the production down hours greater than the  the production down hours entered in the 9^th row in the multiline.

The system fills in the following field:

• Enter the following fields in the “Severity Ratings” multiline, for defining the rating for maintenance expenses:

Note: When you click the “Submit Configuration” pushbutton, the system fills in this field with the value entered in the “Production Down Hrs (Max.)” field in the previous row of the multiline.

• Enter the following field:

Note: This field should be entered in an ascending order in the multiline. You must enter the first nine rows in the multiline and leave the last row blank to indicate the  maintenance expenses greater than the  maximum maintenance expense entered in the ninth row in the multiline.

The system fills in the following field:

• Enter the following fields in the “Occurrence Ratings” multiline:

Note: When you click the “Submit Configuration” pushbutton, the system fills in this field with the value entered in the “No. Of Occurrences (Max.)” field in the previous row of the multiline.

• Enter the following multiline field:

Note: This field must be entered in the ascending order in the multiline. You must enter the first nine rows in the multiline and leave the last row blank to indicate the number of occurrences greater than  the number of occurrences entered in the 9^th row in the multiline.

The system fills in the following field in the multiline:

• Click the “Submit Configuration” pushbutton to define the configuration details.

The system displays the following fields in the “Record Statistics” group box:

To proceed, carry out the following

• Select the “Define Detectability/Safety Ratings” link from the bottom of the page to define the detectability and safety ratings for the base period.

Define Failure Analysis Configuration – An overview

In this page, you can define the failure analysis configuration.

The definition of a failure analysis configuration involves defining the following:

Specifying a base period – You can specify the base period in days, applicable for the production down hours, maintenance expenses and number of occurrences. For example, when you specify the base period as 45 days, it implies that the ranges defined for all the above factors are applicable for a base period of 45 days.

If the failure analysis is done for a period different from the base period, the system apportions the production down hours, the maintenance expenses or the number of problem occurrences using the following formula:

Base period * Production down hours (OR) Maintenance expenses (OR) Problem occurrences in the analysis period

Analysis Period

The following example explains the above concept:

Base Period:     45 days.

If the analysis is done for a period of 60 days and if the actual production down hours is 150 for 60 days, therating for the production down hours is arrived at as shown below based on the formula:

 (150/60)*45                      = 112.5 hours

This falls in the range 100 to 200. Hence the corresponding rating would be 2.

The system uses a scale of 1 to 10 defining the severity, occurrence and detectability ratings. The  system displays the revision number of the configuration, which is incremented by one every time the configuration is modified.

Defining severity rating – Severity rating depends on three factors namely production down hours, maintenance expenses and safety rating. You can specify the various ranges of production down hours and of maintenance expenses corresponding to each rating. The system assigns a rating on a scale of 1 to 10 for each range, applicable for the specified base period. The severity rating increases as the number of production down hours and the maintenance expenses increase. For example, the system sets the severity rating as 1 when the production down hours is between 1 and 60, and 2 when the production down hours is between 60 and 120. This is based on the assumption that the equipment that is down for a greater number of hours has a higher impact on the plant operation. Similarly, for maintenance expenses the system sets the severity rating as 1 when the maintenance expenses are between say $ 1 and $ 500, and 2 when the maintenance expenses is between $ 500 and $ 1000 and so on.

The severity rating is later used in the “Analyze Failures” activity, while analyzing failures on the equipment and the problems that occur on the equipment.

The system ascertains the rating based on production down hours in the following manner:

• The actual number of hours the equipment was down 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 this activity.

• The range in which the actual production down hours of the equipment falls is ascertained, and the rating based on production down hours assigned to this range is arrived at.

The severity rating based on production down hours of a problem that occurs on equipment is ascertained by applying the severity rating defined here to the actual number of hours the equipment was down due to the problem that has occurred on the equipment.  The system ascertains the rating based on maintenance expenses in the following manner:

• The actual maintenance expenses that were incurred 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 this activity.

• The range in which the maintenance expenses falls is ascertained, and the rating based on maintenance expense assigned to this range is arrived at.

The rating based on maintenance expenses of a problem that occurs on equipment is ascertained by applying the rating defined here to the actual maintenance expenses that were incurred due to the problem that has occurred on the equipment.

Defining occurrence rating – You can specify the various ranges of problem occurrences corresponding to the ratings on a scale of 1 to 10 for each range, applicable for the specified base period. The higher the number of occurrences of problems, the greater is the rating. For example, you can define the range as 0 to 100 for equipment failures corresponding to the rating 1 The ratings are provided based on the assumption that the equipment on which problems are encountered are more prone to risk, than the equipment on which a lesser number of problems are encountered.

The occurrence ratings for the given base period, along with the severity ratings, are stored by the system as failure configuration details. A unique revision number is provided for the configuration.

The ratings are later applied in the “Analyze Failures” activity to the equipment to calculate occurrence rating for the equipment. The system ascertains the occurrence rating based on the following calculations:

• The number of closed work orders that have been raised on the equipment during the analysis period is ascertained. This indicates the actual number of occurrences of problems on the equipment.

• The number of problem occurrences is then apportioned for the base period defined.

• The occurrence rating for the equipment is then arrived at, based on the range in which the actual number of problem occurrences falls.

This rating can also be used to ascertain problem occurrence rating, based on the number of work orders that have been raised on the equipment to solve a particular problem.

What you can do in this page

Define the base period for the failure analysis configuration

Define ratings for the base period

Define the base period for the failure analysis configuration

You can define the base period for which the severity and occurrence ratings must be defined.

• Enter the base period in days in the “Base Period For Ratings (No. Of Days)” field.

Define ratings for the base period

Severity indicates the seriousness of the failure of the equipment. Severity rating is defined for every range of production down hours, for various ranges of maintenance expenses that are incurred on the equipment and for the safety implications of the equipment.

• Enter the range, for which severity rating must be calculated based on production down hours, in the “Production Down Hrs (Max.)” field in the “Severity Ratings” multiline.

• Enter the range, for which severity rating must be calculated based on maintenance expenses, in the “Maintenance Expenses (Max.)” field in the “Severity Ratings” field in the multiline.