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Failure Elimination
Failure Elimination
Why OESuite® for Failure Elimination Matters
A reliable plant is a safe plant, and eliminating unplanned equipment failures, especially chronic, recurring failures, is a key component to becoming less reactive and more reliable. Process manufacturers are typically good at analyzing near misses and preventing major incidents, but chronic, recurring losses often fly under the radar and expose operators to serious risks (or opportunities for losses).
Operational Sustainability® approaches Failure Elimination from the bottom up, beginning with accurate failure documentation via work orders. Analyzing repair history leads to identifying bad actors and patterns of commonality across the enterprise. By identifying the root causes of failure, our OESuite® Failure Elimination Solution helps weed out bad actors in your organization, greatly reducing equipment downtime, off-spec products, safety incidents, and environmental excursions.
How Does OESuite® Help Address Failure Elimination?
Through our comprehensive set of integrated modules and features in the OESuite® Failure Elimination Solution, users can:
- Compare the effectiveness of their asset strategies to actual asset performance by collecting and analyzing production loss events, equipment failures, process interruptions, and safety incidents
- Compare asset strategy for the bad actor asset vs execution of the work order to verify the effectiveness of the asset strategy
- Fine-tune asset strategies to achieve world-class asset performance
- Leverage structured libraries of asset master data, including failure codes, in the Work Management + Mobile Module or use our integration connectors to leading Enterprise Asset Management (EAM) software providers
- Log root causes of non-acceptable failures in the Incident Management + Mobile Module
- Bring uniformity to the analysis and elimination of failures
- Apply condition monitoring and generate preventive maintenance and inspection tasks
OESuite® Business Benefits for Failure Elimination
As companies mature and move from reactive to proactive asset maintenance, they target failure modes generated by defects to significantly reduce future work requirements and maintenance costs. When leveraged with preventive and predictive maintenance, the OESuite® Failure Elimination Solution can have profound impact on plant reliability and safety performance.
OESuite® Mobile Applications
When it comes to delivering real-time decision support in the field via mobile devices equipped with integrated mobile apps, we take a “single pane of glass” approach to deliver intuitive, simple-to-navigate Mobile Applications unified with core enterprise applications…and puts them in the palm of your hand. Mobilizing your maintenance and inspection workforce is integral to improving operating efficiencies in the field. Take photos, report new incidents and generate work orders from findings from operator rounds or inspections.
How Does Failure Elimination Tie into Enterprise Loss Prevention (ELP)?
Beyond the obvious benefits of reducing incidents and enhancing reliability, our OESuite® ELP Master Framework helps organizations unlock the potential in your hidden plant. Why? Because running closer to your designed capacity without additional risk enhances your bottom line.
Proper Failure Elimination greatly reduces equipment downtime, off-spec product, safety incidents, and environmental excursions – and therefore contributes to both value protection and value extraction. From identifying the assets that are eating your lunch to determining the solutions to help you become less reactive, our OESuite® Failure Elimination Solution will enhance your bottom line and reduce your potential for enterprise losses.
OESuite® Failure Elimination Solution 8-Step Process
OESuite® delivers on the promise of improved Failure Elimination through our interoperable modules, ensuring processes are orchestrated effectively and variations are minimized from start to finish.
- Collect asset information from the Computerized Maintenance Management Systems (CMMS) and EAM systems while leveraging an asset taxonomy and analyzing the work history
- Analyze failure histories within work orders for failures by asset, component, cause, repair cost, and more
- Categorize and quantify production losses to enrich the Pareto Analysis and assign bad actors through the Production Loss Analysis Module
- Bad actors are identified and nominated for investigation using the Asset Analysis Module
- Bad actors are investigated using the incident type RCA in the Incident Management + Mobile Module
- Recommendations are created to address the root causes of the RCA investigation
- Recommendations not requiring a Management of Change (MOC) or replacement-in-kind are implemented where appropriate (e.g., procedures, asset strategy changes, etc.)
- For the actions that involve a Not-In-Kind change, our MOC process manages items to closure