Up Time Magazine- August/September 2008

Business Level FMEA Analysis Failure = Anything resulting in loss of quality production or in extraordinary costs Cross Functional Team* Raw Material Cross Functional Team* Cross Functional Team* Process A WIP Process B WIP Process C Product Support Team* * - Cross Functional Team, e.g: Operations Supervisor Senior Operator Maintenance Supervisor Senior Technician Vendor Process A Analyze operation Function failures: 1. Type x Freq x Value 2. Type x Freq x Value 3. Etc. Process B Analyze operation Function failures: 1. Type x Freq x Value 2. Type x Freq x Value 3. Etc. Process C Analyze operation Function failures: 1. Type x Freq x Value 2. Type x Freq x Value 3. Etc. Figure 11 - Business Level FMEA Analysis fail often, we can incur extra costs. Or, suppose we routinely have yields that are below, or even well below, our ideal target, that represents an extraordinary cost. Or, suppose we are using excess additives or catalyst to assure proper reactions in a chemical process. That represents extraordinary costs as well. Or, suppose our energy consumption is 20% above the ideal state for conversion of our products. These are all extra costs that we might be able to manage better, and minimize, with a more stable process and reliable plant. 4. Next, the cross-functional team reviews each step of the production process, identifying failures at each step. It’s usually best if each area does its analysis independently, and then presents its findings to the other teams at the end of the day. For example, you would ask: “What is your biggest functional failure in Area 1?” Let’s say it’s a problem with raw material, both quantity and quality. Next question: “How often does this happen?” Let’s say weekly. Next question: “What’s the consequence of each event? “ Let’s say it’s reduced rate, or lost quality, or literally no production. Next question: “How many hours of equivalent production is typically lost for each event?” Let’s say it’s about 2 hours at about 100 tons per hour. Next question: “What’s that worth, in gross profit contribution?” Let’s say it’s $500 per ton of production. Now we have an estimate that poor raw material quality/quantity is occurring once per week, typically resulting in 2 hours of equivalent lost production at 100 tons an hour at $500 per ton, or $100,000 per week in lost gross profit (presuming we could sell all we could make). Or, it’s costing the company over $5,000,000 per year in potential gross profits. Two hours a week doesn’t seem like much, until you add it up. 5. The support functions must also be reviewed for failures in our business system, e.g., poor quality or quantity spares, insufficient utilities, etc. How often does it happen? What’s the consequence to the business in production or ad- Shaft alignment in a Flash. Let us show you how! ® Sure it’s a bold claim. Don’t think it’s possible? The XA, Fixturlaser’s next generation system for laser alignment of horizontal shafts, is designed to get alignments done fast, really fast. In fact, XA even stands for “express alignment” . We’re ready to prove it. Call today for a demo at your location. ©2008 Vibralign, Inc. Flash is a registered trademark of Adobe Systems Incorporated. www.uptimemagazine.com 17 http://ivctechnologies.com http://www.vibralign.com http://www.uptimemagazine.com

Table of Contents Feed for the Digital Edition of Up Time Magazine- August/September 2008

Up Time Magazine- August/September 2008 Contents Upfront Upclose Information Technology Lubrication Infrared Maintenance Management Motor Testing Precision Maintenance Reliability Ultrasound Vibration Upgrade

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