Root Cause Failure Analysis RCFA & an illustration case study.

1. Problem Identification: Production decreased to low level
Plant Capacity: 450ton/day
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By Eng. Mohammed Hamed Ahmed Soliman
Email: mhamed206@yahoo.com
LinkedIn Profile: eg.linkedin.com/in/mohammedhamed

2. Reliability Engineering
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3. Problem with
plant production
performance
Transportation of
raw material
problem
Production labor
problem
Others
Breakdowns
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4. Breakdowns issue
Environmental
downtime issue
Electrical issueOther external
factors
Equipments downtime
(unplanned
maintenance)
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5. Plant downtime report
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6. Equipments
breakdown
issue
Machine 4
Machine 3
Machine #1
Machine #2
Machine 5
Machine 6
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7. Equip
code
Critical Equip
description
Total Downtime
hrs (average)
Downtime
frequency
MTTR
(hrs)
Percentage
1 Centrifugal Fan 16 5 3.2 44.80%
2 Pump station 2
Motor
6
2 3
16.80%
3 Granulator
Drum
4
2 2
11%
4 Feed Belt
Conveyor
3
2 1.5
8.40%
5 Recycle Belt
Conveyor
2.5
1 2.5
7.00%
6 Bag Filter 2.5 1 2.5 7%
7 Burner 1 1 1 2%
8 Belt Conveyor 0.5 1 0.5 1.40%
9 Belt Conveyor 0.2 1 0.2 1.40%
10 Bucket Elevator ---- ---- ---- ----
Priority Identification (Top Failures)
Equipments downtime monthly report:
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8. Pareto Analysis A problem solving tool that breaks data down into
manageable groups and identifies the greatest opportunity for return on
investment. The analysis is based on the Pareto Principle, also known as the
80:20 Rule. Simply stated, the principle says that 20% of a population will cause
80% of the problems associated with the population
0.00%
5.00%
10.00%
15.00%
20.00%
25.00%
30.00%
35.00%
40.00%
45.00%
50.00%
0
2
4
6
8
10
12
14
16
18
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Pareto diagram uses bar graphs to sort problems
according to severity, frequency, cost, nature, or
source and displays them in order of size in order
of size to show which problem is the most
important. Its probably the most often used
statistical tool in Toyota.

10. Motor
Foundation
Bearing FDE Bearing FNDE
Casing
Man Hole
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11. Machine 1
failed
Motor electric
failure
Power off
Machine
unplugged
Overloaded
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12. Overload
Process problem
Electrical problem
Cleaning problem
Mechanical
Vibration problem
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13. Mechanical
vibration
problem
Bent Shaft
Bad maintenance
Bearing failed
Unbalance
Bad
fixation
with the
base
Misalignment
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14. Unbalance
Rotor problem
Bad balancing
Others
Scale
accumulative
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15. Reliability Engineering
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16. Dust
accumulative
Incorrect
balancing
Cleaning
issue
Design
Problem
Problem in
sandblasting
efficiency
Bad
operation
Process
problem
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17. Scale
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System Illustration Diagram
(1) Dryer Drum
(3)
Fan
(4) Bag Filter
(2)
Cyclon
e
Dust settling
Suction

19. Repair the coating for body of
the cyclone
Repair the pneumatic
system for closing and
opening the gates
Get new discharge valve Real Photo
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20. Reliability Engineering
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21. Electric motor
failed
Electric cable
problemPower
off
Machine
unplugged
Motor
overheated
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22. Motor
overloade
d
Motor
overheated
121⁰C
Cooling
fan
Motor located in
bad environment
Bad preventive
maintenance
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23. Motor miss-
installed
Motor
overloaded
Shaft
damage
d
Motor Shaft
Vibration
problem
Machine
problem
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24. Shaft damaged
Misalignment
Incorrect fit Incorrect tolerance
Bearing
failed
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25. Bearing
failed
Insufficient
lubrication
Excessive
clearance
Mounting
problem
Grease
contamination
Failed motor
bearing
Incorrect
bearing
type
Incorrect
lubricant
usage
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26. Use the proper tools for mounting
and train the maintenance crew
Preventive Action
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