EXERCISE 1

There are the failure modes shown below and the following must be calculated:
a) Determine the annual cost of each failure mode, completing the attached tables.
b) Calculate which are the failure modes that generate 80% of the costs.
c) Consider: Labor cost: €20/hr. Lost production cost: €7,880/hr.
Labour cost 20 €/h
Lost prod. Cost 7,880 €/h

TABLE 1
Labor cost Lost
Failure mode Annual Repair time Spare production
frequency (min) parts cost
# Persons Cost L.C. cost
A 40 120 2 3,200 350 630,400
B 200 60 1 4,000 150 1,576,000
C 40 150 1 2,000 500 788,000
D 12 600 3 7,200 200 945,600
E 23 210 4 6,440 600 634,340
F 1 360 2 240 1,000 47,280
G 40 180 4 9,600 220 945,600
H 20 300 3 6,000 1,500 788,000

TABLE 2 TABLE 2

% Failure
Failure Mode TotalCost % Relative TotalCost
Accumulated Mode

A 633,950 9.91% B 1,580,150

B 1,580,150 24.70% G 955,420
C 790,500 12.35% D 953,000
D 953,000 14.89% H 795,500
E 641,380 10.02% C 790,500
F 48,520 0.76% E 641,380
G 955,420 14.93% A 633,950
H 795,500 12.43% F 48,520
TOTAL 6,398,420 100.00% TOTAL 6,398,420
 Total cost

633,950
1,580,150
790,500
953,000
641,380
48,520
955,420
795,500

TABLE 2
% Relative
% 120.00%
% Relative
Accumulated
100.00%

24.70% 24.70% 80.00%

14.93% 39.63%
14.89% 54.52% 60.00%

12.43% 66.96% 40.00%

12.35% 79.31%
20.00%
10.02% 89.33%
9.91% 99.24% 0.00%
B G D H C E A F
0.76% 100.00%
100.00%
A F
EXERCISE 2
There are chronic events within the production system and you want to know
what the order should be in order to eliminate them. According to company policy,
only critical and semi-critical events should be attacked with root cause techniques.

OPERATIONAL
FAILURE RECURRENCE IMPACT

Hydraulic system pump 4 failures in 6

failure months 0.67 Stop production

Oil leak at hydraulic hose 15 failures in

2.14 Partial stop production
joints 7 months

Obstruction of the oil 32 failures in 5.33 Partial stop production

supply system 6 months

Shutdown due to excess 14 failures in

contaminants produced 6 months 2.33 Partial stop production
by the engine

Failure RE IO

Hydraulic system pump failure 2 10

Oil leak at hydraulic hose joints 3 8

Obstruction of the oil supply system 4 8

Shutdown due to excess contaminants
produced by the engine 3 8
mpany policy,
e techniques.

SAFETY,
OPERATIONAL MAINTENANCE ENVIRONMENTAL
FLEXIBILITY COST AND HYGIENE
IMPACT

Spare parts Affects human

moderately available 25.000.-€ security

Spare parts available 16.000.-€ Causes minor damage

Spare parts available 12.000.-€ Causes minimal

discomfort

Easy to get spare Affects human

parts 19.000.-€ security

Conseq.
FO CM ISAH Absolute
Value

2 2 8 320

1 1 4 32

1 1 2 16

2 1 8 128
 Conseq.
Relative value Criticality Order
to 50

25 Semi-Critical 1

2.5 Non Critical 3

1.25 Non Critical 4

10 Non Critical 2