Product · Failures and reliability
Which equipment failed again, and why.
Eighteen months of failures on aeration blower 2. Pick a cause to see its recurrence, the work orders and the parts that went into it.
| Date | Failure mode | Cause | Work order | Part | To restore |
|---|---|---|---|---|---|
| 18 May | High bearing temperature | Inadequate bearing lubrication | WO-0712 | BRG-6312 | 2 days |
| 9 Oct | Belt failure | Incorrect belt tension | WO-0861 | BLT-SPB | 1 days |
| 2 Mar | High bearing temperature | Inadequate bearing lubrication | WO-0954 | BRG-6312 | 3 days |
| 21 Aug | High bearing temperature | Inadequate bearing lubrication | WO-1017 | BRG-6312 | 2 days |
01 · Recording a failure
A failure is recorded with its effect on the process.
A failure event says which equipment or position lost its function, and what that did to which unit or stream. Failure mode, cause and consequence are kept separate.
02 · Temporary and full restoration
Equipment running on a temporary fix is not resolved yet.
A temporary restoration has a limitation, an owner and a review date, and its permanent follow-up is tracked separately. Operationally resolved means the required function is really back.
03 · Cause investigation
Mode, cause, contributing factors and confidence.
A cause assessment is a lasting record with its method, assessor and evidence. If new evidence comes in, a new assessment explicitly supersedes the old one; the old one is never erased.
04 · Recurrence
Failures are linked, not just listed.
A failure can repeat an earlier one, continue an unresolved one, or share a common cause across several pieces of equipment. These links are recorded explicitly.
05 · Reports
Ready-made reports with clear definitions.
Each report has a defined type, filters and time rule, and every run can be reproduced with its parameters.
- Work order backlogOpen work by state, priority and team
- Overdue scheduled workPM that has passed its due date
- Maintenance costDirect part and labour cost by equipment and period
- Process condition historyConditions raised, attention and time to resolve
- Process round historyRounds completed, incomplete and overdue
- Failure event historyFailures, causes and time to restore
- Stock availabilityOn hand, reserved and available by location
- Inventory movement historyReceipts, issues, returns and adjustments
Connections
Where this connects
A failure event is tied to equipment and a process unit in the plant model, the repair is a work order, and its parts come from stores.
- Failure eventFE-0447 · blower 2
- Work orderWO-1017 · bearing replacement
- PartBRG-6312 × 2
- Process unitAeration basin 2
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