> The Shanghai diesel engine limited liability
company (hereafter refers to as "on firewood company") to have more
than 50 years diesel engine manufacture experience, has the domestic
leading diesel engine product technology research and development
ability, simultaneously has the quite perfect nature to guarantee the
system. Intensifies along with the diesel engine produce market
competition with to the reliable understanding gradually enhancement,
this company had been established the independent reliable function
department, establishment specialty reliable engineer has managed the
entire company the reliability design, the analysis and the test work,
and has obtained the certain result. But, along with the
reliable work thorough development, the breakdown information
management appears the more and more insufficient systematization,
moreover before mainly depends on the man-power and the semiautomatic
way processing breakdown information, the working efficiency is not
high, the breakdown information has not obtained the full use, to
breakdown pattern reliable work project the and so on influence
analysis, reliable appraisal data support insufficiency, establishes
the FRACAS system imperative.
FRACAS is "Failure Reporting, Analysis and Corrective Action
System" the abbreviation, Italy is "the failure report, the analysis
and the correction measure system", sometimes also is called "the
breakdown information closed loop management system management
system". FRACAS uses the "information feedback, the closed-loop
control" principle, through set of standardized procedures, enables
the breakdown which the product occurs to obtain the prompt report,
investigates thoroughly the reason, the correct correction, prevents
the reappearance, thus the realization product reliability growth,
achieves to the product reliable anticipated request.
FRACAS is one kind of work system, also is one kind of
information system. When establishes the FRACAS system, first
must establish the FRACAS management structure, guaranteed FRACAS each
flow smoothly carries on, until closed loop; It secondary has
the corresponding FRACAS management standard, guaranteed FRACAS can
according to scientific, standardized, the institution method carry on
the closed loop management to the breakdown information;
Moreover also needs to build the FRACAS software platform,
manages FRACAS through FRACAS management software each information
which produces in each flow, guaranteed the data the integrity and may
the use, enhance FRACAS the operating efficiency.
May carry on the consummation using the FRACAS technology to the
product breakdown information the closed loop management, establishes
the breakdown information database, the accumulation enterprise
reliability project experience, and may provide the good data support
and the experience for other reliable work projects implementations
supports. Therefore, the FRACAS technology extremely suits the
reliable question which the firewood company current exists in the
solution.
Only the introduction advanced breakdown information closed loop
management system management system, can highly effective to the
product breakdown implementation closed loop management, be able fully
to use the reliable data, continues to enhance the product the quality
and the reliable level, and provides the solid safeguard for on
firewood company's following development. After the
investigation and study and the feasibility analysis, on the firewood
company decided transports with domestic specialized reliable
technology consultant firm - Beijing passes permanently reaches the
technical limited company (abbreviation "to transport passes company")
to cooperate, introduces the FRACAS technology, makes every effort
fundamentally to solve the above problem.
In August, 2004, on the firewood company officially with
transports passes the company to establish the cooperation relations,
both sides sets up the FRACAS project group together, according to
following three steps establishment in firewood company's FRACAS
system:
First step: FRACAS demand analysis. Analyzes FRACAS
the operating region, the goal, the request, the flow and the method,
in the establishment the firewood company FRACAS management standard;
Second step: Through investigation and study introduction
appropriate FRACAS software, presses down the firewood company FRACAS
demand and the management standard carries on the disposition;
Third step: FRACAS tries to move, found the problem and
solves the problem.
Demand analysis
In carries on before the FRACAS demand analysis, the
project group the reliable question which existed to on firewood
company has first carried on the analysis and the diagnosis, according
to the FRACAS technology request, in the union the firewood company's
enterprise characteristic and the product characteristic, carried on
the demand analysis in following several aspects:
1. FRACAS organizations and agencies
Had been established the breakdown correction committee
in on firewood company (Corrective Action Board - CAB), took the
breakdown information management the organizations and agencies, its
daily business is responsible by the reliable administration section
to manage. CAB has established the breakdown information closed
loop management procedure and the method, has formulated "On Firewood
Company Breakdown Information Closed loop Executive program And
Method", for department and so on research and development, quality,
production, post-sale service had stipulated the FRACAS
responsibility, has also stipulated the breakdown information
management request to the fitting supplier.
2. breakdowns information gathering
The diesel engine product breakdown information
originates from two aspects: Is the diesel engine three packages
of information, uses the existing CRM system recording diesel engine
breakdown newspaper to repair the information, is the user feedback
information, belongs to the scene information; Another is the
company interior diesel engine quality question information, factory
each department appears any breakdown information including the diesel
engine product. All requests to these two aspects information
completely, promptly to induct to FRACAS in.
3. breakdowns information closed loop management
The breakdown information closed loop management is the
FRACAS core, after to the project analysis and the discussion, on the
firewood company's breakdown information management division will be
four links (see Figure 1):
A. failure report that, The determination must enter the
closed loop management the breakdown information, carries on the
detailed description to the breakdown information, and carries on the
preliminary analysis and the classification, the production failure
report.
B. fault analysis: Seeks and the determination breakdown
root reason, proposes the suggestion correction measure, the
production fault analysis report;
C. breakdown correction: The determination correction
measure, and carries on the analysis to the correction measure,
determined the correction measure the action program, the
implementation effect, leave behind the question and so on, the
production correction measure report.
D. breakdown closed loop: Analysis correction risk,
definite breakdown whether does obtain the basic solution,
extrapolates, proposed prevented the breakdown appears once more
driving measure;
4. breakdowns information use again
Through the FRACAS establishment breakdown information
database, the research again use rule and the method, enable the
FRACAS information fully to obtain uses again, provides the data
foundation and the experience for other reliable work supports.
The project carries on the information again use in following
several aspects the demand analysis:
The a. establishment diesel engine product breakdown pattern
handbook, is the FMEA work provides the support;
The b. establishment diesel engine product reliability appraisal
method, carries on B10, MTBF and so on reliable to the diesel engine
product the parameter appraisal;
The c. recognition diesel engine product reliable key, for its
formulation reliability design criterion, provides the experience for
the following product research and development to support;
D. establishment diesel engine product reliability growth plan,
promotion product long-enduring reliability improvement.
According to the FRACAS demand analysis, constructs the FRACAS
system, the change tradition fragment type management pattern, not
only can carry on the effective closed loop management to the current
breakdown, but also will be able to prevent the future new product to
break down similar, through prevention and improvement realization
product reliability growth.
FRACAS realization
According to the FRACAS demand analysis, should match by
corresponding specialized software assists does the FRACAS work.
Using FRACAS specialized software, may be systematic,
scientifically manage in the FRACAS work each link information,
fundamentally realizes the electron information management pattern,
avoids the duplicated work, enormously enhances FRACAS the working
efficiency. Simultaneously may the data preservation in the
unified database, be advantageous for the statistics and the analysis,
is advantageous to the FRACAS information again use.
After the investigation and study and the analysis, on the
firewood company decided chooses American Relex Corporation Relex
FRACAS software to take on firewood FRACAS system necessary software.
The project group and transports which by on firewood company
passes the technical personnel which company is composed to act
according to FRACAS the demand analysis result, studied and had
determined Relex the FRACAS software work flow (see Figure 2) and has
custom-made the plan, has completed software having custom-made
together.
Relex FRACAS software has custom-made mainly includes following
several aspects:
A. to implements the personnel to carry on the role to have
custom-made, assigns the work duty for each member, the realization
work responsibility, awards the corresponding jurisdiction, matches
works the contact surface, the realization performs its own functions,
the responsibility arrives;
B. to the FRACAS information flow, the content and the contact
surface carries on has custom-made, the realization work contact
surface unitize and the standardization, the work flow automation, is
advantageous for the FRACAS job management personnel to carry on the
centralism unification management;
The c. logarithm according to carries on the analysis and the
computation has custom-made, the definite product key, the heavy
important document, the breakdown frequency send and so on, has
custom-made each kind of statistical analysis chart, has custom-made
in each kind of situation MTTF and MTBF value and so on reliable the
parameter value computational method, has custom-made the reliability
design criterion and the breakdown pattern handbook production rule;
D. has custom-made the unusual situation to report to the police
processing, has made up some loopholes and to significant event urgent
processing which in the routine work manages and so on;
E. has custom-made the real-time monitoring module in view of
the administrative personnel, helps the administrative personnel to
grasp the product breakdown condition and the diagnosis development
tendency immediately.
Implementation effect
After the FRACAS implementation project group completes
has custom-made the work, then starts in on firewood company to choose
the partial departments to carry on FRACAS to try to move, in tries to
move in the process to seek effectively, conforms to on the firewood
company actual condition FRACAS solution. Through unceasingly
moves and the improvement, finally has formed a mature FRACAS system.
The FRACAS system success implementation caused the firewood
company to realize to the diesel engine all levels of products
breakdown information standardized management, the centralized energy
fundamentally solved the significant breakdown and the repetition
breakdown, realized the reliability growth, strengthened the market
competition strength, reduced the entire life cycle cost; At the
same time, also may provide the data foundation using the FRACAS
system for other reliable work, in the promotion the firewood company
in view of the diesel engine product reliable work comprehensive
development. |
