Maintenance Excellence

Failure Modes
Update status of Failure Mode Development

• What are Failure Modes?

• Why use Failure Modes?
• How are they used in SAP
• How are they used in PMO
• SAP Reliability Reports
• Review of Components, Parts and Damage
• Cause Codes – MPC approval to change SAP List
• Where to next?

Failure Modes – Jan 08 2

Failure Mode Definition

What is a Failure Mode?

– Any event that causes a 'Functional Failure' – ie the asset is
no longer able to perform its original function
– Made of four sections
• Component e.g. Gearbox
• Part e.g. Bearing
• Damage e.g. Worn
• Cause e.g. Expected use, wear or tear

GEARBOX, Bearing worn due to expected use, wear or tear

Failure Modes – Jan 08 3

Failure Mode Benefits

Why use a Failure Mode?

– Enter “Reliability Data” when completing a SAP Work Order
listing failure mode and cause
• Feedback from Tradesperson on what failed and why (To
be read in conjunction with “Work Description”)
– Basis for developing Maintenance strategy tasks to prevent
failure modes which have happened in the past or that could
happen and cause a hazard
• PMs are then developed to efficiently plan and undertake
these strategy tasks
– Able to undertake review of all failure modes and strategy
tasks against a particular functional location
• In future able to use BW Reliability reports

Failure Modes – Jan 08 4

How we use Failure Modes in SAP

• There are three main types of Notifications

– M1 Maintenance Requests
– M2 Malfunction Reports
– M3 Activity Reports

• Notifications initiate any request for maintenance

• Notification contain the failure codes
• Notifications capture the tradesmen’s feedback (text and codes)
• Notifications are used to report all equipment failures and
reliability information
• Subsequent Notifications contain the maintenance plan number
and are used to validate the Preventative Maintenance Activities.

Failure Modes – Jan 08 5

 How we use Failure Modes in PMO

Develop Maintenance Strategy tasks aimed at preventing

Failure Modes

Failure Modes – Jan 08 6

 SAP Reliability Report

Re liability Re port for M aintainable Ite m 24/05/2005

Functional Location Floc1
Description X Cylinder System XYZ Plant W

Reasons for Restoration Failure Mode Sum m ary Distribution of Lives Achieved

3
3

Normal ageing & usage

1

Damage / Overload
1

Rod Broken
Mounting

Guide bush
connection

Broken
leaking
Hose

Worn
0
0 - 1 yrs 1 - 2 yrs 2 - 3 yrs 3 - 4 yrs 4 - 5 yrs

Predicted Life (yrs) 5 Current Age (yrs) 1.1

Average life achieved (yrs) 2.9 Condition Assesment at last inspection Very Good
Std Dev (yrs) 2.2 Next Restoration based on predicted life Mar-09
Maximum Life (yrs) 4.7 Next Restoration based on average life Feb-07
Minimum Life (yrs) 0.4

R e pa ir / R e stora tion H istory

T ime Since
Activity Code Activity La st
Group Code R e stora tion Ca use Code Group Ca use Code Fa ilure Mode Fa ilure Mode
D a te D e scription D e scription (yrs) D e scription D e scription D e scription D e scription D a ma ge T e xt
22/08/1995 Restoration On failure Normal ageing & usage Guide bush Worn
27/08/1995 Repair On condition 0.01 Material / Installation Problem Incorrect assy / installation Hose connection leaking
30/12/1995 Restoration On failure 0.36 Damage / Overload external force Mounting Broken Crane tore cylinder off mounting
16/07/1999 Restoration On failure 3.55 Damage / Overload unknown Rod Broken
12/03/2004 Restoration On failure 4.66 Damage / Overload external force Mounting Broken Crane tore cylinder off mounting
31/03/2004 Repair On condition 0.05 Material / Installation Problem Incorrect assy / installation Hose connection leaking

Failure Modes – Jan 08 7

 PMO and SAP Failure Mode Data Coordination

Aim - have the same pick lists for Failure Modes in PMO & SAP
Benefit – facilitates comparison of actual failures with strategy to
manage those failure modes

Failure Modes – Jan 08 8

PMO – Structured Failure Mode Library

Failure Modes – Jan 08 9

 3 Types SAP Reliability Data Codes

• Based on the nature of the equipment (Object type)

• Used to capture the component that failed and the Mode of failure.
Failure Code • The PMO strategy and identified failure modes will form the basis
of the failure Mode codes.
• Are equipment specific and will only be configured once a strategy
review for the equipment has been completed in PMO.
• Common for all equipment.
• Used to understand the nature of the failure
• Groupings are based on the Bath tub curves
Cause Code •Material or Installation Problem (Infant mortality)
•Damage / overload (Random)
•Normal ageing & usage (Wear out)
•Accelerated Deterioration (Wear Out)
•Not Failure Related

• Common for all equipment.

• Used to describe the nature of the action taken in terms of its effect
on the item life cycle
Activity Code • Restoration
• Repair
• Modification
• Not related to an installed item
Failure Modes – Jan 08 10
 SAP Reliability Data

Failure Code
Cause Code

Activity Code Able to add

Long Text

Failure Modes – Jan 08 11

 Tradesperson Access to Failure, Cause & Activity Fields

1. Highlight the job 2. Click on Edit

after hours Job Notes
entered and job
confirmed

3. This opens Work/Breakdown 4. Open Reliability Data screen

Details screen – able to enter – able to enter Failure, Cause
Description information and Activity information

Failure Modes – Jan 08 12

Component List Status

– Components form Device level of

Functional Locations
e.g.NZ/153/H02/GBX002
– Comparison made to PK
– NZS and PK have variations of
alpha/numeric coding
– Further discussions needed with BSL
sites to reach consensus on how to
handle Component Lists. Either
• Try and get commonality against
BSL
• Agree on variations able to be used

Failure Modes – Jan 08 13

Part List Status

Parts List reviewed to

– Eliminate double ups
• Bearing / Bearings
– Incorrect items
• Water cavities
– Use generic term
• Lining becomes Liner
• Motor Bearing become Bearing
• Lead Screw become Screw

Failure Modes – Jan 08 14

Damage List Staus

Damage List reviewed to

– Rationalise items
• Arc becomes arc damaged
• Bent becomes damaged
• Fouled becomes blocked
– Eliminate double ups
• Cracked and cracked weld
• Depleted, empty and discharged
– Become master list for SAP

Failure Modes – Jan 08 15

 PMO Failure Mode - Cause List

• Eg: pump bearing seized due to “lack of lubrication”

• Note: used to be 45 causes, now rationalised down to just 12

Failure Modes – Jan 08 16

 Compare PMO Causes to existing SAP Cause list

PMO Causes mapped to existing SAP Cause list

Showed that there were serious gaps – need to change SAP list

Failure Modes – Jan 08 17

 Recommend change SAP Cause list to:

MPC to approve change to SAP list

Failure Modes – Jan 08 18

 Develop SAP Equipment Catalogues

Able to allocate Functional Reduce selection when

Location Devices to a Failure allocating Failure and Cause
Mode Catalogue in SAP Codes in SAP

e.g NZ/153/H02/GBX001
Only see the following
Failure Modes in SAP

Failure Modes – Jan 08 19

Where to next

1. Distribute SAP Cause recommendations to MPC for

review and comment
2. Complete PMO Part/Damage lists for review by MPC
(These form Failure Mode list in SAP)
3. Load to SAP Test (BRT) for review
4. Communicate with PK and WP regarding our
intentions
5. Load to BR0 and load
6. Continue to develop SAP Catalogues

Failure Modes – Jan 08 20