5 WHY ANALYSIS
5 Whys is a simple investigation tool that helps crafts or technicians find out the root cause. It can be carried out by 2-3 people and can be completed within 1-2 hours if all the required information and data are available.
The tool is available on the web-based as well as mobile app form and having cloud storage capabilities. The tool has AI capabilities and every time 5 whys report is generated, it will be stored in a server or cloud.
The tool will generate various analytical reports such as COMMON CAUSE ANALYSIS REPORT, STAFF ENGAGEMENT REPORT, LESSON LEARNT REPORT, which can be used to prepare maintenance strategies at the corporate level. It works as a HISTORIAN as well to capture all investigations in one place.
Equipment and machines fail many times in their Life cycle. The capture of failure information is extremely important for any LEARNING ORGANIZATION. The tool will help maintenance staff to record all the relevant Failure information for individual equipment or machine. The data to be recorded are Unit, Tag number, Date and time, Machine downtime from stoppage to start, total repair cost (Manpower and material), Root cause identified, Part or component failed, total production lost in USD or Units MT or M3.
The various analytical reports can be generated, such as MTBF Report, BAD ACTOR REPORT, Maintenance cost reports, which in turn can be used by my ASSET MANAGEMENT TEAM for high-level INVESTIGATION or STRATEGY DEVELOPMENT for CONTINOUS IMPROVEMENT.
FAILURE REPORTING AND ANALYSIS TOOL (FRAT)
SPARE PARTS CRITICALITY ASSESSMENT TOOL
Spare form a very critical item in any of the ASSET MANAGEMENT PLAN as the availability of spares avoids the condition of PROLONG PLANT OUTAGE. The identification and assessment of each spare concerning its Criticality to PLANT OPERATION are of utmost importance to any LEARNING ORGANIZATION. The Maintenance Manager or Reliability Manager should be well informed about the Criticality of spares and its availability to meet any failures. The tool can be used for new facilities to identify and categories their spares as INSURANCE, CRITICAL or CONSUMABLE spares. The required inventory can be set accordingly. It can be seamlessly aligned with the INVENTORY MANAGEMENT tool, such as SAP or MAXIMO, to review the availability of the spares, which can help MAINTENANCE MANAGER to identify RISK associated with the NON-AVAILABILTY of CRITICAL SPARES and can take appropriate action proactively.
Any type of maintenance work carried out by an individual or company staff or contractor needs to be recorded. It is a simple tool to record individual maintenance or work activities. Any individual working can use it as an independent worker or company. It will help individuals or companies record and track all the maintenance activities on a day-to-day basis.
Various reports can be generated to review cost, staff engagement and repeat work areas or equipment.