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Failure Analysis - Faults - Function: The Iceberg Effect

This document discusses common root causes of equipment failures and procedural problems including: 1) Poor design practices, inadequate specifications, lack of training, and improper maintenance are common technical root causes. 2) Procedural issues stem from procedures being unavailable, incorrect, difficult to use, or not followed as written. 3) Training problems arise from lack of training, inadequate training programs, or failure to enforce and verify learning.

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167 views9 pages

Failure Analysis - Faults - Function: The Iceberg Effect

This document discusses common root causes of equipment failures and procedural problems including: 1) Poor design practices, inadequate specifications, lack of training, and improper maintenance are common technical root causes. 2) Procedural issues stem from procedures being unavailable, incorrect, difficult to use, or not followed as written. 3) Training problems arise from lack of training, inadequate training programs, or failure to enforce and verify learning.

Uploaded by

m2z.marksman
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Failure Analysis – Faults - Function

The Iceberg effect

Why do people place so


much importance on this

~~~~~~~~~~~~~~~~
10% Planned and
Scheduled work And pay so little
attention to these
Technical Amnesia Late work
90% Inaccurate Information
Oscillating Worklist Lack of plant experience
Misapplication Management Systems Re work
Poor Design Practice Equipment Failure Substitutions
Poor Communication Quality Control
Inadequate Specification
Disorganisation Lack of Training
Complication
Low Bid versus Life-Cycle Cost
Human Engineering
Procurement Practices
Poor Supervision Non compliance
Root Cause Failure Analysis

Common causes of equipment failure

Equipment Failures

Misapplication Operating practices Maintenance Practices Age

Operating Procedures Procedures Age.


outside design inadequate. inadequate.
envelope. Normal
No adherence to No adherence to wear.
Poor design procedures. procedures.
practices. Reached
Inadequate Frequency useful life.
Poor training. inadequate. Accelerated
procurement
practices No enforcement. Lack of skills wear.
Root CauseFailure Analysis

Common Root Causes of Procedure related Problems

Not Used Inadequate Followed incorrectly

Facts or methods Format


No procedure wrong confusing

Excessive
Difficult to use Poor organisation reference

Not available Wrong revision Too technical


used

Situation not
Use not enforced covered
Root Cause Failure Analysis
Common Causes of training-related Problems

Common Causes

No Training Inadequate Not learned

Training not No learning Retention


enforced objectives lacking

Task not
analysed No lesson plan Too technical

Decided not to Did not attend


train Poor instruction course

No learning No practical Mastery not


objective application verified
Root Cause Failure Analysis
Common Factors of supervision-related Causes

Common factors

Selection of
Preparation workers Supervision
during work

No preparation Not qualified


No supervision
No work package Fatigued
Poor crew
Lack of pre job Upset/personal teamwork
training problems
Too many
Inadequate Substance abuse other duties
scheduling
Poor team selection
Root Cause Failure Analysis
Common causes of communication problems
Common Causes

No
Turnover Misunderstanding
communication

No method No standard No standard terms


available process Repeat back not
Late Turnover process used
communication not used Long message
Lack of report Turnover process Noisy environment
data inadequate
Root Cause Failure Analysis

Common causes of human engineering problems

Human Engineering

Worker Work Complex


interface environment system

Arrangement/ Housekeeping . Knowledge-based


placement. decisions required.
Ambient
Excessive environment. Monitoring too
listing/twisting. many parameters.
Cramped spaces.
Tools/instruments Inadequate feed-
Controls/displays back.
Root Cause Failure Analysis

Common Causes of management system problems

Management Systems

Policies & Standards Not


procedures Employee relations
used

No standards. No
No communication.
Not strict enough. audits/evaluations.
Recently changed.
Confusing or Lack of audit depth.
No enforcement.
in complete. No employee
No way to communications.
Technical errors.
improvement.
No drawings or No employee feed-
No accountability. back.
prints.
Root Cause Failure Analysis

Quality control-related causes


Quality Control

No Inadequate
Inspection QC

No inspection required. Poor instructions.


No hold point. Poor techniques.
Hold point ignored. Inadequate training/skills

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