Costs & KPIs · Intermediate

Identify Equipment with Repeated Failures

Learn to identify repeated failures on Pump P-101 by comparing corrective work orders over a defined period. Prepare an evidence-based summary of recurring symptoms, affected components and recorded causes for technical investigation.

Identifying repeated equipment failures is crucial for improving asset reliability and optimizing maintenance strategies. Chronic issues lead to increased downtime, higher costs, and reduced productivity, making their early detection and resolution a top priority. This guide demonstrates how to leverage your CMMS data to pinpoint recurring problems, focusing on practical steps to analyze work orders and build an evidence-based case for technical investigation.

Where it's available and step by step

Step by step in ManWinWin Web

1
In ManWinWin Web, open Items, locate Pump P-101 and select it.
2
Click the WOs icon to display the equipment’s filterable work order history on the right.
3
Use the column filters to retain corrective work orders within your chosen review period, using the relevant work type classification.
4
Open each relevant work order and note its reference, intervention date, affected component, symptom, recorded cause and work performed where available.
5
Compare the intervention descriptions to distinguish separate failure occurrences from follow-up work on the same unresolved incident.
6
Group separate occurrences with matching components and similar symptoms, then compare their recorded causes without assuming that matching symptoms prove a common cause.
7
Count the distinct occurrences in each group and list their dates to show whether the issue returned after previous repairs.
8
Prepare a summary identifying Pump P-101, the review period, recurring issues, occurrence counts and supporting work order references, noting any unconfirmed causes for further technical analysis.

Theory and technical background

The Importance of Failure Analysis

Failure analysis is a systematic process of identifying the root cause of equipment breakdown or malfunction. For repeated failures, this analysis extends beyond fixing the immediate symptom to understanding why the same problem keeps recurring. Effective failure analysis helps prevent future breakdowns, improves asset design, refines maintenance procedures, and contributes significantly to overall asset performance and reliability. ISO 55000 emphasizes the importance of data-driven decision-making, with failure data being paramount.

Corrective Maintenance Data as a Diagnostic Tool

Corrective Maintenance (CM) work orders, when properly documented, are a rich source of failure data. Each CM work order typically records the date of intervention, reported symptom, detected cause, affected component, and the repair actions taken. By systematically reviewing and comparing these records over a defined period, patterns of repeated failures can emerge. This process requires a structured approach to filter, group, and analyze the textual descriptions and categorical data within the work orders, as outlined in EN 13306 for maintenance terminology.

From Symptoms to Root Causes

Identifying repeated failures is the first step; understanding their root cause is the ultimate goal. While symptoms and affected components might be similar across multiple failures, their underlying causes can differ. For instance, a 'pump not priming' symptom could be due to a faulty seal one time and a clogged suction line another. It's vital to compare recorded causes without assuming commonality. The objective is to gather enough evidence from work order history to guide a deeper technical investigation, potentially using tools like 5 Whys or FMEA (Failure Mode and Effects Analysis).

Best practices

Ensure consistent and detailed data entry in work orders for symptoms, causes, and components.
Define a reasonable review period (e.g., 6 months, 1 year) that allows patterns to emerge.
Look for subtle differences in work order descriptions that might indicate evolving issues.
Collaborate with technicians who performed the work for insights into recurring problems.

Frequently asked questions

Why is it important to identify repeated failures?

Identifying repeated failures reduces downtime, lowers maintenance costs, and improves equipment reliability. It allows for proactive adjustments to maintenance strategies, such as implementing preventive tasks or redesigning components, ultimately extending asset life and boosting operational efficiency.

How can CMMS data help in this process?

CMMS data, especially from corrective work orders, provides a historical record of all maintenance activities. By analyzing this data—filtering by equipment, work type, and reviewing details like symptoms, causes, and components—you can systematically uncover patterns of recurring issues.

What if recorded causes are often vague or missing?

Vague or missing cause data is a common challenge. In such cases, focus on consistently recurring symptoms and affected components. This evidence can still strongly indicate a chronic problem, prompting a dedicated technical investigation to uncover the actual root cause, and improve data capture practices.

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