Failure Mode and Cause Code in SAP

Maintenance Excellence

Failure Modes

Failure Modes Jan 08 2

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 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 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


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 tradesmens 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.


How we use Failure Modes in PMO

Develop Maintenance Strategy tasks aimed at preventing

Failure Modes


SAP Reliability Report

Reliability Report for Maintainable Item 24/05/2005

Functional Location Floc1

Description X Cylinder System XYZ Plant W

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

Repa ir / Restora tion History

Date

Activity Code

Group

Description

Activity

Code

Description

T ime Since

Last

Restora tion

(yrs)

Cause Code Group

Description

Cause Code

Description

Fa ilure Mode

Description

Fa ilure Mode

Description Damage T ext

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

Reasons for Restoration

Normal ageing & usage

Damage / Overload

Distribution of Lives Achieved

0

1

2

3

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

Failure Mode Summary

0

1

2

3

Hose

connectio

n

leakin

g

Mountin

g

Bro

ken

Guid

e b

ush

Worn

Rod B

roken


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


PMO Structured Failure Mode Library


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. 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 describe the nature of the action taken in terms of its effect

on the item life cycle Restoration Repair Modification Not related to an installed item

Common for all equipment. Used to understand the nature of the failure Groupings are based on the Bath tub curves

Material or Installation Problem (Infant mortality)Damage / overload (Random)Normal ageing & usage (Wear out)Accelerated Deterioration (Wear Out)Not Failure Related

Failure Code

Cause Code

Activity Code


SAP Reliability Data

Failure Code

Cause Code

Activity Code Able to add

Long Text


Tradesperson Access to Failure, Cause & Activity Fields

2. Click on Edit

Job Notes

3. This opens Work/Breakdown

Details screen able to enter Description information

4. Open Reliability Data screen

able to enter Failure, Cause and Activity information

1. Highlight the job

after hours

entered and job

confirmed


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


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


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


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


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


Recommend change SAP Cause list to:

MPC to approve change to SAP list


Develop SAP Equipment Catalogues

Able to allocate Functional

Location Devices to a Failure

Mode Catalogue in SAP

Reduce selection when

allocating Failure and Cause

Codes in SAP

e.g NZ/153/H02/GBX001

Only see the following

Failure Modes in SAP


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

Documents

Failure Mode and Cause Code in SAP