It is always a good idea to stay on top of your data!!! If you update data older than 4 months, you will not see the changes until the following Monday. (It refreshes Sunday overnight.) If your data is older than 13 months, it may not be worth updating. The changes will not show up until the second day of the next month.
Steps in the screenshots correspond to the numbers in the headings.
One of the most powerful tools that you have in your toolkit is the Failure Analysis Report in Power BI. We should start by saying that this report is only as good as the data that is put into it. Information from this report is driven from the Repair Codes entered on Corrective Maintenance Tasks in eFACTORYPRO. If your Technicians are in the habit of choosing "other" or "unknown," the amount of ACTIONABLE data will be much less than if they are taking the time to select the proper code.
If you find you are consistently needing a code that is not available in the drop-down list, request it through the Feedback button in the portal, and ask others to vote on it. How do I submit feedback in the User Voice?
The first thing you must realize is that the filtering and formatting of this report and its pages works exactly the same as the rest of BI. There are cross filtering and drill-downs. When you want more information on something, don't be afraid to simply click on a chart and see where it takes you. You can always click RESET TO DEFAULT before exiting and nothing will have changed.
Regardless of whether you have a Consumer license or a Pro License, you will access this report through the FMS Metrics Report. We will show how to access it as if you have a Consumer license -- the only difference for a Professional license would be that you would access it through your site workspace vs. Shared with Me.
1. Launch Power BI and from the Shared with Me option go to the FMS Metrics Dashboard.
2. From the home page, click on the Failure Analysis Reports tile.
Each page has been separated out into it's own separate option.
A. The first option is the overview panel. Let's start by looking at the criteria in the far upper right.
3. The default is to see 6 Months of data, but you can change this if necessary by clicking on ALL and entering a checkmark in the box in front of the month(s) you want to select.
4. You can adjust the machine criticality you want to include by simply checking/un-checking the appropriate boxes.
5. By default, all asset numbers are included, but this can be modified.
6. As it stands, the upper right is showing you the summary based on the selections you have chosen. In our example, you have 42 failures for a total of 197.9 hours in the last 6 months on all Critical 1 and 2 assets.
7. To return to the landing page for the Failure Report, click the single curved arrow.
All of the information shown on the next four charts are available in further detail in the remaining tabs. This first screen just gives a really good overview of what is going on.
- For example: Look at the upper left chart. Note that 50% of the failures in January were from Component Failure
- Moving over to the top right chart, you see which machines are failing the most often.
- The bottom right shows you the most common failures by asset number.
- And, if you drill down, the bottom left will give you the corresponding work order data.
Over 2/3 of your failures entered last month were "Other see comments" - you may want to follow up with your techs to see if there are RCA Codes that need to be entered so that the site can get more actionable data.
B. If you only used one tile in this report, I would vote for the Asset/Object Failures and Downtime. It has great information that you can take and make improvements to your site's performance.
As a best practice, you will want to check the filters on the far right side. This report shows all Critical 1 & 2 Equipment for the last 6 months by default. You can modify as needed.
8. The scatter plot takes up the top panel. Each dot represents a piece of equipment: Green means that there are PMs associated to the equipment; Red means that there are no PMs.
9. The Vertical axis shows unscheduled downtime hours. If it is near the bottom, it didn't incur a lot of downtime.
10. The horizontal axis shows number of failures. If the dot is in toward the left access, the machine didn't fail very often.
Ideally, when you look at this chart, you would prefer to see only green dots clustered in the bottom left corner. This would mean they had very few failures with very limited downtime, and that each machine had PMs associated with them.
11. When you hover over the dot at the top of the vertical access, you will see that Asset # 112 failed twice, for 68 hours of unscheduled downtime, and it does have a PM on the machine.
12. However, when you hover over one of the dots farther to the right, you can see that Asset FINN3 failed 6 times, for a total of 36 hours. When you click on this dot, the rest of the information on the screen cross filters.
If you have any dots (green or red, but especially red) in the upper right corner (shaded for illustration), you will want to investigate those immediately! Those would represent machines that are failing often and causing A LOT of downtime!
From here on, you can do some investigation to see how well the PMs are addressing the issues that are causing the failures, and what, if anything, could be tweaked or modified to improve the Mean Time Between Failure. We will come back to that after the other tiles in the report.
C. The third tile gives you information on how things break down by RCA codes.
13. As always, report filters originally default to all, but let's filter just for Asset ID FINN3.
14. Click on "Actuator" to turn on cross filtering.
We chose Actuator because it was one of two codes with the most downtime.
15. Once cross-filtering comes on, you can see more detail on why the actuator caused so much downtime.
D. The forth tile shows you a different view. On this page, you will see Downtime Hours, Failure Count, MTTR (mean time to repair), and MBTF (Mean Time Between Failure), with the bottom panels giving you a little more information on the object and problem.
- As a Best Practice, you should always check the filters on the right-hand side. They do NOT stay the same from one page to the next!
- Also notice that the panels do NOT all start with the same equipment number. The top two begin with TL2 as it is related to downtime, and 3 of the bottom 4 start with different equipment as they refer to Failures.
16. In this case, all criticalities are included.
17. By default, the report is showing Facilities, Machine, and Sub-locations. It does NOT include Tool and Die.
18. The Month/Year defaults to the last 6 months, and Asset Number defaults to all.
19. Looking at the chart below, you can't automatically assume that the top line is where you should begin. In this case, it is... either FINN 5 or FINN3.
In other cases, you could have a single failure that caused a great amount of downtime five months ago, and there have been no breakdowns since that point. It is always important to do a little more digging to get to the root of the problem.
Cross filtering and drill downs will work on this page as well.
E. The final tab will just show you the downtime hours by repair codes.
20. Lets go back to the Scatter plot information, filtered to show only Asset ID FINN3.
21. Notice that the two longest downtime events were caused by Misalignment of the Actuator and the Table being loose. There were two component failures on the Belt and the spring. Additionally, the coupling and the sensor had failures that you will have to do some more research to find out what was wrong. Finally, a programming error with the Conveyor caused 5 hours of downtime.
22. The PMs have not been modified.
23. Although all PMs have been completed, they are only running at a 40% Compliance.
From here, you might want to do some investigation in the portal.
24. From the Main Menu in the Tech Portal, click on Equipment.
25. Click on the three lines next to Asset ID and enter the Asset Number. Click on the line to highlight and load the equipment.
You can look at all work orders, or all tasks from here. This is a better option than looking at the Service History in the CLIENT, as the CLIENT is limited to 50 records.
26. In this example, we probably want to review the Reactive Work Order history. Click on the Work Order Badge.
27. Click View Work Orders.
28. The Work Order Grid screen loads.
29. Click on the three lines next to Type and select just MRCT.
30. From here you have the ability to look at the WO/Task individually or you can export to Excel.
31. The report showed you that there were PMs on the machine, so you will want to see what those are. Go to the CLIENT and from the Main Menu, enter Financials > Contracts.
32. Enter your four digit site number followed by PM. Click the green magnifying glass. The PM Contract loads.
33. Each line is a piece of equipment. Click on ANY of the sequence numbers.
34. The breadcrumb now says Contracts > Contract Lines.
35. Expand the Red Chevron in the search field.
36. Click on the Place Tab.
37. Enter the Asset ID and click the green magnifying glass.
38. The PMs will show in the middle section. This machine has 6 PMs.
39. In this case, there are 2 Monthly, 1 Quarterly, 2 Semi-Annuals, and 1 Annual. The 10 year is actually on hold.
40. You will want to write down the Task Template/Job Plan IDs.
41. You will want to print off the Task Template report to see which steps are contained in those templates. The easiest way to do that is to go to the reporting server in the portal. From the Links drop-down, choose Reports.
42. This will take you to the main page of the Reporting server. Click on the folder in the appropriate language.
43. A list of reports will populate. Click on the tile for the Task Template Report.
44. The Parameters load. Enter your Team Id.
45. Enter the six Task Template numbers with the pipe character separating each. "|"
You will find the pipe character right above the Enter key. Hold down shift and click the \ key.
46. Click View Report.
47. Once the bar below the parameter loads, you will know that the information is processing correctly.
48. Click on the floppy disc and choose the format you want to use to save the file.
49. The report will show in your downloads.
After reviewing the steps in the Monthly Task template, as well as the Reactive Work order descriptions, you decide that an additional PM would help eliminate failures.
50. You create a weekly job plan that includes checking the hydraulic fluid and ensuring proper placement/alignment for clamping of the sheet.
51. As a final step, you may decide to add more comprehensive information to the Monthly PMs for ensuring that coolant levels are accurate.
Both of these things could be done in the Planner Portal. Additionally, as Finns are a relatively common manufacturer of equipment, you might want to investigate Job Plans from other sites, and see if any of them have more detailed PMs that you can copy into your site.
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