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BEST PRACTICES
Carlos Dongo
September 07, CRC Worldwide Conference
Failure
A question emerges...
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Persona
Redaccin Reporte Conocimiento AFA Conocimiento AFA
Analista de Fallas
Conocimiento AFA
Capacidad (Tiempo)
Rpta a destiempo
Falta de respuesta
Microscopio
Respuestas incompletas
Data view
Soporte de Fbrica
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Metodos
AFA Best Practice 2007 - FSAA
Equipamiento
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Lack of information Poor analysis methodology Lack of technical skills Wrong diagnosis Lack of measuring and/or evaluation equipment and tooling Unclear reports Customers distrust (partiality feeling)
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Find the root cause of a failure , using established processes and report it in an accurate and correct way giving recommendations to prevent it to happen again
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Have information about what happened BEFORE, DURING and AFTER the failure event Have a formal failure analysis process and a facility to analyze any component failed Have adequate communication channels, internally and externally Have the proper evaluation tools to analyze Have a qualified full time staff Manage an adecuate database Make an accurate, clear failure report including recommendations Keep communications flow to ensure appropriate follow ups
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Started in 1996, 01 part time dedicated engineer Due to the lack of processes and skills the conclusions presented were not exact nor precise Due to the lack of information reports took a lot of time to be delivered Complete investigation couldnt be performed because the lack of instruments or tools Generates a lot of friction with the customers
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2001 Hire 04 full time engineers with independence from technical communication duties Trained under Caterpillars AFA I,II and III courses Start creating and keeping records about failures and related issues Processes were developed, mapped and implemented A laboratory was developed with appropiate instruments and tools
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07 qualified engineers Complete customers confidence in reports Recognized and requested by customers as a helping tool 1,000 reports delivered in a yearly basis Offered as a service and billed to the customers Online technical support using a Lotus Notes platform, not only for AFA purposes but also for technical communication and information ( working as an internal DSN) Repairs costs distribution aid Processes aligned under the 6 sigma methodology
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Warranty management: Failure analysis reports are used to facilitate claims preparation and SIMS data entries Product problems identification and reporting: Repetitive problems are reported to Caterpillar with detailed failure analysis Improves customers fleet management: Identification of root causes of failures allows customers corrective actions in operation and maintenance Customer relationship: Accurate and helpful reports builds confidence in dealer service support CRC rebuild processes: Gives important information about wrong rebuilt processes reducing re-do rates
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Estereo scope 90X Enlargement With option to register images using a digital camera
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Digital cameras
Measurement equipment
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Recycling cleaners
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1 2 3 4 5 6 7 8
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I C
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Camaras fotograficas Datos generales del componente Embalaje y proteccin del componente Estereoscopio / Lupas Sintoma de Falla Solicitud de servicio Instrumentos de Medicion Reporte del operador Transporte Pruebas metalograficas Historial de Reparaciones Revisin de ajustes y Historial de Mantenimientos montajes Commisioning Historial de Aceite/Tapones/Filtros Informe de desmontaje Reportes del seguimiento del componente Analisis de VIMS / ECM / EPTC Otros
Checklist Email
Informe AFA FSAA Informar Administracin sobre acuerdos finales con el cliente P5
Si Archivar
Informe Pre-afa Campo Informe tecnico mecanicos Informe tecnico Motorindustria Archivos VIMS / ECM / EPTC Historial de Aceite/Tapones/ Filtros
P12
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Mantenimiento
Adm. Fsaa
Planning Antamina
Mantenimiento Antamina
Lab. AFA
Ofic. Tcnica
CRC
Falla Componente
Solicitar informacin
Email Recopilacin informacin Recopilacin informacin Commisioning Datos Maquina Recopilacin informacin Recopilacin informacin Recopilacin informacin Historial Rep. Historial PMs Historia Maq Archiv fisico
Elaboracin Pre-AFA
Envio Pre-AFA
Recepcin Pre-AFA
Recepcin Pre-AFA
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Mantenimiento
Adm. Fsaa
Planning Antamina
Mantenimiento Antamina
Lab. AFA
CRC
Recepcin Pre-AFA
Procesar Datos
Recopilacin de informacin PPM DWF /Inf Mec Talleres Checklist Desar Hist. Reparac DBS SIS / CPI / DSN/ FMMS
Desarmado
Analizar Datos
Evaluacin
Reportear y distribuir
Recopilacin Datos
Consulta Fca?
Consulta a Fbrica
Armado
Emisin de informe
Pruebas en banco
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Mantenimiento Fsaa
Adm. Fsaa
Planning Antamina
Mantenimiento Antamina
Ofic. Tcnica
CRC
Recepcin AFA
Recepcin AFA
Recepcin AFA
Recepcin AFA
Recepcin AFA
Recepcin AFA
Absolver Consultas
Absolver Consultas
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The failure analysis process is supported by an estructured platform called Ferreyros Technical Support (FTS) that allows to register and keep all the failure analysis performed and also the technical information and the inquires asked
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(FTS)
The system works under a Lotus platform having control and protection of the information
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Failure analysis performed, technical inquires and technical information in the same platform
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Information estructured to allow a better administration by responsable Failure description by: Site/ Branch/Shop
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Keep record of all communications regarding a case. The system is tied with the e mail system
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AFA definitions
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Follow up: Through banners indicating in which step of the process and whos responsible is each case
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The Technical Inquires section gives support to the technical communicators about reusability, test in machines, specifications etc.
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The technical information section is used as a virtual library where Ferreyros BITs and Caterpillar Bulletins regarding our machines population are kept and administrated
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tTEAM WORK
Who? Where? When?
Factory
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Thank You
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