Next, check your plant's system that tracks equipment failures.
You should be able to see the frequency of the failures and can then
ask questions, such as does this failure occur in a periodic time-
frame or a specific time of day/year, i.e., every three months, only at
night, in the winter, etc. If the analysis is performed early enough,
you may be able to observe the equipment while it is still running
and on the verge of failing, e.g., a leaking pump that has not yet
been changed. You can then evaluate the equipment's running
conditions, some of which may be a source of damage.
In addition, always inspect the equipment when it is disassembled
to determine which components failed and to look for signs of
damage not visible from the outside. These might include indications
of overheating, lack of lubrication, misalignment and vibration.
Be sure to take pictures and document everything. Use a note-
book or tablet and a digital camera. You can't remember everything
that happened or exactly how it looked, especially if you are writing
the report days or weeks later. A photograph is also one of the best
ways to show how bad the failure was to those who did not see it.
Writing Reports
When writing the report, remember that you want readers to be
able to understand and follow everything being presented. Avoid tech-
nical words or overly complicated terminology. Keep it simple and stick
to the facts. The report may be read by a large number of people who
do not have the same experience or specialized knowledge that you do.
Do not include anyone's name. Instead, use only job titles unless
you need to assign a name to the solution. The report should not
become a blame-game or finger-pointing exercise. You also do not
want to alienate any individuals because they may not offer you
information the next time you are investigating a failure.
Include the photographs taken while gathering information. If
someone does not believe a condition or problem exists, there is no
denying it when you have a picture of it. Be sure to write captions to
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Photographs provide the best way to show the magnitude of a failure.
