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Failure Management

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Your machines run nicely all the time because you perform regularly maintenance....... But then, BREAKDOWN! A failure stops all productivity on a particular machine. The operator has to fill in a failure report. This report is a registration of the activities that are taken by the operator in order to get the machine in working order again. In some cases this means that there has to be made an appointment with the machine's manufacturer to install new parts. This needs to be planned, and this plan date has to be put into the Event calendar.  But there is more! In some cases maintenance on a failure  takes more than one day. This is solved by putting the number of days that the maintenance wil take, and JumpStart DNN will place these number of days into the Event calendar before the deignated end date.

Even the parts that are used to resolve the problem are registered and the stock on these parts is adjusted for the use of them.

 

Failure management is designed to register failures that happen to objects, and that need careful attention.

Any company's management needs to know about failures that can threaten their business because it hinders, or even stops, the production process. And they need to know what costs are made to solve the failure, in terms of time and material cost.

When a failure happens, the machine's operator has to register the failure and fill in what he has done to solve the problem. Because a solving a failure can take more than one day, this can also mean that several different actions are to be taken, this module logs all the work that is done on this failure so far in a log: the "FailureFlow". He also registers the machine parts that are used, in order to re-plenish these parts in stock, and to calculate the direct cost on this particular failure.

In certain cases the operator's discisions about the planning that is required to solve a problem, the company's management need to overrule the descision that the operator made, due to all possible reasons. Mostly this involves the planning of external aid from the object's manufacturer, when it is clear that the own personnel is not able to repair any broken part. The status for the repair will be set to "External"  and the required plandate and number of days for the fix is set to a new date, as shown below. The plandate will be inserted into the Event calendar, if the company has installed this DNN module.

The screen below is the supervisor's management and here the operator's date can be overruled. The number of days is put in the field called RepairDays (= "ReparatieDagen"), and the new date is put in the field called "ExpectedReadyDate" (= "VerwachtGereed")

 

The FailureFlow is the detailed registration of what the operator has done to solve the problem. When you click the "Edit" button on the right of a FailureFlow record, the detail will open in a separate window, showing the details. As long as the update of any attempt to solve a problem is in the same day, the detail will be added to that line. When the attempt is on a later day, then this attempt is added in a new detail line. In this way the company's management is able to follow the soloution on a daily basis.

 

 In the picture above you can see the two fields for the Object and the FailureType (called "StoringType"). A few lines under these is the field that holds the running hours of this object. (called "GeneratorStand"). The combination of these three field values can provide the company's management wit information for analysis of the failures that occur during a certain period. In this way it is possible to take appropriate actions to prevent failures from happening, and thus enableling the comapany to improve internal procedures to realize a better performance and production quality.

The Shopping Cart icon is used when a failure requires parts from stock to be used to resolve the problem. The stock is lowerd for the amount of parts taken, and these parts are added to the machine, and the costs are added to the failure costs.

A part can be labeled as "Special" and may not be in stock due to expences or restricted stock time. If this kind of part is needed, a notice will be mailed to a delivery agent i.e. the manufacturer and to the management to let them know that a purchase is needed.