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Applied Failure Analysis
BEST PRACTICES
Carlos Dongo
September 07, CRC Worldwide Conference
FERREYROS CRC Manager
Failure
Whenever a failure occurs.....
A question emerges...
WHOs FAULT WAS IT?

10/08/2007 AFA Best Practice 2007 - FSAA 2
Failure Analysis Restrains
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AFA Best Practice 2007 - FSAA
Failure analysis process

Restrains
Pre-Afa
Monitoreo de Condiciones ECM, SOS, VIMS, Refrigerante, ASA, Filtros, Tapones Registros Incompleto Acceso Informe Pre-AFA Piezas incompletas Registros Incompleto Acceso Almacenamiento y Transporte Piezas Corroidas Falta de proteccin Soporte al Producto: Perfil de mina, SAT Mecanico Desmontaje Comunicador tcnico Planeamiento Historial de Reparaciones, PMS, Pruebas, Commisioning, Informe Mcanico Registros Incompleto Acceso Cliente Capacidad (Tiempo) Redaccin Reporte Conocimiento AFA Conocimiento Sistemas
Persona
Redaccin Reporte Conocimiento AFA Conocimiento AFA
Conocimiento Sistemas (Maquina, Campo, Actualizacion Fca)
Analista de Fallas
Conocimiento AFA
Capacidad (Tiempo)
Informe no contundente / Informe a destiempo
Rpta a destiempo
Externos (Cte) Procedimientos
Falta de respuesta
Interno (Fsaa) Externos (Cte)
Microscopio
Micrometro, Vernier Herramientas
Respuestas incompletas
Registros Interno (Fsaa)
Lupa, linterna, camara
Data view
Soporte de Fbrica
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Metodos
Equipamiento
4

Restrains
Lack of information Poor analysis methodology Lack of technical skills Wrong diagnosis Lack of measuring and/or evaluation equipment and tooling Unclear reports Customers distrust (partiality feeling)
The failure happens again!!
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Failure Analysis Objective
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Objective
Find the root cause of a failure , using established processes and report it in an accurate and correct way giving recommendations to prevent it to happen again
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Failure Analysis Milestones
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Milestones
Have information about what happened BEFORE, DURING and AFTER the failure event Have a formal failure analysis process and a facility to analyze any component failed Have adequate communication channels, internally and externally Have the proper evaluation tools to analyze Have a qualified full time staff Manage an adecuate database Make an accurate, clear failure report including recommendations Keep communications flow to ensure appropriate follow ups
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Applied Failure Analysis: Our History

Starting point
Started in 1996, 01 part time dedicated engineer Due to the lack of processes and skills the conclusions presented were not exact nor precise Due to the lack of information reports took a lot of time to be delivered Complete investigation couldnt be performed because the lack of instruments or tools Generates a lot of friction with the customers
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Breaking point
2001 Hire 04 full time engineers with independence from technical communication duties Trained under Caterpillars AFA I,II and III courses Start creating and keeping records about failures and related issues Processes were developed, mapped and implemented A laboratory was developed with appropiate instruments and tools
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Up to now
07 qualified engineers Complete customers confidence in reports Recognized and requested by customers as a helping tool 1,000 reports delivered in a yearly basis Offered as a service and billed to the customers Online technical support using a Lotus Notes platform, not only for AFA purposes but also for technical communication and information ( working as an internal DSN) Repairs costs distribution aid Processes aligned under the 6 sigma methodology
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Applied Failure Analysis Benefits
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Applied failure analysis

Benefits
Warranty management: Failure analysis reports are used to facilitate claims preparation and SIMS data entries Product problems identification and reporting: Repetitive problems are reported to Caterpillar with detailed failure analysis Improves customers fleet management: Identification of root causes of failures allows customers corrective actions in operation and maintenance Customer relationship: Accurate and helpful reports builds confidence in dealer service support CRC rebuild processes: Gives important information about wrong rebuilt processes reducing re-do rates
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Failure Analysis Laboratory
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Failure analysis lab

Equipment
Estereo scope 90X Enlargement With option to register images using a digital camera
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Equipment
Digital cameras
Measurement equipment
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Equipment
Cabinets for mid size parts storage during analysis
Cabinets for small parts and tools storage


Equipment
Work stations Washing area Air inlets (100psi)
Recycling cleaners
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Applied Failure Analysis and 6 Sigma
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The failure analysis process

The 8 steps & 6 sigma
1 2 3 4 5 6 7 8
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Define the problem in a specific and simple way Collect data
Measure and register Think: Put the facts in a logical path
Identify the root cause Communicate to responsibles
I C
Repair and/or improve as needed Follow up with customer

AFA Best Practice 2007 - FSAA 21
Failure Analysis Mapped Process
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Applied Failure Analysis Process

Mapped Process
Diagrama de Proceso - Anlisis de Falla
Lunes, 04 de Julio del 2005 Componente desarmado con informacion de campo y de los talleres P5
Informe pre-afa Campo P1, P2, P4,P5, P7,P8, P10,P11 P3
Componente listo para evaluacin P5, P7
Componente desarmado e informacion completa
Falla del componente
Recopilacion de informacin preliminar
Envio de componente a los Talleres FSAA
Desarmado, recopilacin de informacion
Solicitud de informacin complementaria (AFA Checklist)
Camaras fotograficas Datos generales del componente Embalaje y proteccin del componente Estereoscopio / Lupas Sintoma de Falla Solicitud de servicio Instrumentos de Medicion Reporte del operador Transporte Pruebas metalograficas Historial de Reparaciones Revisin de ajustes y Historial de Mantenimientos montajes Commisioning Historial de Aceite/Tapones/Filtros Informe de desmontaje Reportes del seguimiento del componente Analisis de VIMS / ECM / EPTC Otros
Checklist Email
Informe pre-afa Lab AFA P5, P8, P9
Informe pre-afa Lab AFA recibido en supervisin P5, P6
Informe AFA FSAA Informar Administracin sobre acuerdos finales con el cliente P5
Ordenamiento y analisis de datos
Registro y envio de informe a la mina y/o Sucursal
Aceptacion de informe por proyecto y/o sucursal?
Si Informe al cliente Aceptacion de informe por cliente?
Si Archivar
Informe Pre-afa Campo Informe tecnico mecanicos Informe tecnico Motorindustria Archivos VIMS / ECM / EPTC Historial de Aceite/Tapones/ Filtros
DWF Lotus Notes
No Envio de observaciones e informacin complemetaria
No Envio de observaciones e informacin complemetaria
P12
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23

Mapped Process
Planning Fsaa Adm. Gtias Comunic. Tecn. Monitoreo

Martes, 01 de Noviembre del 2005 Monitoreo Condiciones Fsaa
Mantenimiento
Adm. Fsaa
Planning Antamina
Mantenimiento Antamina
Lab. AFA
Ofic. Tcnica
CRC
Falla Componente Componente Fallado Solicitud de servicio
Solicitud de servicio Ficha de cambio Status Garantia
Recepcion Solicitud AFA
Falla Componente
Solicitud de servicio Ficha de Cambio Informacin Sistema
Componente Fallado Solicitud de servicio Falta Inform.?
Solicitar informacin
Email Recopilacin informacin Recopilacin informacin Commisioning Datos Maquina Recopilacin informacin Recopilacin informacin Recopilacin informacin Historial Rep. Historial PMs Historia Maq Archiv fisico
Historial Rep. Historial PMs
SOS VIMS ECM Filtros / Tapones Rellenos Seguim. Comp.
Inf. Serv Evaluaciones Comentarios
Elaboracin Pre-AFA
Observaciones Supervisin CMA
Envio Pre-AFA
Recepcin Pre-AFA
Recepcin Pre-AFA
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Mapped Process

Martes, 01 de Noviembre del 2005 Monitoreo Condiciones Fsaa Recepcin Informacin Minas
Mantenimiento
Adm. Fsaa
Planning Antamina
Lab. AFA
Ofic. Tcnica Minera
CRC
Recepcin Pre-AFA
Recepcin Pre-AFA y Componente
Ingreso de datos al sistema
Procesar Datos
Recopilacin de informacin PPM DWF /Inf Mec Talleres Checklist Desar Hist. Reparac DBS SIS / CPI / DSN/ FMMS
Desarmado
Analizar Datos
Analisis de Datos FMMS
Evaluacin
Reportear y distribuir
PPM Recopilacin datos Faltan datos?
Trabajos Exteriores si requiere
Recopilacin Datos
Consulta Fca?
Consulta a Fbrica
Armado
Emisin de informe
Validacin Pre-Carta Tcnica
Pruebas en banco
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Mapped Process

Martes, 01 de Noviembre del 2005 Monitoreo Condiciones Fsaa
Mantenimiento Fsaa
Adm. Fsaa
Planning Antamina
Lab. AFA Emisin Informe AFA / Precarta Tcnica
Ofic. Tcnica
CRC
Recepcin AFA
Recepcin AFA
Recepcin AFA
Recepcin AFA
Recepcin AFA
Recepcin AFA
Actualiza Checklist Pre-AFA
Actualiza Checklist Mantenimiento
Durante Periodo de Implementacin
Elaboracin de Carta Tcnica
Absolver Consultas
Absolver Consultas
Revision casos AFA / Elaboracin de Carta Tcnica
Presenta caso al Cliente AFA / Carta Tcnica
Ejecuta Acciones Correctivas / Carta Tcnica
Recepciona Carta Tcnica VB
AFA Conforme ? Factura OT
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Ferreyros Technical Support Platform- (FTS)
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Ferreyros Technical Support Platform

FTS
The failure analysis process is supported by an estructured platform called Ferreyros Technical Support (FTS) that allows to register and keep all the failure analysis performed and also the technical information and the inquires asked
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FTS
(FTS)
The system works under a Lotus platform having control and protection of the information
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FTS
Failure analysis performed, technical inquires and technical information in the same platform
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FTS
The information can be sorted by different labels
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FTS
Easy access and information view
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FTS
Information estructured to allow a better administration by responsable Failure description by: Site/ Branch/Shop
Additional information: Mine/ AFA / Tech. Comm.


FTS
All communications regarding a specific case are kept in the system
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FTS
Previous Info: Site / Branch
Additional information: Site / AFA / Tech. Comm.
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FTS
Keep record of all communications regarding a case. The system is tied with the e mail system
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FTS
Records: Allows to attach photos, documents etc
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FTS
AFA definitions
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FTS
Details of the analyzed case
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FTS
Recommended action plans: 3W format for follow ups
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FTS
Hoja de clculo de Microsoft Excel
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FTS
Technical coordinations: Administrative definitions ( support to shops)
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FTS
Follow Up: Timing reports
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FTS
Follow up: Through banners indicating in which step of the process and whos responsible is each case
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FTS
Tool for the elaboration of the final report
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FTS
The Technical Inquires section gives support to the technical communicators about reusability, test in machines, specifications etc.
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FTS
Answer to technical inquires
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FTS
The technical information section is used as a virtual library where Ferreyros BITs and Caterpillar Bulletins regarding our machines population are kept and administrated
Applied Failure Analysis Success Key Factor
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Applied failure analysis success key factor
tTEAM WORK
Who? Where? When?
Customer - Dealer 10/08/2007 AFA Best Practice 2007 - FSAA
Factory
50
Applied Failure Analysis at Ferreyros
Thank You
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Applied Failure Analysis

FERREYROS CRC Manager

Whenever a failure occurs.....

WHOs FAULT WAS IT?

Failure Analysis Restrains

AFA Best Practice 2007 - FSAA

Failure analysis process

Conocimiento Sistemas (Maquina, Campo, Actualizacion Fca)

Informe no contundente / Informe a destiempo

Externos (Cte) Procedimientos

Interno (Fsaa) Externos (Cte)

Micrometro, Vernier Herramientas

Registros Interno (Fsaa)

Lupa, linterna, camara

Failure analysis process

The failure happens again!!

AFA Best Practice 2007 - FSAA

Failure Analysis Objective

AFA Best Practice 2007 - FSAA

Failure analysis process

AFA Best Practice 2007 - FSAA

Failure Analysis Milestones

AFA Best Practice 2007 - FSAA

Failure analysis process

AFA Best Practice 2007 - FSAA

Applied Failure Analysis: Our History

AFA Best Practice 2007 - FSAA

Applied Failure Analysis: Our History

AFA Best Practice 2007 - FSAA

Applied Failure Analysis: Our History

AFA Best Practice 2007 - FSAA

Applied Failure Analysis Benefits

AFA Best Practice 2007 - FSAA

Applied failure analysis

AFA Best Practice 2007 - FSAA

Failure Analysis Laboratory

AFA Best Practice 2007 - FSAA

Failure analysis lab

AFA Best Practice 2007 - FSAA

Failure analysis lab

AFA Best Practice 2007 - FSAA

Failure analysis lab

Cabinets for mid size parts storage during analysis

Cabinets for small parts and tools storage

Failure analysis lab

Work stations Washing area Air inlets (100psi)

AFA Best Practice 2007 - FSAA

Applied Failure Analysis and 6 Sigma

AFA Best Practice 2007 - FSAA

The failure analysis process

Define the problem in a specific and simple way Collect data

Measure and register Think: Put the facts in a logical path

Identify the root cause Communicate to responsibles

Repair and/or improve as needed Follow up with customer

Failure Analysis Mapped Process

AFA Best Practice 2007 - FSAA

Applied Failure Analysis Process

Informe pre-afa Campo P1, P2, P4,P5, P7,P8, P10,P11 P3

Componente listo para evaluacin P5, P7

Componente desarmado e informacion completa

Falla del componente

Recopilacion de informacin preliminar

Envio de componente a los Talleres FSAA