Breakdown Analysis system

EFESO © 1999 - 2015

 The system for Breakdown analysis

1. Define a procedure for breakdown analysis

2. Design the organisation to implement breakdown analysis

3. Include the breakdown analysis in the Performance Control System

4. Follow up the results

5. Reapplication

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 Preparation for an effective breakdown analysis system

1. Create an appropriate breakdown analysis sheet

2. Prepare and lead a pilot project on the breakdown analysis: give a good example
of breakdown analysis

3. Train maintenance technicians on breakdowns and/or check the skills required to

support the breakdown analysis

4. Train operators so that they can give suitable information concerning the
breakdown analysis

5. List the conditions required to complete the breakdown analysis

6. Review the system and allocate the conditions

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 Define a procedure to support breakdown analysis

N. Step of breakdown analysis Who When

Breakdown general data, what

1 happened, prior signs
Operator At the time of breakdown

Component failed, failure mode,

2 fix intervention, spare parts
Maintenance Technician After restarting the machine

Maintenance Technician 1st draft immediately

3 Root cause analysis (5 why's)
& Operator Reviewed by team within 24 hours

Countermeasure identification
4 and plan
Team ASAP, maximum 1 week

5 Implementation and follow -up Team Daily

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 Support the organisation

Machine Machine C Countermeasures plan

After repairing a B
breakdown, the Machine A Machine D
maintenance
operator fills in a
breakdown analysis
One

form Point
Lesson

Machine H ■ Breakdown
Machine E
Maintenance
Breakdown
Owner
analysis sheet
■ Maintenance WCOM™
Machine G Machine F
Owner Countermeasures' plan
Actions
Reapplication Descr. Resp. Date

During the daily maintenance meeting, Planned Done

Breakdown analysis sheets are revised.

Is the analysis complete? Yes

Have countermeasures
been identified?

Training and
■ Breakdown Maintenance Operator support to
■ Maintenance shift leader production and
■ Maintenance area supervisor maintenance Breakdown
No operators analysis sheet
■ Production Operator

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 Check results

Check…

 Breakdown frequency

 Complete data collection

 Quality of the analysis

 Action effectiveness

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 Keep breakdown analysis and its evolution under control

# of B/D Target B/D/day Total B/D Total sheets

70 70

60 60

50 50

40 40

30 30

20 20

10 10

0 0
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
1
2
3
4
5
6
7
8
9
1994
January 1995
July
August
September
October

November

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 Breakdown analysis
Further stratification can lead to a precise countermeasure

When we analyse breakdowns we often find:

 design weakness

 concentration on components families

 human errors:
– from maintenance
– from production

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 A board can help

Breakdown analysis
Breakdown evolution Main breakdowns (number and times)
Days
Type of Breakdowns 1 2 3 4 5 6 7 8 9 29 30 31

Worn part 1/15 1/20

Seized part 1/90

Short circuit 1/10

Total (#/times) 1/15 1/10 1/90 1/20

Breakdown Analysis Sheet Action Plan Improvement / OPL

Improvement Week
Machi ne Ti me of breakdow n Producti on Operat. No. Date Problem Who
Date
Shi ft
Ti me of i nterventi on
Ti me to repai r
Mai ntenance Techn.
Team
action 1 2 3 4 5 6 7
Ti me to start-up WCOM
What happened and w here (secti on/subassembl y) Sketch
Plant OPL
Basic Knowledge Problem Improvement N°
Pri or si gns before the breakdow n
Filled by: Date:

Descr. of the repai r i nterv. (speci fy component you have Before Why has the After
w orked on) + spare parts used machine
stopped?

F ai l ure mode + sketch (use the back of the sheet)

Use the back of the sheet for 5 w hy anal ysi s on the fai l ure mode i denti fi ed (Operator + Mai ntenance Techni ci an)

Root c a u ses Ca t.(*) Cou n termea su res

It is easy to see
the reason for the
I am not sure,
I am looking for the problem
stoppage now!
Were checks al ready pl anned to prevent thi s fai l ure?
D esc rip tion By wh om Freq u en c y

Are new checks / acti ons requi red to total l y eradi cate breakdow ns?
Problem: Big machines stoppages frustrate operators Improvement: Coloured light system introduced
D esc rip tion By wh om Freq u en c y / lon g term a c tion
Results: From a distance operator can see the reason and position of machine stoppage. Reduced stoppage time

Training date
(*) 1. Desi gn faul ts 2. Lack of preventi ve mai nt. 3. Previ ous qui ck fi x 4. Incorrect prod. operati on 5. Spare part
qual i ty/avai l abi l i ty
Trainer
Trainee
Planned Realized

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 Check results

MTBF MTTR
Mean Time Between Failures Mean Time to Repair
# of Breakdowns/month

hours 400 Min. 250

Plant

200
300 3000 2570

N./month
2500
150 1849
200 2000
100 1500 1074
100 1000
50 537 385
500 205
0

Jun.
Jul.
Jan. 97
Feb.

Sept.
0

May
Mar.

Target 97
Target 98
Apr.
1995
1996

Nov
Oct.
Jun.
Jul.
Jan. 97

0
Sept.
Feb.

May
Mar.

Target 97
Target 98
Apr.
1995
1996

Nov
Oct.

1993 1994 1995 1996 1997 Target

98

Breakdown index Maintenance Cost Maintenance policies

100
120
Euro/motor

100 350

% on time
100
80 72
50
Index

60 150
42
40
21
15 0
20 8 -50
1995 1996 1997 Target Target 1996 1997 1998 Target 99
0
1993 1994 1994 1995 1996 Target 98 99 breakdown maint. periodical maint.
98 breakdown maint. planned maint.
predictive maint. improvement maint.
improvement maint.

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 Result assessment
Ability to eliminate breakdowns

N ° Breakdown
0 80 160 240 320 400

Breakdowns 357

Compiled B/D
293 (82%)
Analysis sheet

Analysed B/D 236 (66%)

Identified Action 202 (57%)

Realized Action 187 (52%)

Action with result 118 (33%)

(*)

* that is, the breakdowns DO NOT OCCUR ANYMORE !

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 Are breakdown analysis sheets really effective?

100

80

60

40

20

0
Jan - July September October November

% recorded b/ds % analysed b/ds % identif. counterm.

% implem. count. % effective actions

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 Reapplication Management

 Breakdown causes and Design weakness

 How to eliminate design weakness: tools and reapplication

 Reapplication on similar equipment: MP Information

 Reapplication on similar components: Analysis of weak components

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