Understanding Industrial Failure Patterns
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ScribdTranslationsUnderstanding Industrial Failure Patterns
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ScribdTranslationsJosé Antonio Páez University
Faculty of Engineering
School of Industrial Engineering
Chair: Industrial Maintenance
Assignment No. 2 - Week 2
FAILURE PATTERNS
Progressive
WHAT IS A FAULT?
When a productive medium ceases to carry out one or more of its FAILURE PATTERN Random
functions, long before the end of their useful life, it is said that it has
failed. These failures can cause losses, stoppages
E
• Pattern E represents a permanent
unexpected plant issues, cost increases of conditional probability of failures at any age,
maintenance and repair. (casual failures)
WHAT IS A PLAN OF • The top spinners are a good example of a component.
with this failure pattern
MAINTENANCE?
It is the set of preventive tasks to be carried out in • 14% of components belong to this pattern
a facility in order to comply • The faults depend on the interval between the
some objectives of availability, of reliability, potential failure and functional failure, failure that can
of cost and with the ultimate goal of increasing to be better using the maintenance condition
maximum possible the useful life of the installation • Pattern F begins with an infant mortality,
which eventually decreases to a probability
FAILURE PATTERN B Cyclic failure conditional very slowly.
• Electronic components are an example of this.
• Represents a constant or gradual increase in the type of failures.
probability of failure, followed by a pronounced region of • 68% of components are governed by this pattern of
desgate. failure
• 2% of the components in general exhibit this pattern.
of failure
• The best maintenance strategy for components
that fit the failure pattern B is to determine the "useful life"
of the component and establish a replacement event based
in the time or number of cycles for its replacement.
• The elements that fit this failure pattern - Bands,
pulleys, chains, gears, consumable tools to a
process such as anvils, electrodes, etc
FAILURE PATTERNS
INDUSTRIAL MAINTENANCE
The well-known maintenance plan is nothing more than a
series of tasks that are planned and scheduled
they must be done to a team or
productive system with a determined frequency.
The Analytical Detection program of Model C shows a probability of failure
WHAT IS A FAULT DAF failures provide the skills. slightly ascending, but there is no age of
The failure is the situation in which it enters. and skills for problem-solving wear defined that can be identifiable, in order of
game the performance and efficiency of prevention of problems in environments jobs, there is a constant increase in the
system, leading to losses in the productive, supporting the efforts probability of failure. Recommended strategy:
production, economic losses for the of continuous improvement. Time-based or cost-based replacement or
company and loss of available time risk.
to continue manufacturing Time-based or cost-based repair or
risk.
They are failures that occur randomly during the period of failures.
premature and the period of failures due to wear. Several of the
parameters used by engineers and managers are Model D shows us a low failure probability.
associated with reliability; these help to keep control and to measure when the component is new or has just been installed,
the performance of reliability. The 'failure rate' is a parameter followed by a rapid increase to a constant level.
key. When a product fails, we can usually associate the rate Recommended strategies:
of failure with a specific mode of failure, which is represented in units Condition monitoring.
of 'failure events' per unit of time The mode of failure is only Failure analysis if the failure rate is very high.
a form of product failure. Provision of spare parts.
BEHAVIOR OF FAULTS
What are the faults:
The failure occurs when a machine or one of its components is in a condition that prevents it from continuing.
optimally fulfilling the function for which it was designed. Among the types of failures that may occur are
it has fractures, cracks, wear, and corrosion
One of the things that must be taken into account in maintenance strategies should be defined
at the level of failure cause, that is, an asset has many functions that
they can fail due to different causes and each cause corresponds to a
physical phenomenon of wear, a human error, an environmental influence,
loss of integrity or sudden phenomena that can make it
degrade or suspend the fulfillment of their functions.
Among the main causes
Types of failures:
Model F begins with Model A is known as the 'bathtub curve'. It starts with
common: a very high infant mortality
• Corrosion a high failure probability (known as mortality
high, that descends infantil) followed by an increasing failure frequency
• Wear and tear finally up to a
• Fractures gradually what is constant, and then through an area of
random behavior wear. Recommended strategies: Failure analysis for
• Sliding of the probability of failures.
• Among others determine the causes of childhood failures. Monitoring of the
condition. Time-based replacement or repair.
Strategy to address infant mortality issues:
A surprising number of failures occur when the asset is new. Even
his condition could be below the failure state level as soon as the
system is put into service, or when it returns to service after a repair.
These failures are usually caused by errors in design, manufacturing or
assembly and are evident at startup or at a later time
FAILURE PATTERNS
FALLAA Y B FAILURE
Patterns A and B present a "constant or
gradual increase in the probability of failure,
Dis characterized by
It
a low probability of
followed by a pronounced region of failure when the component is new,
"wear and tear" and therefore "a limit age can" followed by a rapid increase to a
to be desirable.” The curve B “is characteristic constant level
of airplanes with reciprocating engines
FAILURE
E
presents a 'failure probability'
constant at all ages (function
of exponential survival.
FALLAF
FAULT C
It presents 'infant mortality,' followed
It is described with a "gradual" for a constant or very low
increase in the probability of failure, increase in the probability of
but an area is not identified failure (particularly applicable in
deterioration. It would usually not be desirable electronic equipment.
impose an age limit (this curve is
characteristics of airplanes with engines of
turbine)
