Root Cause and Failure Analysis (RCFA) Workshop

Root Cause and Failure Analysis (RCFA) Workshop

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RCFA :

. . RCFA .

:

RCFA

RCFA

RCFA � � M P PDCA

)FTA(

)FMEA( )MFMEA(

:

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cement technology magazine: 021-22883306, 22861343

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: (Systematic Approach)

RCFA Root Cause and Failure Analysis

. RCA Root Cause Analysis .

. RCFA .

: 1- )Symptom ( 2- )Problem( 3- )Root Cause(

: .

. . . . .



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: 1 :

.

.

. Restart . Shut Down

. CPU CPU Restart . Shut Down

. CPU .

2 3 .

The Pyramid of Causes Deeper Causes Root Causes



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RCFA : RCFA :

1 � )Data Collection( 2 � )Assessment ( 3 � )Corrective Actions( 4 � )Inform( 5 � )Follow-up(

)Data Collection (

) Assessment (

) Corrective Actions(

)Inform (

)Follow-up (



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1 : )Data Collection( .

. .

.

2 : )Assessment ( .

. : ) roots Physical : ( ....

)Human roots : ( .... )roots Latent : ( ....

3 : )Corrective Actions(

2 . :

1 � 2 - 3 �

4 : )Inform( .

.

5 : )Follow-up( .

.



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)( :

:

1- )Reactive Maintenance System (: . Breakdown Maintenance )BM ( Emergency Maintenance )EM ( .

2- )Preventive Maintenance System( PM :

)Time Based Maintenance( .

.

3- )Predictive Maintenance System ( PdM : )Condition Based Maintenance (

)Vibration Monitoring ( )Thermography ( )Oil Analysis ( )Ultrasonic Analysis ( . . .

.

4- )Proactive Maintenance System ( PoM : .

.

RCFA

. . RCFA

.



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. 4

)RCM( .

:

)Whys(5 . )Problem ( )Why ( )Root cause(

. : )Problem : ( (Conveyor failed)

1 �

. (Burned out) 2 �

) .Overheating( 3 �

.(Unbalanced) 4 �

) .Dust( 5 �

) .Unclean(

Reliability Centered Maintenance = RCM



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)Root cause : (

)Preventive action( :

: P-M

P-M 5 .

. .

:

P-M ) Planned Maintenance (PM Preventive Maintenance) (PM . P P-M

)Phenomena ( )Physical ( .M )Mechanism ( . 4M . M4 : )Machine ( )Man ( )Method ( )Material(

Analysis P -M



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P-M :

1 - ) : ( )Over load (

2- : )Tension (

3 � :

4 - 4M :

·

·

·

5 � :

·

·

6 � :

:

· Over load

·



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: 6 PDCA . PDCA

:

Plan : SMART Do :

Check : Act :

:

P1 : Define Problem & Objective (& Do Quick Fix) P2 : Identify Likely Causes P3 : Identify Major & Root Causes P4 : Develop Solutions / Agree Action Plans D5 : Implement Action Plans C6 : Determine Effectiveness Of Plans A7 : Standardize Results / Implement In All Relevant Areas

SMART :

SMART Specific, Measurable, Achievable, Realistic,Time based

Specific : .

Measurable : . Achievable : .

Realistic : . Time based: .

:

Deming Cycle = PDCA Cycle



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PLAN : ) (10 % MTTF . ) (5 % MTTR .

PLAN : MTTF :

Recollect

MTTR :

)Off-Line (

DO : MTTF :

Recollect



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MTTR : )Off-Line (

Check : MTTF :

MTTR :

Act :

MTTF :

MTTR :

:

7 . 80 20 . 80 20 )80 -

20 ( . :

80 20 . 80 20 .

.

. 80 . .

.

Diagram Pareto



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80 .

:

8 9 10 .

)Effect ( )Causes ( .

. :

Cause and Effect Diagram Fishbone Diagram

Diagram Ishikawa



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4M ) ( 4P ) ( 4S ) - (

.

. 11 : .

) ( .

. . .

Brain storming



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: 12 )

MTTF MTTR( :

) ( CNC :

220 240 200 340 280 160 200 180 240 300

240 220 380 160 120 240 280 240 220 400

200 180 200 240 120 240 280 300 220 240

280 320 180 280 260 300 220 140 180 300

MTTF

Histogram



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. ) ( :

Air Tool 11 12 10 17 14 8 10 9 12 1512 11 19 8 6 12 14 12 11 20

Air Tool 10 9 10 12 6 12 14 15 11 1214 6 9 14 13 15 11 7 9 15

MTTR

2 1 . )CV ( :

CV1 = StDev1 / Mean1 = 3.573 / 12.15 = 0.294 CV2 = StDev2 / Mean2 = 2.83 / 11.7 = 0.241

: Minitab

.



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: 13

. 14

. : :

CNG .

:

. . :

.

"6 "4 : "6 "4 .

"6 "4 .

:

Mistake Prooing

Poka Yoke



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15 . 16

)Top down approach . ( 17 AND OR . . . . .

.

18 19 . 20 )MCS ( .

. .

.

FTA Fault Tree Analysis =

Top Event

Logic Gates

Qualitative Analysis

Quantitative Analysis

Minimal Cut Sets = MCS



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. :

TOP = G2 +G3 + E5 = (E1 + E2) + (E3 + E4) + E5 :

{E1} , {E2} , {E3} , {E4} , {E5}

)MTTF( . . . )Top Event ( . ) (MTTR )(Probability Frequency . . . .



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: 21 )FMEA ( " "

. FMEA . . . . FMEA

. " "

. FMEA

FMEA 5 : FMEA - 1 )Design FMEA = DFMEA(

- 2 FMEA )System FMEA = SFMEA( - 3 FMEA )Process FMEA = PFMEA( - 4 FMEA )Service FMEA( - 5 FMEA )Machinery FMEA = MFMEA(

DFMEA SFMEA PFMEA Service

FMEA . MFMEA MFMEA DFMEA .

Failure Mode and Effect Analysis = FMEA

FMEA

FMEA FMEA

Process FMEA

Service FMEA

Design FMEA

System FMEA



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FMEA . FMEA

.

FMEA . PFMEA

. SFMEA DFMEA .

22 )S ( 23 )O ( 24 )D ( FMEA .

. 25 )RPN ( . )S ( )O (

)D ( . RPN = (S) × (O) × (D)

26 . )S ( )O ( )D ( 1 10

RPN 1 1000 . )S ( )O ( )D ( .

)S ( . 1 10 10

9 5 1 .

Severity = S

Occurrence = O

Detect ability = D

Risk Priority Number = RPN

Failure Mode



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)O ( 1 10 10 8 5 1

. )D(

27 )SPC ( 28 )DOE ( . . . 1 10 10 5 1

.

RPN . .

Statistical Process Control = SPC

Design Of Experiments = DOE



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FMEA . FMEA

. .

. .



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: (Technical Information)

: SAE : API :

MIL:

)Viscosity: ( ) (

. .

W ) =Winter (

: SAE 0W � 20

SAE 0W � 30

)Multi Grade /Multi Viscosity: (

. :

SAE 5W � 20 SAE 10W � 30 SAE 20W � 40

SAE 5W � 20 SAE 5W SAE 10W SAE 20W SAE 20

. W W



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SAE :

SAE : SAE 5W SAE 10W SAE 20W SAE 20 SAE 30 SAE 40 SAE 50

SAE :

SAE 70W SAE 75W SAE 80W SAE 85 W SAE 90 SAE 140 SAE 250

SAE SAE .

:

:

BEHRAN: 32 K or 68 K BABAK: 32 or 68

SHELL: 12

ESSO: 32

: .



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API :

S Service) Station ( Commercial) C ( S C . S C

A .

API :

API )EP ( :

API GL 1 API GL 2 API GL 3 API GL 4 API GL 5

)EP =pressure Extreme: (

EP .



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: ) (

(thickener) . ) ( . .

. .

:

NLGI : ISO :

NLGI )Consistency ( 9 .

:

)(

:



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: 60 : 120

: 130 ) (: 140

:

SKF : LGMT 2 LGMT 2 NLGI 2 . LGMT 2 120 ) + . ( - 30 to

SKF : LGMT 3

LGMT 3 NLGI 3 . LGMT 3 120 ) + . ( - 30 to

SKF : LGWA 2

LGWA 2 NLGI 2 . LGWA 2 140 ) + . ( - 30 to

: Additives)( .

.

SUNOCO: EP 1 EP 1 NLGI 1 . EP 1 120 ) + . ( - 18 to

SUNOCO: EP 2

EP 2 NLGI 2 . EP 2 125 ) + . ( - 15 to

SUNOCO: EP 3

EP 3 NLGI 3 . EP 3 130 ) + . ( - 12 to



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: 1. )Spur Gear( 2. )Helical Gear( 3. )Double - Crossed Helical Gear( 4. )Herringbone Gear( 5. )Internal Gear( 6. )Rack Gear( 7. )Straight Bevel Gear( 8. )Angular Bevel Gear( 9. )Crown Bevel Gear(

10. )Skew Bevel Gear( 11. )Spiral Bevel Gear( 12. )Zeorl Gear( 13. )Hypoid Gear( 14. )Worm Gear( 15. )Double-enveloping Worm Gear( 16. )Spyroid Gear(



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:

1. ) Wear ( 2. )( Breakage 3. )(scoring

21 3



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) Wear ( :

. 100 � 20 .

CuFe



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)( Breakage : over load Breakage) ( .

)(scoring : .

. .

:

1. (Atomic Emission Spectroscopy) A.E.S 2. Viscosity 3. P.Q (Particle Quantifier) 4. Particle Counter Laser 5. (Direct Reading Ferrography) D.R.F 6. (Total Acid Number) T.A.N 7. (Analytical Ferrography) A.F



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) : (A.E.S : PPm

(Part Per million) : 5 6

(Viscosity) :

: : 20 % + 10 - %

:

(P .Q) :

: : 1 1000

Particle Counter) (Laser : :



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(D.R.F) : : : 5 )DL : Direct Large (

5 )DC : Direct Small ( .

DL DS : DL DL + DS .

DL - DS . DL � DS) / ( DL + DS)(IS = ) ( .

(T.A.N) : :

: 1.5 2 T.A.N .

(A.F) : :

:

.

: IRANOL: IG BEHRAN: Bordbar PARS: Nissan CASTROL: Alpha MW BP: Energol GR-XP ESSO: Spartan EP SHELL: Omala TOTAL: Carter EP



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: ESSO: Unirex N2 (Maintenance - Free)

Unirex N2 NLGI 2 . Unirex N2 .

: 500 .

3000 5000 . 3 6 .

:

: D . B G = 0.005 )( =G )( = D )( = B

4 1 :

25.4)]. (1 x 25.4) = 12.9 gr [(4 x x G = 0.005

4.25

3 .

30 % 60 % .



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:



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) / ( :

Sleeve Bearings



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: 1. )Ball Bearing( 2. )Bearing Roller( 3. � )Thrust Ball Bearing( 4. � )Thrust Roller Bearing( 5. - )Tapred Roller Bearing (

Antifriction Bearings

1 2

3 4

5



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: )Bore Dimensions( .

00 01 02 03 :

10 mm =00 12 mm =01 15 mm =02 17 mm =03

04 05 . . . 5 :

20 mm =04 25 mm =05 50 mm =10 120 mm =24

:

)Radial Clearance ( C2 CN C3 C4 C5 . C2 C5 .

CN = Normal Clearance

.

C2 C3 C3 .



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:

: )Fatigue(

)Load( )Lubricant(

)Mounting( )Clearance(

)Speed( )Temperature(

)Vibration( )Contamination(

)Corrosion( )Electrical Erosion(



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: 2 8 10 . 2 .

°c 15 .

:

Excessive Load Overheating



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1. ) (Flaking 2. - )Seizure( 3. )Cracking and notching( 4. )Cage damage( 5. )Meandering wear patterns( 6. )Smearing and scuffing( 7. )Rust and corrosion( 8. )Fretting( 9. )Wear(

10. )Electrolytic corrosion( 11. )Dents and scratches( 12. � )Creep( 13. )Surface matting( 14. )Peeling(



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Root Cause and Failure Analysis (RCFA) Workshop

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