3.2 Failure Codes

Question 1

What is done in the Failure Codes application?

Answer 1

Build and display failure hierarchies

Question 2

What do Failure Hierarchies help construct?

Answer 2

An accurate history of the types of failures that affect assets and operating locations

Question 3

How are Failure Codes helpful for a business?

Answer 3

After analyzing and reporting failure trends, preventive measures can be taken

Question 4

Failure Hierarchy

What can failure data be used for?

Answer 4

Record and view asset and location problems, causes, and remedies associated with work orders

Question 5

Failure Hierarchy data

What ability does this provide?

Answer 5

Identify trends and isolate probable causes of breakdowns

Question 6

Failure Hierarchy data

What can this be used to analyze?

Answer 6

Reliability of vital equipment components

Question 7

Failure Data

What can this be correlated with?

Give example

Answer 7

Preventive maintenance schedules

Question 8

Failure data

Can be used to review the history of [fill in the blanks]

Answer 8

asset and location failures

Question 9

Failure Data

What key aspects can this be used to review?

2 things

Answer 9

• breakdown trends
• mean time between failures

Question 10

Failure Data

How can failure information be used to reduce or limit asset and location failures over time?

3 steps

Answer 10

1. Review history
2. Identify breakdown trends & mean time b/w failures
3. Correlate this with other data

Question 11

Where can failure data information be viewed for an asset?

Answer 11

Failure Reporting tab of Assets application

Question 12

What can be specified, in addition to failure data information, for an asset?

Answer 12

• Component-level failures
• Failure mechanism codes in support of ISO 14224
• Safety-related system failures

Question 13

What is created in the Failure Codes application?

Answer 13

Failure hierarchies

Question 14

What must failure data belong to?

Answer 14

One or more failure hierarchies

Question 15

What is a failure hierarchy?

Answer 15

Organized set of data on problems, causes, and remedies related to assets and locations

Question 16

What is your failure hierarchy identified by?

Answer 16

Top-level Failure Code, called the Failure Class

Question 17

What is the default failure class value on a work order?

Answer 17

If the asset or location on the work order is associated with the failure class, that will be the default failure class value

Question 18

How does a failure hierarchy work?

i.e. How is it built?

Answer 18

Uses an organized structure of codes given to a particular asset or location

Question 19

At what stages of the work management process can failure coding be done?

Answer 19

• Initiation of the work order
• Record creation of assets, items, or locations

Question 20

Examples of Problem Codes

Answer 20

• Excessive vibration
• Fluid leak
• Too hot
• Not Running

Question 21

Failure Coding in Work Management Process

Initiation of the Work Order

Describe

Answer 21

Enter the appropriate failure class and problem code prior to performing any maintenance

Question 22

What is the coding structure in a failure hierarchy used for?

Answer 22

Identify and quantify maintenance and failure patterns with similar assets

Question 23

What does failure coding allow?

Answer 23

Quantified measurements to determine new maintenance practices or to influence purchasing decisions

Question 24

List the 4 levels of failure codes

Answer 24

1. Failure class
2. Problem code
3. Cause code
4. Remedy code

Question 25

Failure Coding in Work Management Process

Record creation of assets, items, or locations

Describe

Answer 25

Can associate classes to make the [work management] process simpler and more consistent.

Question 26

Define Problem Codes

Answer 26

Sense-based means of identifying that something is wrong with an asset.

Question 27

Problem Codes identify [fill in]

Answer 27

the type of problems seen when the work was identified

Question 28

True/False: For a given Problem, there can be 1 or more Cause Codes assigned

Answer 28

True: Can have a many-to-one relationship

Question 29

When are Cause Codes determined?

Answer 29

Further inspection of the asset

Question 30

Purpose of cause codes

Answer 30

Indicate the root or determine the cause of the identified problem

Question 31

Examples of cause codes

For a given Problem

Answer 31

Fluid Leak problem
–> Could have the following possible Cause Codes:
- Damaged housing
- Worn gasket
- Loose connector

Question 32

Remedy Codes

Answer 32

Detail the means by which a particular cause was addressed

Question 33

True/False: For a given Cause Code, there can only be one associated Remedy Code

Answer 33

False

There can be a many to one relationship between a cause and its remedy set.

Question 34

Remedy code example

For a given Cause

Answer 34

Loose Connector cause

Possible remedies:
- Replace the asset connection
- Replace inlet connection
- tighten connector
- align connection
- apply sealant

Question 35

True/False: Failure Codes can be reused

Answer 35

True: Failure codes can be reused among many similar asset types.

Question 36

True/False: Failure hierarchies should be 100% specific to a particular asset

Answer 36

False: Failure hierarchies should not be 100% specific to a particular asset

Question 37

Example of reusing Failure Codes

Answer 37

All pumps can leak or fail to start - they would have similar general causes and remedies for generic problems such as these.

Failure Class for a fluid pump can be the same if constructed as such - regardless of specific fluid pumped, or particular sub-class of pump (centrifugal, screw type, etc.)

Question 38

True/False: Failure Classes are Site-Specific

Answer 38

False: Failure Classes are Organization-Specific

Question 39

How is the Organization on a Failure Class record determined?

Answer 39

Crosses in from user’s default insert site information

Question 40

True/False: Failure hierarchies should be created as you go along in creating records in Maximo

Answer 40

False: Strongly recommended to create what you expect the various hierarchies to look like prior to entering records in Maximo