FRACAS Training, Failure Reporting Analysis and Corrective Actions Systems

FRACAS Training, Failure Reporting Analysis and Corrective Actions Systems  

FRACAS Training Course Description

FRACAS training covers the fundamental of failure reporting, analysis, and corrective actions systems. FRACAS training focuses on incident reporting, failure analysis, problem resolution and other related analyses.

FRACAS training will teach you the FRACAS process, best practices, problem resolution methods and how to adjust FRACAS based on your needs. The FRACAS training course provides the concepts and techniques to help you apply a closed-loop process to respond to reported failures, identify the root cause of failure, and manage the actions required to successfully resolve issues.

What is FRACAS?

FRACAS, short for Failure Reporting, Analysis and Corrective Action Systems, was invented in the 1970s by the defense and aerospace industries. However, currently the FRACAS is used in various applications, including but not limited to safety/risk reduction systems, process control systems, and incident reporting systems. Failure Reporting and Corrective Action System is a reliability tool invented to handle your daily failures in an organized way that assesses the failure and establishes a maintenance strategy to predict, prevent, eliminate, or reduce the probability of failure. FRACAS presents a standard and assertive closed-loop process for solving issues at the design, development, production and deployment. Below are some of main tasks:

• Documenting information about failures and problems
• Determining, choosing, and prioritizing failures and problems
• Determining, applying, and verifying corrective actions to inhibit recurrence of failures
• Specifying information from failure analysis and corrective actions to support reliability data analysis
• Preparing the report of incidents counts, and presenting the data used for reliability and quality metrics

Benefits of FRACAS 

• Presents engineering data for corrective actions and preventive actions
• Determines deficiencies developing patterns
• Presents failure data for reliability analysis
• Helps preventing the occurrence of failures again in future designs
• Provides a central location to learning lessons, helping to reduce time and effort for resolving both individual accidents and problems
• FRACAS is crucial for Quality/ISO certifications and audits

Audience

FRACAS training is a 2-day course designed for:

• Maintenance supervisors and managers
• Senior trades personnel
• Lead people
• Planners
• Production managers
• Plant managers
• Project engineers/managers
• Quality engineers/managers
• Reliability engineers
• Root cause analysis team personnel

Learning Objectives

Upon the completion of FRACAS training, the attendees are able to:

• Understand what is FRACAS and how it works
• Explain the steps of FRACAS process
• Discuss the FRACAS best practices
• Analyze data with FRACAS software
• Track features, including alerts and audit trail
• Identify deficiencies configurations
• Demonstrate reliability analysis data for failure modes
• Develop action plans to inhibit the reoccurrence of failures
• Submit the report of incidents
• Provide engineering data for corrective action
• Evaluate historical reliability performance, such as mean time between failures (MTBF), mean time to repair (MTTR), avail- ability, preventive maintenance, etc.
• Develop patterns for deficiencies
• Provide data for statistical analysis

Course Outline

Overview

• FRACAS
• FRACAS background
• FRACAS benefits and limitations
• FRACAS applications
• Organizational issues addressed by FRACAS

The FRACAS Process

• Failure reporting steps/considerations
• Localized resolution considerations
• Failure analysis considerations
• Problem resolution process

Problem Solving Tools

• 8D
• DMAIC (Define-Measure-Analyze-Improve-Control)
• DFSS (Design for Six Sigma)
• DMADV (Define-Measure-Analyze-Design-Verify)
• IDOV (Identify-Design-Optimize-Validate)

FRACAS Best Practices

• Adjusting FRACAS to your needs
• Setting expectations and goals
• Involving the stakeholders
• Gaining the management support and involvement
• Defining the FRACAS process
• Leveraging software tools
• Providing training
• Data storage, use and reporting
• Data analysis

FRACAS Most Common Challenges

• Complex organizational communications
• Missing prioritized goals
• Inefficient data tracking

Steps to a Successful FRACAS 

1. Define the goals and success factors
2. Define the output
3. Map the process workflow
4. Map the required data and input method
5. Implement a prototype FRACAS
6. Accept feedback and modify the FRACAS
7. Rollout and training
8. Continue to change and adapt the FRACAS

Avoiding Failed Implementations

• Defining goals
• Potential issues?
• Reporting Incident
• User interface IT
• Organizational roadblocks to change
• Collecting the data
• Reporting equipment failures
• Reporting software problems
• Logging data
• Using FRACAS reports

Analysis

• Failure analysis process
  • Reviewing the field service reports
  • Gathering data from the database
  • Assigning owners for action items
  • Root cause analysis (RCA)
  • Developing corrective actions
  • Obtaining the failed items for RCA
  • Writing a problem analysis report (PAR) and, if needed, a material disposition report (MDR)
• Failure review board
• Root cause analysis
  • Brainstorming
  • Histogram
  • Flow chart
  • Force field analysis
  • Pareto analysis
  • Nominal group technique
  • FMEA
  • Trend analysis
  • Fault tree analysis
  • Cause and effect diagram (fishbone)
• Failed parts procurement

FRACAS Database Management System

• Configuration table
• Events table
• Problems table
• Report types

FRACAS Training