MAINTENANCE Document # : GMD-500-03-FMT

Revision # 3.0

FAILURE ANALYSIS FORM Effective Date:

2016-09-16
Page # 1 / 7

1. INFORMATION OF THE ANALYSIS

Register the general information of the analysis

Site

Date of analysis

Asset or system analyzed; Diesel Generator

Event date;

Analysis group Maintenance team

Hour of stop (if applies) NA Time of stop( if applies) NA

Was the event corrected? Yes

Work order number #WO -

Which action were taken? Inspected and confirm HMI controller cards malfunction

Failure cost: -

What was the impact? Can’t change generator priority and display can’t check
 MAINTENANCE Document # : GMD-500-03-FMT
Revision # 3.0

FAILURE ANALYSIS FORM Effective Date:

2016-09-16
Page # 2 / 7

2. IDENTIFICATION OF THE EVENT

Initial information of the failure

What happened? Generator HMI Malfunction

When did it happen? When checking daily inspection, found HMI fault

Where did it happen?

What changed? NA

Who was involved? Maintenance team

Could it happen again? - Could be

Draw a flow diagram that is able to register the sequence of the events
 MAINTENANCE Document # : GMD-500-03-FMT
Revision # 3.0

FAILURE ANALYSIS FORM Effective Date:

2016-09-16
Page # 3 / 7
 3. EVIDENCE
Indicate if you have the requested information, make a brief description and relate the names of the associated documents if existing.

Evidence Description –Associated Document

Reading of the operation items Normal operation even HMI malfunction

Register of operators or maintenance training Following the procedure

associated to the asset
Observations in the route of inspection before the Normal
failure

Reports of operators or maintenance shift Assigned technician informed immediately

Conditions of the environment Normal

Changes in the prime matter NA

Report of activated protections Yes

Interviews to implicated people NA

Redesign of the parts Yes

Diagrams, photos, plans, maps, failure videos NA

Analysis of changed parts (in laboratories or NA

specialized companies)

4. SELECTION AND CONFIRMATION OF PROBABLE CAUSE

Use the failure tree to indicate the possible probable causes of the event.
 Confirmed
Classification Category Describe probable cause What started the event? Why do you think this happened?
cause

Random sudden failure HMI Normal As per inspected Yes

Equipment and 1 controller card
Facility

Failure Tree
 OPERATIONS DESIGN/ASSEMBLY EQUIPMENT AND FACILITIES MATERIALS MAINTENANCE ENVIRONMENT SPARE PARTS
inexistent of Not acting in inexistent procurement inadequate inadequate
lack of supervision inadequate concept Periodic wear inexistent procedure temperature
procedure protection procedure supervision identification
Random sudden inadequate procurement inadequate inadequate
failed procedure Training supervisors inadequate execution Corrosion training supervisors humidity
failure procedure procedure specification

undisclosed shift change with inadequate procurement procedure shift change with inadequate inventories
Abrasion Bad adjustment failed procedure storms
procedure miscommunication terminology not fulfilled miscommunication model

improper change in the process purchasing procedure undisclosed procurement

improper installation impact movement no maintenance plan evaporation of gases
document is not documented undisclosed procedure procedure not fulfilled

inadequate inadequate improper improper storage and

overloaded equipment inadequate selection dirty Lubrication inadequate transportation wind
terminology document maintenance plan handling

manual language point quality control / inadequate maintenance plan

Power supply release residual stress bad quality lightning inadequate delivery
other than native measurement absent terminology failed

frequency of
tool outside induced electric manual language Earthquake /Natural technical acceptance
operator skills inadequate reception oxidation Supplier's competences inadequate
Specification current other than native disaster inadequate
maintenance plan

manual language incomplete planning

operator training bad specified tool inadequate inspection technician skills state of infrastructure spare not suitable
other than native activities
bad instruction Tool outside Supplier's
inadequate tool inadequate redesign inadequate specification technician training contamination
provided specification. competences
Redesign not bad instruction
inadequate delivery bad specified tool public order quality
documented provided
technical acceptance
lack of supervision inadequate tool organizational climate
inadequate

inadequate identification erosion

improper storage

improper handling

defective raw material

 5. DEFINITION OF PROPOSED ACTIONS

Indicate the proposed actions for the confirmed causes.

Type of action
Confirmed cause Preemptive task Procedure Training Redesign Other
Random sudden Install new HMI
failure HMI - - controller card -
1 controller card

6. PLANNING AND FOLLOW-UP TO THE DEFINED ACTIONS

Use the technique 5W1H to realize the planning and follow-up to the defined actions.

PLANNING AND FOLLOW-UP TO THE DEFINED ACTIONS

Man-hours needed 2 persons P: Planned
Duration of the analysis 40 min R: Realized
What must be done? Why? Where? How? When? Who? Measure
Achievement
Assigned technician and
Arranged no power Daily Generator Installation P
Install new HMI vendor technician 50%
Action shortage at Plant operation shelter and testing
controller card Assigned technician and
R
vendor technician