The “Breakdown Analysis Sheet” Basic questions for breakdown analysis Why did the equipment break ? Why did that specific component break? What about the stress applied on that component? Why was that stress applied on that component? What are the requirements to prevent this breakdown? Who takes the responsibility of the above said breakdown prevention? When? How? Was there any symptom before the breakdown occurrence? Does the breakdown show any visible symptom? Through which symptom can we make a breakdown prevention? Can breakdowns be prevented through symptomatic analysis? How can symptoms be identified?
What kind of skills and abilities are required the operator to identify the event? Efeso © 1999 -3- Tips to fill the Bd analysis sheet The “Breakdown Analysis Sheet” Basic questions for breakdown analysis In case of internal wear: Did any anomaly occur before the breakdown appearance? Is this breakdown mode usually linked to these anomalies? Why in this case weren’t any breakdowns detected? Which is the simplest way to pay attention to symptoms? Which knowledge and skills enable the operator to understand the predictive breakdown symptoms? Efeso © 1999 -4- Tips to fill the Bd analysis sheet.
Tips to fill a “Breakdown Analysis Sheet” Main questions Breakdown type Electric Mechanic .. … Intervention type Replacement Restoration .. … Time required for restoration Efeso © 1999 -5- Tips to fill the Bd analysis sheet Tips to fill a “Breakdown Analysis Sheet” Why did it happen? Why did the breakdown happen? Which part was injured? Why did the constraint occur? Another component breakdown Overload Why did this part break? In which way did it break? Piece resistance reduction? What can be done not to repeat it? Which maintenance policies can be adopted? What kind of constraint was applied on that part?
Mechanic Electric Corrosion Vibration Efeso © 1999 Who is in charge of these activities? The maintenance operator The production operator The technician -6- Tips to fill the Bd analysis sheet Tips to fill a “Breakdown Analysis Sheet” Examples of failure modes … Impeller worn out Impeller falls off Impeller smashed by a foreign body Efeso © 1999 -7- Tips to fill the Bd analysis sheet Tips to fill a “Breakdown Analysis Sheet” Has any predictive signal been identified? Were bad running symptoms evident before the machine failure? Vibration Oil leakage .. … Does the breakdown mode have early symptoms?
Yes No Efeso © 1999 -8- Tips to fill the Bd analysis sheet Tips to fill a “Breakdown Analysis Sheet” Has any predictive signal been identified? Which symptom can anticipate a breakdown? Speed losses Defects Noise .. … Why cannot a breakdown be early identified through its symptoms? Breakdown symptoms are unknown The measure is unknown What can be done to identify symptoms? What kind of progressive or predictive maintenance should be implemented? What further kind of knowledge and competence should the operator have to identify early symptoms? Efeso © 1999 -9- Tips to fill the Bd analysis sheet.
Tips to fill a “Breakdown Analysis Sheet” The root causes are … Impeller worn out: lack of preventive maintenance: changing impeller before end of useful life was not considered Impeller falls off human error: some operators are not able to fit impeller correctly impeller smashed: design fault: no protective screens have been provided Efeso © 1999 – 10 – Tips to fill the Bd analysis sheet Tips to fill a “Breakdown Analysis Sheet” Countermeasures Root cause Design fault Lack of preventive maint. Quick fix Incorrect production operation Spare part quality / Lack of spare parts Countermeasure.
Design modification Preventive maint. activities Maintenance training Production training Improved spare part management system Efeso © 1999 – 11 – Tips to fill the Bd analysis sheet Tips to fill a “Breakdown Analysis Sheet” Has a planned maintenance operation to prevent breakdown been identified? What is the best planned maintenance task? The failure mode is due to weakness of components related? Scheduled discard task (plan replacement) Has the failure mode early signs? Scheduled on condition task (condition monitoring) Is the failure mode due to absence of machine basic conditions?
Autonomous maintenance activities Is there a method/parameter measurable to carry out an equipment diagnosis? Predictive maintenance Efeso © 1999 – 12 – Tips to fill the Bd analysis sheet Tips to fill a “Breakdown Analysis Sheet” N° 1 2 Reasons for interventions Low breakdown reparation quality for operator training lack, or bad upstream work quality Insufficient documentation. No records for M/C, specifics, changeover, etc. Low breakdown reparation quality caused by training lack of production operators: operating errors, no observance of specifics during operative proceedings, etc.
M/C out of specifics, M/C restoration according to specifics Bds in M/C design phase (moreover repetitive ones) caused by M/C design errors. Even if the M/C is defined according to the specifics Suggested actions Train maintenance people, in other words carry out One Point Lessons Improve record and make them available to everybody N° 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Breakdown mode Wear part Adhesive part Jammed part Broken part Loosened part Fold part Steam leakage Water leakage Air leakage Oil leakage Machine contact or weak electric Broken wire Loosened wire Overload Insufficient insulation Burn-out Electric component breakdown.
3 Train production people, etc. 4 5 Train operators and maintenance people Machine re-design 6 Make certain that spare parts are No breakdown following to previous restorations known, recorded, available and on defective parts used There are no preventive maintenance actions able to prevent breakdowns through PM controls, Define AM and/or PM controls correct lubrication, restoration scheduling Efeso © 1999 7.