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Reliability Software, Safety and Quality Solutions / Services / Failure Data Collection (FRACAS)

Failure Data Collection (FRACAS)

The success of an R&M program depends critically on the quality of the failure data that is used to improve design, processes and operations. Without accurate and complete data it is difficult to assess where improvements can make a difference and where your organization may be running into problems.  The problem is two-fold:

  • Collecting good, accurate, failure and maintenance data

  • Properly analyzing the failure and maintenance data to close the loop and improve the product

Together these form the backbone of a successful Failure Reporting, Analysis and Corrective Action System (FRACAS). SoHaR has spent decades performing these tasks: assisting organizations in developing the right tools and methods to collect the best possible R&M data, and performing the analyses required to generate improvements and remove problems. Our methods and analyses have been applied to aerospace data (NASA, FAA and prime contractors), the defense industry (DoD and prime contractors), Nuclear power plants (NRC) as well as telecommunication and electronics industry (Motorola, AT&T, Juniper, Cisco and many more).

At SoHaR we offer our customers both specialized, specifically-tailored, tools for R&M data collection & analysis, as well as a third-generation FRACAS tool, FavoWeb.

Failure data collection and analysis
Trend Analysis
Corrective Action
Field Reliability Analysis
FRACAS Software Customization
Legacy Data Analysis
 

Failure data collection and analysis                                                    

Failure data collection and analysis are tied closely to all reliability activities. Failure data collecting should begin in the early stages of system design and go on through the entire product life cycle. Detailed tracking and analysis of equipment malfunctions and failures should be performed in all stages and by all players: vendors, users, operators, testers and maintainers.  

SoHaR R&M and FRACAS specialists establish failure data collection procedures (including the critical data types for each lifecycle phase) as well as the required follow-on and processing activities that lead to corrective actions and preventive maintenance measures. These, in-turn, ensure that failures do not recur and support the simplification  and reduction of maintenance tasks.

A Failure Reporting, Analysis, and Corrective Action System (FRACAS) is a closed-loop feedback path in which users and suppliers work together to collect, record, and analyze failures of both hardware and software data sets. Both user and supplier capture predetermined types of data about all problems with a specialized (software) tool and submit the data to the supplier FRACAS. A Failure Review Board (FRB) at the supplier end analyzes the failures, considering such factors as time, money, and engineering personnel. The resulting analysis identifies corrective actions that should be implemented and verified to prevent failures from recurring.

Trend Analysis                                                                                        


Accurate trend analysis is an extremely valuable outcome of a timely and well-defined FRACAS. We perform trend analysis based on any data available: current and historical. Reliability performance: MTBF, MTTR, availability, preventive maintenance, etc.  are studied for trends and progress/regression. The analysis of patterns either of deficiencies leading to failure or maintenance events allow us to identify trends. The trends teach us much more than individual incidents and offer many more opportunities for effective Corrective Actions. This type of analysis requires deep understanding of failure mechanisms and a lot of experience reviewing and analyzing R&M data. SoHaR?s experts have experience and knowledge accumulated over dozens of projects and are able to leverage this expertise to offer your organization effective information within a reasonable timeframe.

Corrective Action

Determination of an appropriate corrective action sequence is one of the main goals of the process of collecting failure data. Our FRACAS experts will assist you in defining
corrective actions based on the engineering data collected and historical data, as well as the ISO 9000 requirements for corrective action . The benefits of early implementation of corrective actions become apparent  as failure occurrence decreases both at the manufacturing line and in the field.  

Field Reliability Analysis                                                                       

 
The collection of field performance data is a crucial element in monitoring reliability, and field data collection is a vital part of a FRACAS process.

Field data collection should include:

  • Incident/Failure technical info (part no. s/n, operation time/meters)

  • Description/Symptoms

  • Environment conditions

  • Suspected cause

  • Repaired/replaced items

  • Repair time and comments

  • Root cause
     

Collecting field data as part of a FRACAS process enhances product reliability, safety, and quality, and allows calculation and prediction of the following: 

  • Field MTBF ("real" failure rate) vs. Calculated MTBF (predicted failure rate)

  • ILS Optimization - Establish correct spares levels

  • Enhanced maintenance policy (RCM - reliability centered maintenance

FRACAS Software Customization                                                      

When adopting a FRACAS program it is crucial to maintain a flexible and adaptive environment. The FRACAS program must be able to keep up with the natural changes and growth that take place as a program matures and a product/system go from lab, through testing and production, to the field. Without this flexibility it is very difficult to maintain the high level of data required for the evolving information and engineering needs of the R&M program.  It is also very clear that every organization may require a different FRACAS data structure and different FRACAS process flow. Forcing a global structure and process flow are not possible and will necessarily constrain the data collected and limit the success of the program. 

SoHaR offers its customers a user configurable system which easily adapts to organizational needs: Customizable workflow, data collection forms, user configurable output reports and much more. 

The FRACAS application we offer allows organizations to retain independent management of the FRACAS program while allowing significant changes: the tool is developed to offer easy management for a FRACAS administrator who does not necessarily have a background in database management and data analysis. For customers who prefer our continuous support we offer this option as well.   

For more information, please see details of our FRACAS application FavoWeb.

Legacy Data Analysis                                                                            

SoHaR has extensive experience reviewing, processing, and analyzing legacy failure data of varying quality and size. Whether your organization is installing a new process or FRACAS program, or attempting to weed through overwhelming quantities of legacy data, SoHaR has the experience to query legacy databases, sift for the usable entries and provide informative analysis. Some of our work is detailed in these specific case studies.  

See also:
Reporting, Analysis and Corrective Action System (FRACAS) Software  
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