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FRACA 1 (Failure Reporting and Corrective Action)

O c t o b e r 2 0 1 1

FRACA 1 (Failure Reporting and Corrective Action) | October 2011

© 2011, HCL Technologies. Reproduction Prohibited. This document is protected under Copyright by the Author, all rights reserved.

TABLE OF CONTENTS

Abstract ............................................................................................. 3

Abbreviations .................................................................................... 4

Market Need ...................................................................................... 5

Solution ............................................................................................. 6

Best Practices ................................................................................... 8

Common Issues .............................................................................. 10

Conclusion....................................................................................... 11

Reference ........................................................................................ 12

Author Info ....................................................................................... 12



3

Abstract

Failure Reporting and Corrective Action (FRACA 1) is a closed-loop response path for collecting, recording and analyzing failures of mechanical, hardware and software data sets.

This document describes how FRACA can be planned and

implemented at a service provider site as a process for continuously

improving reliability.



4

Abbreviations

Sl. No. Acronyms Full Form

1 FRACA Failure Report and Corrective Action

2 MTTR Mean Time To Repair

3 MTBF Mean Time Between Failure

4 MTTF Mean Time To Failure

5 TSN Time Since New

6 CSN Cycle Since New

7 E/I External Induced

8 LRU Line Replaceable Unit

9 RCA Root Cause Analysis



5

Market Need

1. How FRACA can be planned and implemented at a service provider site

2. Continuously improving reliability 3. The method to be used throughout the life cycle of the

equipment, during in-house tests, field tests, and production/operations

4. Customer and the Manufacturer/Supplier work together to collect, record, and analyze failures of LRU’s, Control Systems and all the sub level components

5. The Customer/Airliner captures predetermined type details like serial number, service order number, customer complaint data, TSN, CSN and Flight details through Srvice Order Scanned Document or available customer portal

6. Supplier or manufacturer analyzes the failures, considering such factors as time, money, and engineering personnel

7. The resulting analysis identifies corrective actions that should be implemented and verified to prevent failures from recurring

8. Supplier collate the data from customer report in FRACA1 method/format for analyze to finding out the end failure

9. FRACA 1 will help to carryout FRACA 2 for reliability analysis, failure analysis and corrective preventive actions

10. FRACA 1 promotes reliability improvement throughout the life cycle of the LRU's

11. The FRACA 1 method can be used during in-house (laboratory) tests, field tests, and production/operations to determine where problems are concentrated within the design of the equipment



6

Solution

FRACA 1 helps determine where maximum number of LRU returns are, repeated customer complaints, maximum number of returns by customer and their reasons for returns/problems, the number of repairs and what repairs are to be done, the number of No Fault Found (NFF), no information available, maximum number of returns per year and TSN & CSN information are concentrated on the LRU or system level.

Corrective actions will be implemented in the FRACA 2 stage as well as analysis to prevent further a recurrence of failures of the systems/LRUs. FRACA 1 can provide control and management visibility for improving the reliability and maintainability of the product, manufacturing equipment mechanical, hardware and software. Timely, disciplined use of failure and maintenance data can help generate and implement effective corrective actions to prevent failures from recurring and to simplify or reduce maintenance tasks. FRACA 1 objectives include the following:

Providing history of failure data for corrective action

Assessing historical reliability performance, such as o Mean Time Between Failures (MTBF), o Mean Time To Repair (MTTR),

o maximum return from particular customer, o maximum number of repair done for particular LRU, o Trend analysis (upward/downward) etc.

Developing reports to FRACA 2 for failure analysis and corrective action

Providing data for statistical analysis

Providing data for design and analysis

Providing information can help measure contractual performance to better determine warranty information

FRACA 1 report generating includes the following:

Failure report will be submitted by customer through service order scanned documents.

For each line item will be tracked by notification number or serial number or service order number.



7

FRACA 1 report will be captured / tracked by Service Provider Received Date for number of returns per year or quarter.

Preliminary evaluation will be captured mainly for visual inspection, shipped item problems (dents or scratches), TSN and CSN information and reason for return information etc.

High level analysis information will be captured through Teardown report.

Based on the analysis, what repair will be conducted or number of NFF information will be tracked.

Repeated reason for return analysis captured for customers.

Maximum number of returns will be captured for customers.

Number of Repair, NFF, No information available will be captured for further action on FRACA 2.

Year by return or quarterly return analysis also gives Trend A removal or rejection where an indicated fault is externally

induced (E/I) or not caused by the LRU removed.



8

Best Practices

The data included in the FRACA 1 reports should be verified and then the data should be submitted on simple, easy-to-use format.

Collecting the Data from field/maintenance department

Operators and maintenance personnel are usually the first to identify problems and, therefore, they should be trained to properly capture all of the information needed for an event report.

Consolidate all the data into a field service reports (FSRs). Reporting LRU Failures

In-house test reports

Field service reports

Customer activity logs

Customer equipment history As a result of the data collected to FRACA 1, minimum reliability performance metrics (such as MTBF, MTTR, and uptime percentage) could be determined for each LRU’s or systems. FRACA 2 analysis processes also include:

Review, in detail, the field service reports.

Capture historical data from the database of any related or similar failures.

Assign owners for action items.

Do a root cause analysis (RCA).

Develop corrective actions.

Obtain the failed items for RCA (as needed).

Write a problem analysis report (PAR) and, if needed, a material disposition report (MDR).

FRACA 1 Report Type FRACA 1 reporting mechanism for database should be flexible enough to accommodate various customer types and their needs. For example, at a minimum, the following reports should be available:

Trend charts to show a number of events during a time period.

Event history to show a list of events for during a time period.

Problem history to show a list of problems during a time period.

Reliability statistics to demonstrate the system performance in terms of MTTR, MTBF, mean time to failure (MTTF), etc.

A removal or rejection where an indicated fault is externally induced (E/I) or not caused by the LRU removed.



9



10

Common Issues

Providing control and management visibility

For improving the reliability and maintainability of the product,

Manufacturing equipment mechanical, hardware and software.

Timely disciplined use of failure and maintenance data

Generating and implementing effective corrective actions to prevent failures from recurring and to simplify or reduce maintenance tasks.



11

Conclusion

This document describes how FRACA can be planned and implemented at a service provider site as a process for continuously improving reliability. The method can be used throughout the life cycle of the equipment - during in-house tests, field tests, and production/operations.

FRACA 1 document helps in FRACA 2 for Corrective actions implementing and analyzing to prevent further recurrence of failures of the systems / LRU’s.



12

Reference

Current project experience working as Technical Support Engineer and supporting to Field Engineers.

ATA Common Source Data Dictionary (CSDD) which includes the World Airlines Technical Operations Glossary (WATOG).

Author Info

Vinayak K S, has 12 years of work experience,

which includes manufacturing, design,

development and technical support. He has

worked for HCL since 2004

Hello, I’m from HCL’s Engineering and R&D Services. We enable technology led organizations to go to market with innovative products & solutions. We partner with our customers in building world class products & creating the associated solution delivery ecosystem to help build market leadership. Right now, 14500+ of us are developing engineering products, solutions and platforms across Aerospace and Defense, Automotive, Consumer Electronics, Industrial Manufacturing, Medical Devices, Networking & Telecom, Office Automation, Semiconductor, Servers & Storage for our customers.

For more details contact [email protected]

Follow us on twitter http://twitter.com/hclers and our blog http://ers.hclblogs.com/

Visit our website http://www.hcltech.com/engineering-services/

About HCL

About HCL Technologies HCL Technologies is a leading global IT services company, working with clients in the areas that impact and redefine the core of their businesses. Since its inception into the global landscape after its IPO in 1999, HCL focuses on 'transformational outsourcing,' underlined by innovation and value creation, and offers integrated portfolio of services including software-led IT solutions, remote infrastructure management, engineering and R&D services and BPO. HCL leverages its extensive global offshore infrastructure and network of offices in 26 countries to provide holistic, multi-service delivery in key industry verticals including Financial Services, Manufacturing, Consumer Services, Public Services and Healthcare. HCL takes pride in its philosophy of 'Employee First, Customer Second' which empowers our 77,046 transformers to create a real value for the customers. HCL Technologies, along with its subsidiaries, had consolidated revenues of US$ 3.5 billion (Rs. 16,034 crores), as on 30 June 2011 (on LTM basis). For more information, please visit www.hcltech.com

About HCL Enterprise HCL is a $6 billion leading global technology and IT enterprise comprising two companies listed in India - HCL Technologies and HCL Infosystems. Founded in 1976, HCL is one of India's original IT garage start-ups. A pioneer of modern computing, HCL is a global transformational enterprise today. Its range of offerings includes product engineering, custom & package applications, BPO, IT infrastructure services, IT hardware, systems integration, and distribution of information and communications technology (ICT) products across a wide range of focused industry verticals. The HCL team consists of over 85,000 professionals of diverse nationalities, who operate from 31 countries including over 500 points of presence in India. HCL has partnerships with several leading global 1000 firms, including leading IT and technology firms. For more information, please

visit www.hcl.com

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