Hi,
Is anyone logging their lost production time in a database or spectialist software. We are trying to develope a database system for logging all production loss events. Some of the features we are after are.
Fields,
Date, Time, Duration, short description, loss in dollars (calculated), potential loss if nothing is done (tonnes lost x dollers per tonne x probability of repeat failure), equipment, component, root cause, sequence of events, link to problem solving tools i.e. apollo template, action log, others??
From this data we hope to generate some graphs showing how we track against completing actions as this is an area we struggle with. We also want to be able to prioritize events so we focus onle on the top 10 or so highest cost items. Some basic fields will be filled in by the operator who will use the potenial loss field to decide how urgent further action is needed. The failures will be sorted by impact cost and assigned owners we will carry out RCA and complete the fields. RCA reports can be generated straight from the system.
All this is in early developement but I am interested in finding out if any existing systems are out there.
Thanks in advance.

It's in our WO system: Break-down/unplanned, PM, etc... Outage, manpower & materials are documented in CMMS.

Good day,

For the lost production tracking we use an inhouse developed tool created in SAP where we record the type of losses, amount, flaring volume, etc

regards

quote:

Maintenance and Reliability Root Cause Analysis Lost production/RCA database

We created a separate spreadsheet but could have easily been a database where we tracked a portion of the downtime events. By portion, I mean we established thresholds for each area. For example, a process area down for 2 hours and a packaging machine down for 4 hours. These numbers were agreed to by Operations and Maintenance. We found that if we tried to capture everything, we ended up getting garbage in becasue it was a pain for the operators. These critical events exceeding the time thresholds automatically initiated a simplified RCA process. We used an 8 step form to capture the actual event and start the process. The information from the form was captured in the spreadsheet to show status and a quick history. We trended these incidents by area with losses in yield $, tonnes, labor, scrap and the number of incidents. It was neat to go back into a specific area, quarter on quarter to see the amount of improvement in a particular area.

Regards,
Jeff

quote:

Originally posted by Faisa:
Good day,

For the lost production tracking we use an inhouse developed tool created in SAP where we record the type of losses, amount, flaring volume, etc

regards

Hi
Can you provide some more details about the downtime system you have in SAP including transaction codes etc and whether the downtime is linked to a maintenance order where the loss was equipment related .
Thanks

The timing of this thread came when I had already submitted an iPresentation on the same topic. That iPresentation was put up today and can be found here A Practical Approach to Simplified Root Cause Analysis. The iPresentation provides much more detail around the post I made above.

Regards,
Jeff

Thanks all for your input.
Sam and Faisa, we use Maximo. We explored the use of this fore storing and tracking RCAs but we would make to make many costly changes to get it to work.
Jeff, Ive tried viewing your presentation but it chashes just as it gets into the SRCA form. I will keep trying but it looks very similar to what we are trying to develope. Ours will (hopefully) prioritize on future potential downtime, i.e. this will bring out the events that didnt cost much this time but could if there is a high probability of repeat failure. The issue here is trying to be objective. We also want to use it as a troubleshooter so we will be recording all events with symptom keywords and solutions (if they are known). By listing failure symptoms and fixes in a searchable database the next time it happens the operatoror maintainer should be able to fix the problem without getting in specialists. Like yours it will include links to problem solving tools and prompts/hints for what actions to take, i.e. are there other processes/equipment under similar operating conditions that need checking. Do we need to expitite spares. Find alternative supplies for our customers etc. Some of these features are where our CMMS and other current systems struggled.

Cheers

Planty,
Your project sounds like fun. We also track work with Maximo (5.2). Our group is trying to get a work type in place to use only for downtime events. As a batch operation we can’t assume every CM is a downtime event. We built a Brio query to bring work orders with all problem codes except "No Failure-Acceptable" into a report. We built a neat SQL statement that look for "keywords" in the WO Description, Failure Remarks and LDtext for each. It lists each keyword that it finds in a Keyword column. We use it to look for problem trends. What database are you setting this up with? Will it be hand entered or will it query Maximo? It would be interesting to see what you come up with.

Cheers

Hi Wally,
We would like to have both manual input and query but will probably query our downtime recording tool which is PLA (production loss analiser, and piece of software supplied by Kvaerner) This software automatically records and categorises downtime based on triggers from the process lines but stops there, i.e. does not capture non downtime losses such as quality losses or breakdowns not resulting in downtime. We see our database querying PLA and being edited each morning at the main/production mtg
SQL rings a bell but I am not the computer guy so will ask him.
Cheers

We've been using a system like this for 8-9 years and have seen some merit to it. The current system has a basic product counter and OIT for the operator to input a 3-digit code pinpointing the downtime event. The terminal is loaded with a production schedule as many of our lines have different target rates for different products and to prevent logging DT on a weekend. When a DT evemt is sensed or the line is running @ a sub-standard rate, the operator of the machine deemed the "control point" is prompted to input the event code. This took some training...ever heard the phrase "Garbage In, Garbage Out"? The problems with this were that the events were up to interpretation and only DT events affecting the control point were recorded. In addition th DT minutes, we look at # of stops. Starts and Stops are hard on equipment and the steady state is better for quality. We like steady state!
The new system we will be lighting up in May is more of a PLC/HMI based system. Any critical fault on any machine HMI will be recorded in the DT system. So, rather than "Machine C is down", we will get "VFD 6 on Machine C Faulted" or whatever. The operator will be prompted for DT code only when it can't be otherwise determined. Another key you touched on is the events not resulting in DT. This will be a plus for the new system. Example: If the robotic casepacker breaks down, the operators hand-pack to keep the product flow. There is a higher probability that quality checks will be missed, espescially if help comes from a different line...plus it makes for a long day for those operators. Those events were off the radar of the old system because the control point kept plugging away.
We have a full time guy that compiles all of this data and updates our scorecard. He's a real "Stats"guy with a never-ending supply of charts and graphs. DT is first divided into mechanical and non. We in Maintenance look at the mechanical uptime. 3 weeks below goal requires action items...that may be an RCA, work order or in the case of maintenance induced failure it is training or more job procedures etc. With the DT pushing us, it is usually easy to locate the events in the CMMS.
Engineering gets involved with some of the non-mechanical. Once the low-hanging fruit clears, you'll be looking at reducing change-over times, shortening clean-ups and other ways to lessen the impact of the unavoidables. This data is great when your trying to justify new equipment or upgrading old.

quote:

Originally posted by trevors:

quote:

Originally posted by Faisa:
Good day,

For the lost production tracking we use an inhouse developed tool created in SAP where we record the type of losses, amount, flaring volume, etc

regards

Hi
Can you provide some more details about the downtime system you have in SAP including transaction codes etc and whether the downtime is linked to a maintenance order where the loss was equipment related .
Thanks

Good day,

In the slides attached you can see some screen shoots of the system that was developed in SAP to track the Opportunity losses and Basic root Causes.

Regards

Opportunity_Losses_DataBase_in_SAP.ppt (302 Kb, 18 downloads) OLDB example

Guys,
I have been completely snowed under for weeks and have not been able to respond until now.
By the sound of things, we have developed pretty much what Planty has asked for. Without going into a long email, our company, OMCS international specialises in reliability assurance which involves the integration of the CMMS with maintenance strategy development, data collection, investigation management. I have attached abrief overview.
Our idea is to provide a reliability engineer with all the information he needs to review failure through the one portal.
The other interesting factor is that on the one site, there will be many ways data needs to be collected. For example, in an aluminium refinery, data about crane, pot room, finishing, Rodding and carbon, ingot etc all have different needs. Our enterprise data analytics system covers all these permutations via user developed screens and one single database that can be viewed across any enterprise.
At OMCS, we concern ourselves entirely with the provision of simple and effective tools for reliability engineers. I know this is a bit of an ad, but I know the areas of data collection and investigation are amongst the most poorly developed information systems in capital intensive businesses.
I suggest that those that are interested in finding out more, that they first download the attached pdf and then contact me by email at:
steve@omcsinternational.com
Rgds
Steve
www.reliabilityassurance.com
PS, we dont keep all our presentation material and demo software on the web.
If you want the leading edge stuff, you need to contact us direct... or come and see us in Vegas at RCM 2008 or Euromaintenance in Brussels next month.

This message has been edited. Last edited by: Steve Turner,

ReliabilityAssurance_MuchMoreThanaCMMS.pdf (302 Kb, 14 downloads) Four quadrants of Reliability Assurance