Up Time Magazine- August/September 2008

value, or quantity of product “lost” per year. Business Level FMEA Questions Major “Failure Modes” that result in Production Losses? Frequency of occurrence of each? Typical effect and consequence in Units or $$$? Any extraordinary repair or operating costs?? Preliminary view of causes of these failures? Preliminary Priorities for action? Source: Making Common Sense Common Practice Elsevier, Butterworth-Heineman Books Boston, MA & London, England The process is shown in a simplified form in the Model for Performing a Business Level Failure Modes and Effects Analysis (FMEA) in Figure 11. Each Area Team asks the questions described above and summarized in the Business Level FMEA Questions graphic in Figure 12. For example, assume in step one of our production process that we identified supplier quality as a major problem. That is, once a week the supplier provided raw material of substandard quality. This quality problem required adjustment of the process and resulted in lower yields and/or extra costs. Suppose we calculated that this lower yield resulted in the loss of the equivalent of 10 tons of product (or 1000 units or whatever appropriate unit), with each ton having a gross profit of $500. This would result in a loss of $260,000 per year. Further suppose other disruptions for accommodating this poor raw material were valued at $2,500 per event - lost productivity of people, plant re-configuration, and so on. Overall the value of this failure in our system would be estimated at ($260,000 + $130,000) or $390,000 per year, a fairly substantial sum. We continue with this process until we’ve identified all major losses in each production area, as well as those attributable to Figure 12 - Business Level FMEA Questions ditional costs? What’s that worth, over a year’s time? 6. As discussed above, during the review, the value of each business level production failure is analyzed and estimated/calculated – Type of Failure, and its Frequency Per Year x Losses per Failure x Value per Loss to estimate the dollar Our Students Call It CSI for Engineers. We call it “Practical Plant Failure Analysis” It’s a reasonably-priced practical seminar with hundreds of hands-on examples designed for plant people and engineers. You’ll work with gears, bearings, shafts, belts, fasteners, seals, and a selection of corrosion examples. With the hands-on analyses, you’ll learn how and why they fail – and how to diagnose the multiple causes. The public session is three days long and is held in Syracuse,NY in November. Private sessions range from two to four days and can be held at your site. From the Reliability Professionals who “wrote the book on logical and practical plant failure analysis”. For more details contact Dale Gamba at 315-487-4390 or email us at reliable@twcny.rr.com 18 16 august/september 2008 http://www.hawksightglasses.com http://www.hawksightglasses.com

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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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