PeopleSoft Enterprise Maintenance Management 9.1 PeopleBook

Setting Up and Performing Work Order Failure Tracking and Analysis

This chapter presents and overview and discusses how to:

Set up for work order failure tracking and analysis.
Define a failure event.
Perform failure analysis.

Understanding Work Order Failure Tracking and Analysis

PeopleSoft Maintenance Management provides users the capability to track and analyze equipment failure incidents for various operational and regulatory needs, such as health, safety, and environmental compliance. These failure incidents are defined as failure events in a work order which are directly tied to a target asset that has failed in a work order task.

You can analyze these asset failures to:

Help prevent recurrence or minimize the number of future incidents.
Reduce associated downtime and repair costs.
Measure and track both asset reliability and maintenance and repair effectiveness.
Support repair versus replace decisions.
Support related planning and budget allocation activities for constrained maintenance resources.

To accomplish these goals, PeopleSoft Maintenance Management enables users to set up failure severity and failure impact codes to define data that describes, quantifies, and qualifies asset failure events from the various perspectives of the Work Order, Work Order Completion, or Technician Workbench components. You can analyze failure events based on specific detail or summary criteria in Failure Analysis inquiry, where you can discover trends and relationships affecting future failure occurrence, asset reliability, and maintenance and repair effectiveness measures. Failure tracking and analysis are optional activities that can assist supervisors and managers to carefully manage their assets.

Failure Tracking Setup

You define failure severity and failure impact codes based on the requirements of your organization. When you perform a failure analysis, you can select failure severity and failure impact codes to search for specific failure events to analyze on the Failure Analysis page. PeopleSoft Maintenance Management delivers sample data that contains examples of these two types of failure codes. You can use this sample data to help you define your own failure codes.

You must set up failure severity codes for your organization before you can track failure events in PeopleSoft Maintenance Management. Each code describes the seriousness of the asset failure to your organization. For example, you could define failure severity codes as critical, high, medium, low, or none or with numerical values. You are required to select a failure severity code on the Work Order Failure Tracking page.

Failure impact codes are useful for identifying how the failure of an asset will affect specific organization circumstances or requirements such as hazardous conditions or materials, health issues, safety issues, and more. You can assign more than one failure impact code to a failure event on the Work Order Failure Tracking page. However, you are not required to set up or use failure impact codes to complete the Work Order Failure Tracking page.

Failure Event Definition and Tracking

Once the failure impact and severity codes are established, you can enter, maintain and review the data associated with an asset failure event in the Work Order Failure Tracking component. You can create a failure event directly from the Work Order, the Work Order Completion, and the Technician Workbench components. A failure event is defined based on the failure or problems of an asset selected for a work order task. While tracking failure events is an optional activity and is only appropriate for certain critical assets or classes of assets within an organization, defining failure events will enable your organization to obtain additional information that quantifies and qualifies the nature of an asset's failure.

When you create a failure event from the Work Order, the Work Order Completion, or the Technician Workbench components, the system automatically assigns the next Failure ID in the system to the failure event. You cannot override this value. When you save the Work Order Failure Tracking page, the system updates this failure ID number in the Last Failure ID field on the Definition page of the work order business unit associated with the failure event.

If you create a failure event from the Work Order Failure Tracking component, you can accept NEXT as the default for the Failure ID and the system assigns the next failure ID to the failure event. You can also override NEXT with a unique failure ID. A unique failure ID is not tracked on the Definition page of the work order business unit.

If you entered a unique failure ID for one failure event, and created the next failure event from the work order, which automatically assigns a failure ID number, when you save the Work Order Failure Tracking page, the number generated is automatically updated in the Last Failure ID field on the Definition page of the work order business unit.

In addition to failure ID, the Work Order Failure Tracking page consists of:

Information about the work order, work order task, and the asset associated with the failure event.
Problem reporting information.
Detail information describing the failure event.
Failure impact information.
Asset downtime information.
A list of causal parts.
Meter reading data.
Warranty claim information.

Much of this data is replicated form the work order task data. It appears in this component to enable you to review or update any of this data that may have a bearing on the failure event without returning to the work order. You can also this data as search values in the Failure Analysis component.

However, you can, at a minimum, log a failure event by selecting a severity code and the start date for the failure.

You can access the Work Order Failure Tracking page to update or review an existing failure event or add a new failure event from the:

Work Order page.

Access the Problem Reporting tab of the Work Order Tasks group box on the Work Order page. (Maintenance Management, Work Order Management, Work Order,, Work Order tab) (Maintenance Management Center, Work Order Management, Work Order, Work Order page.)

See Defining a Failure Event.
Work Order Requirements page.

Access the Problem Reporting group box of the Requirements page. (Maintenance Management, Work Order Management, Work Order, Requirements) tab.

See Problem, Cause, and Resolution Data.
Work Order Completion page.

Access the Work Order Completion page. (Maintenance Management, Work Order Management, Work Order Completion.)

See Using the Work Order Completion Component.
Technician Workbench page.

Access the Failure Reporting tab in the Work Order Tasks group box of the Technician Workbench page. (Maintenance Management, Workbenches, Technician Workbench, Technician Workbench page.)

See Using the Technician Workbench to Complete Work Order Tasks.
Work Order Failure Tracking, Add a new value page.

Access the Work Order Failure Tracking page. (Maintenance Management, Work Order Management, Work Order Failure Tracking, Work order Failure Tracking page.)

See Defining a Failure Event.

Failure Analysis

The PeopleSoft Maintenance Management Failure Analysis component enables you to perform a meaningful analysis of system-calculated metrics based on the tracking of failure events associated with a work order task. You can easily search and group the asset failure event data that you want to analyze. When the system calculates the metrics and displays the data for the selected asset failure events, the resulting data may include:

Total Failure Count.
Mean Time (Days) Between Failure (MTBF).
Mean Time (Hours) to Repair (MTTR).
Mean Cost (Currency) to Repair (MCR).
Mean Reading (Meter Units) Between Failures.

To analyze one or more asset failure events, you:

Enter the search criteria for the failure event data that you want to analyze.
Select the appropriate analysis method by:
- Selecting an analysis option from the available list of failure events.
  
  The default option for a new search is Failure Event (Detail), which shows all of the failure events that match your search criteria. You can choose one of the summary optiosn that provide different summary views of the detail failure event data.
- Selecting the failure event data that you want to analyze from the search results.
- Selecting the Show Totals button to display the failure event totals based on the selected analysis method.
- Creating a chart based on the select data.

Setting Up for Work Order Failure Tracking and Analysis

This section discusses how to:

Set up failure severity codes.
Set up failure impact codes.

Pages Used to Set Up for Work Order Failure Tracking and Analysis

Page Name	Definition Name	Navigation	Usage
Failure Severity	WM_FAILURE_SEVRTY	Set Up Financials/Supply Chain, Product Related, Maintenance Management, Set Up, Failure Severity, Failure Severity page.	Set up failure severity codes for work order failure tracking and analysis.
Failure Impact	WM_FAILURE_IMPACT	Set Up Financials/Supply Chain, Product Related, Maintenance Management, Set Up, Failure Impact, Failure Impact page.	Set up failure impact codes for work order failure tracking and analysis.
Failure Impact Notes	WM_WO_FAILIMPC_SEC	Click the Add link in the Notes column of the Failure Impacts grid	Add notes about the impact of this failure on the organization.
Failure Causal Parts	WM_WO_FAILCAUS_SEC	Click the Add link in the Comments column of the Causal Parts grid.	Add comments about the selected causal part, such as the part has corroded.

Setting Up Failure Severity Codes

Access the Failure Severity page. (Set Up Financials/Supply Chain, Product Related, Maintenance Management, Set Up, Failure Severity, Failure Severity page.

SetID and Failure Severity

Select a SetID and enter a code, which can contain up to five characters, that best represents a level of the severity of an asset failure to your organization on the Add a New Value page. For example, you can set up code values of: 0 (none) 1 (minor), 2 (low), 3 (medium), 4 (high), and 5 (critical).

Descriptionand Short Description

Enter a meaningful long and short description of this failure severity code such as Critical, High, Medium. These are both required fields.

Setting Up Failure Impact Codes

Access the Failure Impact page. (Set Up Financials/Supply Chain, Product Related, Maintenance Management, Set Up, Failure Impact, Failure Impact page.)

SetIDand Failure Impact

Select a SetID and enter an identifiable code to define a circumstance or requirement that can be impacted by a failure event on the Failure Impact Codes - Add a New Value page. For example ENV to represent Environment or ASST to represent Asset Lifecycle.

Descriptionand Short Description

Enter a long and a short meaningful description of the entered failure impact code such as Environmental impact. If you choose to define a failure impact code, these are both required fields.

Note. You can assign more than one failure impact code to a failure event on the Work Order Failure Tracking page. However, failure impact codes are not required to complete the Work Order Failure Tracking page.

Adding and Reviewing a Failure Event

This section discusses how to define a failure event.

Pages Used to Add and Review a Failure Event

Page Name	Definition Name	Navigation	Usage
Work Order Failure Tracking	WM_WO_FAIL_TRACK	Maintenance Management, Work Order Management, Work Order Failure Tracking, Work Order Failure Tracking page.	Add or modify a failure event.
Work Order	WM_WO_HDR	Maintenance Management, Work Order Management, Work Order, select the Work Order tab, click the Failure ID Add link in the Work Order Tasks, Problem Reporting grid.	Access the Work Order Failure Tracking page and to add or review a failure event. Note. The Add link is only accessible after you specify the target asset of the work order task.
Work Order - Requirements	WM_WO_TASK_RQMT	Maintenance Management, Work Order Management, Work Order, select the Requirements tab, click the Failure ID: Add link in the Problem Reporting group box.	Access the Work Order Failure Tracking page to add or review a failure event. The Add link is only accessible after you specify the target asset of the work order task.
Work Order Completion	WM_WO_ACT	Maintenance Management, Work Order Management, Work Order Completion, Work Order Completion page, click the Failure ID: Add link.	Access the Work Order Failure Tracking page to add or review a failure event.
Technician Workbench	WM_WOE_WB	Maintenance Management, Workbenches, Technician Workbench, Technician Workbench page, select the Failure Reporting tab in the Work Order Tasks group box, click the Add link in the Failure ID column.	Access the Work Order Failure Tracking page to add or review a failure event.
Task Status History	WM_TASKSTATUS_SEC	Click the As of date on the Work Order Failure Tracking page.	Displays a grid containing the history of status changes including the date and time the status was changed and the name of the user who changed the status.
Asset Information	WM_WO_ASSET_SEC	Click the link associated with the asset's description. Click the Hazardous icon next to the Criticality field.	Review details about the attributes of the selected asset.
Asset Warranties	ASSET_WARRANTY	Click the Warranty icon on the Work Order Failure Tracking page.	Review to find out if the warranty covers the repair or partial repair of the selected asset.

Defining a Failure Event

Access the Work Order Failure Tracking page. (Maintenance Management, Work Order Management, Work Order Failure Tracking, Work Order Failure Tracking page)

Refer to Creating a Work Order chapter for a complete description of creating a failure event.

See Defining a Failure Event.

Performing a Failure Analysis

This section discusses how to:

Search for failure event data to analyze.
Specify a failure analysis method.
Review the Totals grid data.
Create an analysis chart.

Pages Used to Perform a Failure Analysis

Page Name	Definition Name	Navigation	Usage
Failure Analysis	WM_FAIL_ANLYS_INQ	Maintenance Management, Inquiries and Reports, Failure Analysis, Failure Analysis page.	Search for failure event data to analyze.
Failure Analysis – Save/Restore Criteria	WM_FLEXSRCH_MAINT	Click the Save/Restore link on the Failure Analysis page.	Save the search criteria entered on the Failure Analysis page or select a previously saved version of the search criteria.

Searching for Failure Event Data to Analyze

Access the Failure Analysis page: (Maintenance Management, Inquiries and Reports, Failure Analysis, Failure Analysis page.)

Field Name

Click the downward arrow and select a field name from the list of field names related to the failure events that you want to use in your analysis. Fields in the drop down list with an asterisk (*) indicate the possibility of a one or one to many matches, while fields without an asterisk indicate a one to one match.

For example, if you select Failure Impact* as the Field Name value and you indicate that it is Equal To a specific value, the system will search for any failure events that have at least that specific failure impact value. However, there may be other impact values that could also be associated with a particular failure event.

Equal To

Based on the field name you selected, select a specific value for this field.

Depending on the value that you select for the Field Name, the Single field or Range of fields will appear in a drop down list, a prompt, a date prompt, or with no controls.

Single Value

Select this option if you select a value in the Equal To field and you want the search to include that one selected value.

You can also select this option if you select a blank value for the Equal To field and you want the search to include all values for the field name. For example, if you select Business Unit for the Field Name value and leave the Equal To field value blank, then the system will search for failure events associated with all business units.

Range of Values

Select this option if you selected a value for the Equal To field and want the system to search for failure events located within a specific range of values. You can specify only the From Value and leave the To Value blank and the system will search for values greater than or equal (>=) to the From Value. When you specify the To Value and leave the From value blank and the system will search for values equal to or less than (=<) the To Value.

For example, if you select Business Unit as the Field Name value, and you select BU0001 as the Equal To value, when you click this Range of Values button, the Equal To field name changes to a From Value and a To Value field. If you already selected BU0001 as the From Value, you can select from the list of business units, such as BU0001, BU0002, BU0003, BU0004, BU0005, and BU0006, and select BU0004 for the To Value field. This indicates that the system will include from BU0001 to BU0004 in the search for associated failure event data when you click the Search button. You can also leave the To Value blank and the system will search for all business units greater than or equal to the From Value.

Note. When you select a Field Name such as Asset ID as your search criteria, you must select an Asset BU before you can select a specific value for the asset ID.

You can add more than one row and select different search criteria to narrow your search for failure events.

Search

Click this button to search for failure events based on the selected search criteria.

Reset Criteria

Click this link to reset the search criteria to its default setting.

Save/Restore Criteria

Click this link to display the Failure Analysis – Save/Restore Criteria page.

Note. If the search criteria includes more than one row, the system includes all the rows when you restore the specified search criteria.

Saving and Restoring Search Criteria

You can save current search criteria or restore a saved search by selecting the appropriate option on this page. If you restore a saved search, the search criteria will include all rows included in the search criteria.

Access the Failure Analysis - Save/Restore Criteria page. (Click the Save/Restore Criteria link on the Failure Analysis page.)

Maintenance Option

Select one of these options:

Restore Search Criteria from:

Select this option to enable the Search Name field. Select the name of a previously saved search criteria. A description of this Search Name option appears as read - only the Description field.

Click the Process button to update the Failure Analysis page with the restored criteria.

Save Search Criteria as:

Select this option to enable you to enter a search name and description in the Search Name and Description fields for the search criteria that currently appears on the Failure Analysis page.

Click the Process button to save the current search criteria under the name that you entered.

Cancel

Click to return to the Failure Analysis page.

Specifying a Failure Analysis Method

After you click the Search button, the system displays the search results. You can select all or some of the search results to include in your analysis. This type of analysis is good for ad hoc queries. You can conduct a failure analysis for many different combinations of detail and summary data.

Access the search results on the Failure Analysis page.

(Click the Search button on the Failure Analysis page.)

Analyze By

Click the downward arrow and select one of these values:

1 - Failure Events (Details) ID.

Select this value to display the Search Results by Failure. This is the default selection following a new search.

2 - Asset Identifier

Select this value to summarize the retrieved failure events by the asset identifier keys: AM business unit, asset ID, asset location, area ID.

3 - Asset Classification

Select this value to display the Search Results based on asset classifications.

4 - Problem Classification

Select this value to display the Search Results based on problem categories.

5 - Project-Activity ID

Select this value to display the Search Results based on project and activity IDs.

6 - Shop-Crew Assignment

Select this value to display the Search Results based on crew assignment criteria.

Summarize By

The buttons that appear in this group box enable you to control the columns that appear in the Search Results grid so that you can group the summary data in different ways for your analysis.

This group box appears or does not appear depending on value that you selected in the Analyze By field.

If the value you selected in the Analyze By field is:

1 - Failure Events (Detail)

The Summarize By group box does not appear on the page.

2 - Asset Identifier

These buttons appear in the Summarize By group box:

AM Business Unit

Asset Identification

Asset Location

Area ID

If you select a green button and the button changes to a red x, then that value's column does not appear in the selected search results. In other words, you can toggle a particular key field on or off to include or exclude that field in the summarized results.

For example, if you select the green button next to Asset Identification, a red x replaces the green button, then the Asset Identification column does not appear in the selected search results. If you select the red x next to Asset Identification and the red x is replaced with a green button, then the Asset Identification column reappears in the selected search results.

In addition, if you select the green button for AM Business Unit and the green button for Asset Location, these buttons are each replaced by a red x, and the AM Business Unit and Asset Location columns do not appear in the selected search results.

3 - Asset Classification

These field names appear with green buttons next to them in the Summarize By group box:

Asset Type

Asset Subtype

Manufacturer

Model

4 - Problem Classification

These field names appear with green buttons next to them in the Summarize By group box:

Problem Group

Problem Code

Cause Code

Resolution Code

5 - Problem - Activity ID

These field names appear with green buttons next to them in the Summarize By group box:

PC Business Unit

Project

Activity

6 - Shop-Crew Assignment

These field names appear with green buttons next to them in the Summarize By group box:

Crew Business Unit

Crew Shop

Crew

Supervisor

Show Totals/Hide Totals

Once you have selected the type of analysis you want to conduct, as well as determined the summary columns (if applicable), select the Show Totals button to display a grid of failure data totals based on your selected search results.

When you select the Show Totals button, the button name changes to Hide Totals. When you click the Hide Totals button, the grid of failure data totals is hidden and the Show Totals button replaces the Hide Totals button.

Reviewing the Totals Grid Data

The totals grid data is calculated based on your selection in the Analyze By field, selection of the Summarize By buttons (if applicable), and the number of selected rows

Access the Totals grid. (Click the Show Totals button to display the totals grid on the Failure Analysis page.)

Totals Of

This column contains these row:

Selected Details

Unselected Details

All Details

Record Count

Displays the number of records included for each row value.

Failure Count

Displays the total number of failures events based on the row and the selected failure data rows.

Mean Time Betw Failure (Days) (mean time between failure)

Displays the mean number of days between failures for the Selected Details, the Unselected Details, and All Details. This metric is based calculating the individual days between a failure, which subtracts the start date of a subsequent failure event from the start date of a prior failure event. These individual days between a failure event are summed and divided by the total number of failure events.

Mean Time to Repair (Hrs) (hours)

Displays the mean number of hours that it takes to repair the failure. This metric is based on the number of hours entered in the Time to Repair field on the Work Order Failure Tracking page.

AMean Meter Units Betw Failure column will appear to the right of Mean Time to Repair, if you specified a single meter type as part of the search criteria. The column label will display Meter Type, Meter Units Betw Failure, and Meter UOM.

Mean Cost to Repair

This amount is calculated based on the Cost to Repair value entered on the Work Order Failure Tracking page for the Selected Details, the Unselected Details, and All Details.

Creating an Analysis Chart

Access the Analysis Chart group box on the Failure Analysis page. (Scroll to the Analysis Chart group box on the Failure Analysis page.)

Chart Type

Select one of these types of charts:

Bar Chart

Pie Chart (Percent)

Stacked Bar Chart

If you select Stacked Bar Chart, in addition to Failure Metric, a second Group By field l appears, which enables you to choose the underlying attribute describing the segments or composition of the bar. A stacked bar chart may be particularly useful in highlighting lower-level relationships between various task or failure attributes and the primary failure metric.

Failure Metric

Select the type of failure metric that you want to appear on the selected chart:

Cost to Repair

Days Between Failures

Failure Count

Time to Repair

Units Between Failure

This metric appears the search criteria included meter type.

Include Unselected as 'Other'

Select this check box to include the unselected data values in the chart.

Selecting this option displays the unselected results data as a single pie slice or bar labelled as OTHER.

SetID and Failure Severity	Select a SetID and enter a code, which can contain up to five characters, that best represents a level of the severity of an asset failure to your organization on the Add a New Value page. For example, you can set up code values of: 0 (none) 1 (minor), 2 (low), 3 (medium), 4 (high), and 5 (critical).
Descriptionand Short Description	Enter a meaningful long and short description of this failure severity code such as Critical, High, Medium. These are both required fields.

Field Name	Click the downward arrow and select a field name from the list of field names related to the failure events that you want to use in your analysis. Fields in the drop down list with an asterisk () indicate the possibility of a one or one to many matches, while fields without an asterisk indicate a one to one match. For example, if you select Failure Impact as the Field Name value and you indicate that it is Equal To a specific value, the system will search for any failure events that have at least that specific failure impact value. However, there may be other impact values that could also be associated with a particular failure event.
Equal To	Based on the field name you selected, select a specific value for this field. Depending on the value that you select for the Field Name, the Single field or Range of fields will appear in a drop down list, a prompt, a date prompt, or with no controls.
Single Value	Select this option if you select a value in the Equal To field and you want the search to include that one selected value. You can also select this option if you select a blank value for the Equal To field and you want the search to include all values for the field name. For example, if you select Business Unit for the Field Name value and leave the Equal To field value blank, then the system will search for failure events associated with all business units.
Range of Values	Select this option if you selected a value for the Equal To field and want the system to search for failure events located within a specific range of values. You can specify only the From Value and leave the To Value blank and the system will search for values greater than or equal (>=) to the From Value. When you specify the To Value and leave the From value blank and the system will search for values equal to or less than (=<) the To Value. For example, if you select Business Unit as the Field Name value, and you select BU0001 as the Equal To value, when you click this Range of Values button, the Equal To field name changes to a From Value and a To Value field. If you already selected BU0001 as the From Value, you can select from the list of business units, such as BU0001, BU0002, BU0003, BU0004, BU0005, and BU0006, and select BU0004 for the To Value field. This indicates that the system will include from BU0001 to BU0004 in the search for associated failure event data when you click the Search button. You can also leave the To Value blank and the system will search for all business units greater than or equal to the From Value. Note. When you select a Field Name such as Asset ID as your search criteria, you must select an Asset BU before you can select a specific value for the asset ID. You can add more than one row and select different search criteria to narrow your search for failure events.
Search	Click this button to search for failure events based on the selected search criteria.
Reset Criteria	Click this link to reset the search criteria to its default setting.
Save/Restore Criteria	Click this link to display the Failure Analysis – Save/Restore Criteria page. Note. If the search criteria includes more than one row, the system includes all the rows when you restore the specified search criteria.

Totals Of	This column contains these row: Selected Details Unselected Details All Details
Record Count	Displays the number of records included for each row value.
Failure Count	Displays the total number of failures events based on the row and the selected failure data rows.
Mean Time Betw Failure (Days) (mean time between failure)	Displays the mean number of days between failures for the Selected Details, the Unselected Details, and All Details. This metric is based calculating the individual days between a failure, which subtracts the start date of a subsequent failure event from the start date of a prior failure event. These individual days between a failure event are summed and divided by the total number of failure events.
Mean Time to Repair (Hrs) (hours)	Displays the mean number of hours that it takes to repair the failure. This metric is based on the number of hours entered in the Time to Repair field on the Work Order Failure Tracking page. AMean Meter Units Betw Failure column will appear to the right of Mean Time to Repair, if you specified a single meter type as part of the search criteria. The column label will display Meter Type, Meter Units Betw Failure, and Meter UOM.
Mean Cost to Repair	This amount is calculated based on the Cost to Repair value entered on the Work Order Failure Tracking page for the Selected Details, the Unselected Details, and All Details.