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Seven Steps to an Effective FRACAS (Failure Reporting, Analysis, and Corrective

Action System)

DESIGNED FOR
Maintenance and Operations personnel who will be involved in the implementation of a Failure Reporting, Analysis, and
Corrective Action System (FRACAS)

ABOUT THE COURSE

This course is designed to provide attendees with the basic skills and knowledge to begin implementation of a Failure
Reporting, Analysis, and Corrective Action System (FRACAS). Seven Steps to an Effective FRACAS  

WHAT YOU WILL LEARN

• What a FRACAS is
• The definition of failure
• The basic elements of a FRACAS
• How to develop failure codes for a FRACAS
• How to develop a failure data collection plan
• How to manage FRACAS responsibilities
• How to develop a training plan
• How to analyze FRACAS data
• How to Develop FRACAS KPIs
• How to monitor Corrective Actions

WHAT YOU WILL DO

• Build an outline for a FRACAS policy manual for your organization
• Build a FRACAS data collection plan
• Build a set of failure codes for an item of equipment
• Build a RAS(C)I for a FRACAS
• Develop a training matrix
• Build a set of criteria for selecting a corrective actions
• Build a basic set of FRACAS KPIs

OVERVIEW
Oil, Mining, and Chemical industry incidents over the past several years have focused new light on the need for improved
Asset Integrity Management practices. PAS55 and ISO55000 have been developed to provide a top down approach to
managing physical assets throughout their life-cycle in a way that ensures reliability, availability, and maintainability
levels that are sustainable, and that provide maximized return on a company’s investment. Failure Reporting, Analysis,
and Corrective Action Systems (FRACAS) are an essential element in continuously improving asset performance by
eliminating recurrence of failures. This course focuses on developing and managing an effective FRACAS.
WHY YOU SHOULD ATTEND THIS COURSE
This course is designed to give you the basic tools you need to build an effective FRACAS for your organization. You will
create a basic outline of your FRACAS policy, develop roles, goals and responsibilities for members of your organization,
create a RAS/CI to capture organizational responsibilities within the FRACAS, and learn how to incorporate Root Cause
Analysis (RCA) management into your FRACAS.

KEY BENEFITS OF ATTENDING

• Understanding how to develop and effective FRACAS
• Creating a data collection plan
• Creating a basic outline for your FRACAS policies and procedures manual
• Understanding the role of FRACAS in improving system performance
• Creating an initial set of Roles, Goals, and Responsibilities for your FRACAS
• Creating a basic training plan for implementation
• Understanding what a Corrective Action really is.

DAY 1-2
Session 1: What is FRACAS

Definitions of the terms within FRACAS have significant implications about what needs to be included in a FRACAS. This
session focuses on understanding the definitions and how they may impact what is included in your FRACAS.

• What is a failure?
• What is a corrective action?
• What is a system?
• How does FRACAS fit with Asset Integrity Management (AIM), PAS55, and ISO55000

Session 2: Data collection plans

It is important to understand what data should be collected in the FRACAS. In this session you will develop an outline of a
data collection plan for use in helping develop a FRACAS for your organization.

• Determining which data needs to be collected

• Understanding how your organizational goals drive data needs
• Understanding the relationship of equipment criticality and data collection
• Developing a data collection plan

Session 3: Failure Codes for FRACAS

Good failure codes are essential to being able to analyze failure data to look for patterns of failure across the
organization. In this session you will work with failure modes analysis to develop an example set of failure codes for use
by your organization.

• Understanding what a failure mode is

• Understanding how to develop easy to use failure codes
• Understanding how to deploy failure codes in your data collection system

Session 4: Organizational Roles in FRACAS

Every member of the organization has a role within the FRACAS. In this session you will work through determining which
members of your organization will have key roles in the development and deployment of your FRACAS

• Understanding the role of the boss

• Understanding the role of the champion
• Understanding the role of operators and crafts people
• Understanding the role of various engineering staff

Session 5: Developing FRACAS Policies and Procedures

Sustaining a FRACAS requires that it become part of organizational policy. Developing a policy and procedures manual is
an essential step in helping establish and sustain the system. In this session you will create a basic outline for your
FRACAS Policies and Procedures Manual.

• Understanding the importance of a FRACAS policy statement

• Developing data collection procedures
• Developing data analysis procedures
• Developing Corrective Action management procedures

Session 6: Developing the RAS/CI Matrix

Various individuals within the organization have varying responsibilities depending upon their role in the organization. A
RAS/CI is an effective tool for helping individuals understand what their FRACAS roles and responsibilities will be. In this
session you will develop a RAS/CI matrix for your FRACAS based on the job titles within your organization.

• Understanding the job of the Responsible person

• Understanding the job of the Accountable person
• Understanding the job of the Supporter/Consultant
• Understanding the importance of informing others
• Developing the organizational task list  

Session 7: Deploying the FRACAS

Deploying a FRACAS is not as simple as announcing that your organization is going to begin collecting failure data.
Deployment requires extensive communication and training in order to provide the best chance of getting data recorded
for further analysis. In this session you will develop an initial communication and training plan for deploying a FRACAS.

• Developing the basic communication structure

• Creating a training matrix based on organizational need
• Creating training responsibilities
• Understanding how to handle training for new employees

Session 8: Analyzing FRACAS Data

Analyzing collected data is the first step in understanding system failure patterns. In this session you will learn about
different ways to turn FRACAS data into information for decision making. You will work with a sample data set to
determine failure patterns.

• Understanding the impact of repetitive failures

• Using Pareto Analysis to prioritize work
• Using Weibull Analysis to understand common failure threads

Session 9: Generating Corrective Actions

Understanding failure patterns and frequencies is not the end goal of a FRACAS. In this session you will learn the
different ways of creating corrective actions, and how to analyze whether or not the potential corrective actions are in
line with business goals.

• Understanding failure analysis

• Knowing when to use Root Cause Analysis (RCA)
• Knowing when to use Reliability-Centered Maintenance (RCM) Methods
Session 10: Measuring FRACAS Effectiveness

Keeping score is an important part of everyday business practice. Key Performance Indicators help organizations
understand the health and effectiveness of various programs. In this session you will develop a set of KPIs designed to
help your organization understand whether or not the FRACAS is being used, and whether or not the corrective actions
are being effective.

• Understanding the importance of simple leading indicators

• Measuring whether basic FRACAS activities are occurring
• Measuring whether Corrective Actions are being implemented
• Measuring Corrective Action effectiveness

Session 11: Picking a Software System

Picking the correct software for recording FRACAS data is an important step. In this session you will develop criteria for
understanding which type of software package you will want for implementing your FRACAS.

• Understanding the basic components required in the data collection software

• Understanding the basic data elements that need to be recorded  

About the Instructor

Bill Keeter is a Certified Reliability Engineer who has been implementing equipment performance
improvement programs since the late 1970’s when he was the motor officer for a newly activated field
artillery battalion. The unit was activated using surplus Korean War era equipment that was proving to
be difficult to maintain and operate. Under his guidance the battalion implemented a comprehensive
and effective equipment maintenance plan that resulted in zero equipment failures during extensive
field exercises.

As a maintenance manager in the late 1990’s, Bill led his maintenance team through a very successful reliability
improvement effort at a plastic film manufacturing plant. They were able to improve equipment availability from the low
80% range to the upper 90% range within a two year period of time by implementing a comprehensive condition
monitoring program, creating a culture of “why”, and emphasizing the importance of the involvement of every team
member in the reliability and planning effort.

Bill has been providing consulting and training for reliability improvement efforts in a wide variety of industries since
2001. During that time he has used analytical methods such as Reliability-Centered Maintenance (RCM), Root Cause
Analysis (RCA), Reliability, Availability, Maintainability, and Safety Modeling (RAMS), and Life-Cycle Cost Analysis (LCCA) to
analyze failures, develop equipment maintenance plans, and improve system performance. Bill became interested in
FRACAS when he found that most companies he worked with did not have the detailed data they needed to make the
analyses as accurate as they could be. Few if any organizations were documenting which parts were failing and causing
functional failures in their systems.  

Practical informatip,
English training

19 & 20 September 2016

Radisson Blu Astrid Hotel Antwerpen

Koningin Astridplein 7
2018 Antwerp
(Hotel located 100m from train station Antwerpen-Centraal)

• € 1.595 (excl. btw) for members

• € 1.795 (excl. btw) for non-members
 Event date: Monday 19/09/2016 - 8:30
Tuesday 20/09/2016 - 17:00

Language: English

Location:
7 Koningin Astridplein
Antwerpen 2018

Price members: € 1.595 (excl btw)

Price none members: € 1.795 (excl btw)

Organised by: BEMAS - Belgian Maintenance

Association

Activity type : Training

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Maintenance Management

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