Weak Component Analysis (WCA)

EFESO © 1999 - 2015

 WCA (Weak Component Analysis) is an improvement strategy for the
advanced phase of the PM schedule

 Repetitive breakdowns have been attacked, sporadic breakdowns, due to lack of

ability and organisation, are under control

 It's time to develop an improvement strategy allowing the organisation of teams

able to reach relevant improvement targets on crosswise topics relating to the
plant

 The improvement target in this phase consists of attacking machine components

presenting repetitive reliability problems on various plant machines

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 Analysis of components: activate teams on weak parts

 Apparently sporadic breakdowns can hide repetitive breakdown patterns at the

component level
 To identify weak components the information of the breakdown data collection will
be necessary
 The Pareto will reveal which component is most subject to breakdowns
 To analyze the specific breakdowns further data will be necessary for the critical
components
 Teams on critical components will be launched
 Results of the pilot projects should be reapplied across all areas to prevent the
reoccurrences of known problems

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 To identify weak components the information will be necessary

Example

 The information concerning the

damaged components is
essential to cluster the different
kinds of problem
Damaged
components

Components ( B/D cause )

Roll. guide
Conveyor

Readlight
Cylinder
Bearing

Valves
Harrow
Chains

Clutch

Teflon
Leaks

Gears

Pump

Brake
Spray
Shaft

Filter
Tank
Belts

Nuts
Machine Machine
No of B/D
group n°

A 12 1 1 0 2 2 3 0 3 4 0 0 1 0 0 3 4 0 1 2 5 32
B 12 0 0 1 1 0 3 0 2 4 2 0 1 0 0 0 3 3 2 3 5 30
C 11 1 0 0 0 0 2 0 2 4 2 0 2 1 3 2 3 0 1 3 5 31
D 10 1 0 0 0 0 2 0 3 5 3 1 1 0 0 0 3 1 2 2 5 29
E 15 0 0 1 0 0 1 0 2 3 2 0 2 0 0 1 3 2 0 2 5 24
Total 3 1 2 3 2 11 0 12 20 9 1 7 1 3 6 16 6 6 12 25 146

Possible weak components

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 The Pareto for each component will reveal which component is most
subject to breakdowns (in this case, brakes)

30 100%

90%

25
80%

70%
20

% accumulated
60%

15 50%

40%

10
30%

20%
5

10%

0 0%

or
w

g
s

t
ns
ht
r

y
h

e
e

nk

rs
ts

s
lts

af
de

f lo

lte
lve

in
id

ra

ak

m
tc

rro
ak

ey
lig
Nu

ea
ai
Ta

Be

Sh
ar
gu
lin
u

Sp

Pu
Te

Fi
Br

Le
nv
Va

ad
Ha

Ch
Cl

G
Be
Cy

ll.

Co
Re

Ro

Components

1.2 Weak Components Analysis EFESO © 1999 - 2015 -5-

 # of breakdowns # of breakdowns

10
20
30
40
50
60

0
10
12
14

0
2
4
6
8
Knives Motor

Proximity Proximity

1.2 Weak Components Analysis

Chains Shaft

Shaft Pipe

Boots Tapes
Boots
Tube
Cylinder
Tapes
Electrovalves
Bearing
PLC Cards
Photocells
Knives
Joints
Joints

DEPARTMENT C
DEPARTMENT A

Belt
Riductor
Relay
Pump
Cylinder Filter
Electrov. Button
PLC carts
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%

0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
% accumulated
100%

% accumulated

# of breakdowns # of breakdowns
10
15
20
25

0
5
10
12
14
16

0
2
4
6
8

EFESO © 1999 - 2015

Proximity Proximity

Boots Knives

Shaft Shaft

Tube Taoes

Knives Pump
Electrovalves
PLC carts

Electrov. Boots

Motor Magnets

Cylinder
Pareto of B/Ds by components - by area (another example)

Beraring
WCA could give different indications in different departments

Cylinder Joints
DEPARTMENT D
DEPARTMENT B

Joint Termoc

Relay Motor

Chains Act. Card

Ac. Cards Chains

Photocells PLC carts

0%

0%
10%
20%
30%
40%
50%
60%
70%
80%
90%

10%
20%
30%
40%
50%
60%
70%
80%
90%
100%

100%

% accumulated % accumulated
-6-
 To analyse the specific breakdowns further data will be necessary for
the critical components

Data sheet for component analysis

Format

1.2 Weak Components Analysis EFESO © 1999 - 2015 -7-

 Teams on critical components will be launched

 Teams will be launched…

 … according to Pareto prioritisation

 The team will analyse the failure mode for each component…

 … and find countermeasures

1.2 Weak Components Analysis EFESO © 1999 - 2015 -8-

 Teams on critical components will be launched
Pareto of B/Ds by components - Total plant

Analysis over 3 month period (March - May 1996)

100

30 25
25
# of breakdowns / month

20
15
%
15 12 12
10
10 7
5
4
5 3
2 2
1 1 1

Breakdowns intervention: adjustment Breakdowns intervention: substitution

1.2 Weak Components Analysis EFESO © 1999 - 2015 -9-

 … according to Pareto prioritisation

Actions Months
Resp.
n° Description Sept Oct Nov Dec Jan Feb Mar
1 Weak Component Improvement P. Howard
Team
Proximity Switch
2 Weak Component Improvement J, Muller
Team
Knives
3 Weak Component Improvement F. Seesen
Team
Loosen Bolts
4 Weak component Improvement Team
Team R. Taylor
Shafts and Rols

Done Planned

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 The team will analyse the failure mode for each component
(example: WCA on Proximity)

Staff bracket b/d

% of B/Ds
35
30
25
Electrical connection broken
20
15
10
5
0
Failure mode

Impact Bolt out of position

It is really important to
collect the damaged
components!

In RED : design weaknesses

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 … and find countermeasures
WCA: Proximity (cont’d)

Staff bracket b/d Electrical connection broken

Bolt out of position Impact

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 WCA: Knife
Countermeasure relates both to the component and to PM

Failure Mode: 5 Why analysis: root causes Countermeasures:

Knife does not cut Design weakness Supplier involvement and definition of
material, sharpening specification

■ wear Material charact. not repetitive

■ damage Thick joint of cut material Use of tape for material joint

Poor setting procedures improved setting specification

Knife out of position
Drift due to cutting vibration AM checks and restoration

Results

Highly variable life

(Material charact. not repetitive )

35 Counterblade interference
30 (Poor setting procedures)
25 Thick joint of material
# of B/Ds

20
15
10
5
0
B.M: 94 95 J.96 F.96 M.96 A.96 M.96 J.96

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 Results of the pilot projects should be reapplied across all areas to
prevent the reoccurrences of known problems

 At the end check the results and benefits thoroughly

 Industrialise the solution to be reapplied with lower costs

 Define the reapplication plan and responsibilities

 Follow up times, costs and results

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 WCA Check results, Team audit

MTBF MTTR # of Breakdowns/month

Mean Time Between Failures Mean Time to Repair

hours 400 Min. 250 Plant

200 3000
300 2570

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

Jun.
Jul.
Jan. 97
Feb.

Sept.
0

May
Mar.

Target 97
Target 98
Apr.
1995
1996

Nov
Oct.
Jun.
Jan. 97

Jul.

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
100

% on time
80
100
72 60
80
Index

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

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