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Failure Code Quality Plan Implementation
ALCOA NAPM MASSENA, NY
DRIVERS: • Future demand for anodes to support new pot lines -
Modernization Project• Strained capacity of current anode production• Need for Downtime and Equipment Failure reporting mechanism• Available functionality of Oracle eAM Quality Failure Collection
Plans to identify opportunities
MJClemens
SOLUTION:
Only events that affect
OEE and actual
Production will be
captured in the DMS
Downtime Reporting Tool
(including Equipment
Failures)
Fo c u s o n D o w n ti m eMJClemens
SOLUTION:
All Equipment Failures
(whether or not they
create process Downtime)
will be captured on an
Oracle Work Order
through Failure Codes in
a Quality Failure
Collection Plan
Fo c u s o n Fa i l u r e sMJClemens
OWNERSHIP:
RELIABILITY
ENGINEERING
Providing the Tools, Analyzing the Results
MJClemens
OWNERSHIP:
MAINTENANCE
EXECUTION
Applying the Tools, Capturing the Data
MJClemens
PROCESS:
• Review Equipment Work Order Histories by Asset Category (Description Fields and Spare Parts Usage)
• Capture Known Failure Modes• Review Alcoa or external FMEA data if available• Rely on personal experience and that of Plant personnel• Create Quality Failure Collection Plan
FOCUS ON PREDOMINANT FAILURE MODES OR THOSE MOST LIKELY TO OCURR
MJClemens
PROCESS:
CURRENT ALCOA QUALITY PLAN MODEL:
YES/NO
DAMAGEDESIGNFABRICINSTALLMAINTMAT’LMISUSELUBRCTN
CONT OILDIRT OILIMP FILTINSUF OILLOW PRESSPUMP FAILPLUG LINEWRONG LUB
LIST BY CLASS/CATEGORY
MJClemens
Order of entry confusing to many
PROCESS:AIR CONDITIONING ELEC CONTROLS, JOYSTICKALARM CIRCUITS ELEC CONTROLS, TROLLEYBEARING ELEC POWER PANELBLOCK, BOTTOM ELEC CONTROLS, OTHERBLOWER/FAN FRAME/BODYBRAKE HOISTSBRIDGE, END TRUCKS HOSES/LINESBRIDGE, FOOTWALKS HYDRAULICSBRIDGE, GIRDERS LIGHTINGBUMPERS, STOPS AND SWEEPS LINKAGECOMPRESSOR LUBRICATION SYSTEMSCONVEYING MEDIA MOTOR AC/DCCRANE ACCESS LADDER MOTORS/DRIVESCRANE COLLECTOR RAIL OPERATOR CABCRANE RAILS PLCCYLINDER PNEUMATICSDRIVE TRAIN POLLUTION SYSTEMSDRIVEN UNIT RADIO CONTROLSDRUM REDUCTION UNIT/TRANSMISSIONDUCTS, PIPING SAFETY EQUIPMENTELEC CONTROLS, ANTI COLLISION SYSTEM SWITCHELEC CONTROLS, HMI MODULES TRANSFORMERELEC CONTROLS, PENDANT VALVE ELEC CONTROLS, TRANSDUCERS WHEELELEC CONTROLS, WARNING DEVICE WIRE ROPEELEC CONTROLS, BRIDGE WIRING AND CIRCUITSELEC CONTROLS, GRABS
Alcoa Standard Component
Codes for Bridge Cranes
MJClemens
List of Components to choose from over five screens long, not always clear or applicable
PROCESS:PTC Model (2008) – Follows FMEA methodology, but all Codes become one string – must scroll through entire list to appropriate combination.
MJClemens
PROCESS:
MASSENA QUALITY PLAN MODEL:
YES/NO
Three levels of Failure Code Hierarchy, and
Lubrication Codes rolled into Root Cause Codes
MJClemens
PROCESS:
MASSENA QUALITY PLAN MODEL:
LEVEL 1 LEVEL 2
MJClemens
PROCESS:
MASSENA QUALITY PLAN MODEL:
LEVEL 3
Z_OTHER Allows for manual input; multiple inputs would clue the RE to add the code to the list
MJClemens
ADVANTAGES:
MASSENA QUALITY PLAN MODEL:
• Failure Code Hierarchy allows for fast “drilldown”• Codes reflect FMEA or RCM methodology;
“The Magnetic Separator Drive System Motor Bearing Failed due to under-lubrication”
• Quality Plan components can be configured and modified at the site level to reflect the granularity of the Asset Hierarchy (Today’s Components may be tomorrow’s Assets, and the codes must adjust)
• Quality Plan results can be extracted through Discoverer and Pareto Analyses conducted
• Quality Failure Code Plans are living tools – the Reliability Engineer has the ability to add or remove those Failure Codes (Failure Modes) that either surface or disappear from Proactive Maintenance.
MJClemens
From the Work Order Screen, Select the Quality Tab and then “Enter Quality Results”
The “Enter Quality Results” screen is now enabled
MJClemens
If a Failure occurred (Y), entering a “% ENTER”
opens an LOV for Level 1Z_OTHER, (listing a new code in
Comments) is an option at every level
MJClemens
Having Selected “BELT” at Level 1, entering “BE,
ENTER” at Level 2 would make available only those
codes for “BELT”
This Smart Coding eliminates the need to scroll through the entire list of codes to select the most appropriate one.
Having Selected “BELT” at Level 1, and
“BELT_DAMAGED” at Level 2, all 15 existing Root Causes
would be available to select IF KNOWN
PARETO: W
ear
or F
ailu
re fr
om E
xces
sive
Use
(Ove
rstr
esse
d)
Rela
ted
to a
Fai
lure
of A
noth
er C
ompo
nent
(Not
e in
Com
men
ts)
Cont
amin
ation
, Dus
t, D
irt,
Chem
ical
Und
er L
ubri
catio
n
Mis
alig
nmen
t
Impa
ct fr
om In
tern
al o
r Ex
tern
al F
orce
Wea
r or
Fai
lure
from
Nor
mal
Use
(End
of L
ife)
Mis
alig
nmen
t
Envi
ronm
enta
l, H
eat,
Cold
, Hum
idity
Impa
ct fr
om In
tern
al o
r Ex
tern
al F
orce
Corr
osio
n fr
om W
ater
or
Chem
ical
s
Magnetic Controller Failed Separator Drive Motor Bearing Seized, Damaged
Separator Belt SS Slats Loose, Worn, Damaged
Separator Drive Belts Frayed, Damaged, Broken
Separator Fasteners Loose, Missing, Damaged
0
2
4
6
8
10
12
Magnetic Separator Failure Count – JULY (EXAMPLE)
MJClemens
Current Failure Collection Quality Plans
Applied to 176 Assets in Green Anode
MJClemens
“A well designed Failure Reporting, Analysis, and Corrective Action System (FRACAS) can be an important part of any continuous improvement effort. Failure codes developed using functional analysis of plant equipment greatly improve the ability of the Reliability Engineer to analyze failures and initiate changes in equipment design, maintenance strategies, and operating strategies.
Simple, two-part failure codes for use in the CMMS/EAMS allow operators and maintainers to better record failure information for use in the FRACAS.”
Bill Keeter, Allied Reliability
MJClemens
Other Quality Plans ….
Incorporates Oracle eAM “Specifications” in the Quality Plan
MJClemens
Other Quality Plans ….
MJClemens
Other Quality Plans ….
MJClemens
