Doc Ref No: ESCC/RP/2021/001 Rev:01

ENGINEERING SERVICES, Page No:- 1

REGION
Document …./Component/
No:- 001
FAILURE ANALYSIS LEARNING AND CAPA* (TRC/Engg/001)

Date:- 31/03/2021

Report Header Information

HITACHI Equipment EX1200 Equipment serial 0001

Equipment Make
Model No
Component Make
Equipment HMR 25000 Component Engine MITSUBISHI / S6R
/ Model

Component New/Reman/
Component Serial No 60245 10000 HRS Component type
Life Repaired/Old used
 Data/info in this sheet is only an attempt to indicate as an example of what is generally expected in a broad sense and is not absolute…..if in doubt pls ask ESCC Team .Kindly feel
free to share any ideas for improvement of this doc….We expect it to evolve over time……

Failures observed:

1. Connecting rod end play recorded as Zero

2. 1st journal connecting rod bearing seized

First information of failure/ Observations:

Spares changed History:

Sl.No Parts Description Part No Qty If Known source Remarks

         

           

           

           

           

           
Note: Not changed. (Scope: Inspection & testing)

Team who attended:

1. Magesh - Expert technician (Scope: Inspection and testing).

2. Sump removed and inspected. No metal particles observed.
3. No damages observed viewing from the bottom
4. (Only 2nd bearing inspected)
5. All tappet covers removed and valve mechanism Inspected.

Team who observed failure:

1. Vinod kumar

Team who did failure analysis:

Where was failure observed:

1. Test bench (While testing observed white smoke in breather and hence stopped immediately)

Failure Analysis Steps:

1. Mention the problem clearly
2. Organize facts gathering –Identify areas that could have led to failure.
3. Observe and record facts: Digital images, record interview with operator/s.
4. Based on facts, think logical reason for failure – record sequences of events led to failure,
determine first failed part.
5. Minute Reason/s for failure and discuss.
6. Write sub assembly reclaim process and techniques.
7. Follow up with end user and ensure the problem is not to repeat

State facts, History & Observation:

1. Operator interview
2. How the problem started initially
3. Timeline and events leading to failure
4. First Part failed
5. ECM data downloads, TCM, MCU error codes etc whatever is accessible immediately…
 6. SOS analysis
7. Maintenance records
8. Minor and Major repairs carried out – History /Dates/HMR
9. Clear digital images of failed components from different angles.

List of possible causes for this failure:

Investigation steps:
a) Summary of Facts gathered that eliminates each Possible root cause

b) Summary of facts gathered that supports each possible root cause

Is it a Repeated failure: ( If yes ,1st.2nd,3rd …..with dates & HMR

1. Not known (Old & purchased)

Spares consumed to attend failure:

1. Connecting rod bearing - 1 set

2. Gasket kit

3. Fuel pump & fuel injector need to calibrate

Is there further scope to investigate failure: If yes what all next steps planned….

1. Yes. Fuel pump and injector need to be calibrated

Share any documents related to this failure:

Digital images related to this failure:

Cost of failure: ( Direct eg….& Indirect ie. Consequential only upto parts , lubes )

Final learning from failure:

1. Fuel pump malfunctioning and hence to be calibrated

2. High idle limit setting not available.

File Note:
a) Conclusion of root cause analysis

b) Scope of work carried out to recondition the sub assembly

c) Caution to be adopted to avoid repeated failure:

Prepared By:

Validated By:

Document in charge:
ESCC/KRN - Checked, Verified & Saved

Document Header reference: (Example….)

Region*: PB/ ODISHA / MGP

Component*: ENGINE / TRANSMISSION / HYD

CAPA*:CORRECTIVE ACTION / PREVENTIVE ACTION

Note: 1.This failure analysis report is applicable for all major components failures and also for all kinds of
Electrical, Electronic , Mechanical and hydraulic troubleshooting.
2.These reports / data /specifics will eventually go to a repository of Information for future reference,
knowledge acquisition & Learning.