Failure Analysis, Reliability Solutions

FRACAS, ILS, RBD. FMEA, FTA. Weibull, Markov Chains, Failure Trending, MTBF /Failure Rate Predictions


ALD is one of the world leaders in conducting failure reporting, analysis and corrective actions (FRACAS) activities as well as developing and customizing FRACAS software tools. Back in 1984, the first full-scale failure data collection and reporting system for the big customers from aircraft and military industries contributed to ALD's solid reputation in the world reliability community. ALD established the failure data collection procedure, participated in actual data collecting and developed software for easy processing, analysis and reporting of accumulated data. Since then we have created, established and maintained FRACAS systems for dozens of satisfied customers widening our scope to telecommunication, semiconductors, software, chemical, and automotive industries.

See also FavoWeb FRACAS Software web site for more information about our web-based dynamic Failure Reporting System.


Failure Data Collecting & Processing
Failure data collection and analysis are closely connected with all other reliability activities. Failure data collecting should start at an early stage of systems design and go on through the entire product life cycle. Both suppliers and users must perform the detailed tracking and analysis of equipment malfunctions and failures. ALD FRACAS specialists have established the failure data collection procedure defining the most critical data types for each phase of a product life cycle and ensuring the comprehensive processing leading to corrective action and preventive maintenance. Timely failure data collecting, recording and processing supported by the ALD software helps prevent failures from recurring as well as simplify and reduce maintenance tasks. Providing data for statistical analysis Failure Reporting, Analysis, and Corrective Action System (FRACAS) is a closed-loop feedback path in which the users work together with suppliers to collect, record, and analyze both hardware and software failures. The user captures predetermined types of data about all problems with a particular tool or software and submits such data to the relevant supplier. A Failure Review Board (FRB) at the supplier site analyzes all corrected failures, considering such factors as time, money, and engineering personnel. The resulting analysis identifies corrective actions that should be implemented and verified to prevent failures from recurring.

Trend Analysis

Accurate trend analysis is one of the most valuable outcomes of timely and well-defined FRACAS. ALD FRACAS experts will perform the trend analysis by incorporating all existing historical reliability information: MTBF, MTTR, availability, preventive maintenance, etc. Analysis of deficiency patterns allows to define possible failure trends, and finally contributes to prevention of failures and unnecessary maintenance activities.

Corrective Action
Our FRACAS experts will assist you in definition of corrective actions based on the collected engineering data. The benefits of early implementation of corrective action become apparent also to the manufacturer as failure occurrences decrease at the manufacturing line and in the field. Thus, your organization will be able to meet the ISO 9000 requirements for the corrective action. Determination of an appropriate corrective action sequence is one of the main goals of failure data collecting process.
Field Reliability Analysis
Collection of field performance data is a crucial element in monitoring reliability. Field data collection is a vital part of a FRACAS process.

Field data collection should include:

·         Incident/Failure technical info (part no. s/n, operation time/meters)
·         Description/Symptoms
·         Environmental conditions
·         Suspected cause
·         Repaired items
·         Repair time and comments
·         Root cause, if available

Collecting field data as a part of a FRACAS process enhances product reliability, safety, quality and allows calculation and prediction of the following:

·       Field MTBF ("real" failure rate) vs. Calculated MTBF (predicted failure rate)
·         ILS optimization by establishing optimal spares levels

·         Enhanced maintenance policy (RCM - reliability centered maintenance)

FRACAS Software Customization
Adaptation of FRACAS process to the needs of each customer is an indispensable element of FRACAS success. Each organization has its own unique data collection sources, process and desired outputs. Forcing a global data collection forms, pre-defined workflow and outputs proved to constrain potential FRACAS results.
ALD offers a highly flexible, user configurable system which easily adapts to organization's needs:
Customized workflow, data collection forms, user configurable output reports and much more.
ALD's administrator mechanism allows each organization to retain their freedom with implementation of new projects into the failure reporting and analysis system, enhancing workflow and data collection by themselves.
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