Which are the Basic 123 Steps to perform RCFA?

In rotating machinery: alignment is always a first. It is estimated over 60% of problems are alignment related. Either out of round parts, excessive run-out, poor alignment, soft foot, pipe stress, etc.........

Or, what failed? Always a lead in. Process related. I was called in on one that was weird. Checked alignment; OK! Everything OK?????????
Got a quart of process fluid - it was clear and somewhat slick - nothing wrong??? Held a rare earth magnetic up to the jar and particles started gravitating to it and a dark clump accumulated - that was the problem --- magnetic pump!!!!!!!!!!!!!!!!1

Eugene,

RCFA basic step will be :

1st : Determine the Physical Cause
This is the metallurgical aspect or the science on why a part failed in the first place.

2nd : Determine the Human Cause
RCFA believes that almost all failures have some form of human intervention that ultimately led to the physical cause

3rd : Determine the Latent Cause
Once the lattent cause of the problem had been achieved then the Root Cause is completed

My Warm Regards,

Rolly Angeles

Sam: Thanks, well explained example.

Rolly: Thanks, questions:
* Does all Physical Failures has the 2nd and 3rd causes? (Or 3rd cause, you said "almost all" for the Human Cause).

quote:

If you continue with the anaylysis after the latent cause then you will end up on 2 things :

Corinthian 6-10 For the love of money is the root of all evil

or down the way to Adam and Eve, if we continue to ask why

Sorry guys, it's 2nd Timothy Chapter 6 verse 10, I think no one is reading the bible lots of words of wisdom in it.

This message has been edited. Last edited by: Rolly12,

Amen.

quote:

Originally posted by Eugene:
Amen.

Let us illustrate an example :

1st : Why did the pump screwed up ?
Because the bearing failed.

2nd : Why did the bearing failed ?
It got stuck up.

3rd : Why did the bearing stuck up?
Lab indicates spalling on the raceway
(Physical Cause)

4rth : Why was spalling present on the raceway?
It is because the machine was vibrating
excessively

5th : Why was the machine vibrating excessively?
The pump and motor was misalinged

6th : Why was the pump and motor misalinged ?
It was not part of the maintenance
activities (Human Cause)

7th : Why was it not part of the procedure
for maintenance to align?
They were never trained for that
(Latent Cause)

8th : Why was the maintenance not trained ?
There was no budget for training

9th : Why was there no budget for training?
It was part of cost reduction measures

10th : Why was it part of cost reduction measures ?
So the company can profit more

11th : I guess you know the answer

Well said brother.

But a question arises.

Will you be doing all this questioning by yourself or a formal studygroup is set up that will investigate the phenomenon and make concrete and binding conclusions that will have companywide implications.

We may need to caution people against making it appear as if RCFA is done with one hand tied behind one's back -so to speak

Eckem

I think you need a small team composed of:
* Maintenance or Reliability Engineer to facilitate meetings / ensure the discussion keep the focus on the RCFA method and real causes are defined, (someone to judge if after the 7th or 8th question we could move to the next equipment in the list or if more questions must be asked).
* Maintenance Technicians who know the equipment, the failures it had experienced, and the maintenance that has been applied.
* Equipment operators who know the equipment is used and also how it fails
* Maybe a resource from safety, but I think he/she will be optional.
---
Those above would form the studygroup; later the Maintenance or Reliability Engineer will present the findings/conclusions to Management and deal with the companywide implications:
* Changes in PM/PdM/other maintenance instructions/programs?
* Modify operational procedures?
* Retraining operators/maintenance crew?
* Design modifications? Proyect proposals/budgeting?
* Others

The companywide implications are the reasons for management commitment needed before starting the RCFA studies. If nothing will be done with the findings the group will decrease the moral.

Now one question nromally vexes me.

This is on the issue of 'Computer Assisted RCFA methodologies' like Taproot, Proact and the like.

Are they essential and indispensible or they are some manual methods that can lead to results with the same effectiveness and efficacy

Eckem

Ecky, RCFA is basically a manual procedure.
The computerized interfaces are just a way to make life easier.
You could ofcourse conduct investigations using the correct methodology, a note pad, some sticky paper and maybe a digital camera.
Good luck with your investigation.

Eugene, what about having the PdM guy/girl on the RCFA group if available? Seems like one more perspective on the equipment would be valuable. Have to admit a vested interest, that is my current postiton & I am trying to get a formal RCFA program started here.

I gladly welcome the input from anyone with deep knowledge on the equipment operation, maintenance, failures and performance.

If the maintenance organization has a PdM team (even a team of 1), their (his/her) participation in the RCFA group would be valuable.

This message has been edited. Last edited by: Eugene,

Hello All,


RCFA is always recommended for a group of people involved in the asset, Fractography, failure analysis, can be done by a single person with extensive knowledge on the aspect.

Shoul I perform an RCFA investigation team, I'll place an operations, maintenance, PM person, PdM person and even contractors if third party is involved.

My Warm Regards,


Rolly Angeles
Teacher