What's a Function and what's Functional Failure?

Understanding Functional Failures in Helpdesk and Incident Management: A Guide by Infizo Desk

In the realm of asset management, understanding the expected functions and potential functional failures of equipment is crucial for establishing effective maintenance programs. A function defines what a piece of equipment is supposed to do, and the level of performance expected. Functional failures, however, describe conditions that prevent equipment from operating as intended, thus hindering its optimal performance. By recognizing these elements, businesses can significantly improve their maintenance strategies and overall asset performance.

Learning the Nuances of Failure in Function

Organizations often overlook the subtle signs of equipment failure, viewing it as an "if" situation rather than a continuous possibility. The common mindset is that if a machine is operational, there's no cause for concern, and only when it breaks down is it considered a failure. This reactive approach leads to inefficient maintenance practices and unplanned downtimes.

However, the reality should be different. Functional failure should not only be identified when complete breakdowns occur but should also consider minor issues that deviate from normal functioning. The definition of "normal" can vary across different employees, leading to inconsistencies in understanding equipment operations. This discrepancy underscores the importance of clearly defining functional standards and recognizing deviations as potential failures.

Functional Failure Example

To illustrate, consider a piece of equipment designed to produce 200 grams of output in 10 seconds, with a tolerance of plus or minus 10 percent. Several functional failures could be identified in this scenario, such as irregular output, where the equipment produces less or more than the specified range. These deviations from expected performance are considered functional failures and should be addressed promptly.

To manage these issues, sensors can be integrated to monitor output levels and alert the relevant personnel when deviations occur. This proactive approach allows for timely interventions and helps maintain the equipment's efficiency and reliability.

Further Steps: Creating a Condition Monitoring Program

Once functional failures for all assets are understood, the next step is to establish a comprehensive condition monitoring program. This program should involve regular monitoring and analysis of equipment performance to detect patterns in functional failures. Anticipating these failures before significant damage occurs allows for the implementation of predictive maintenance strategies, which can prevent extensive downtime and costly repairs.

Documenting functional failures throughout the lifecycle of an asset—from procurement to disposal—is essential. This documentation enables informed decision-making and the development of targeted maintenance actions. For example, categorizing failures based on severity can help prioritize responses. In cases where output significantly deviates from expected standards, a complete shutdown may be necessary for thorough repairs. However, minor deviations might be addressed without halting operations entirely.

Conclusion: The Importance of Analyzing Functions and Functional Failures

Implementing a thorough understanding of functional failures into maintenance practices ensures that sudden equipment breakdowns are minimized. This proactive approach allows organizations to maintain optimal function and efficiency. It is vital for organizations to engage with all employees who interact with the machinery, compiling a comprehensive list of all asset functions and potential failures. This list should include hidden failures that may not be immediately apparent.

Moreover, safety, environmental risks, and health considerations should always be prioritized. By establishing clear performance standards and regularly reviewing them, organizations can quickly identify when equipment is not operating correctly. This knowledge is key to determining the most effective maintenance programs for each asset, ensuring long-term reliability and safety.

Frequently Asked Questions (FAQs)

What is a functional failure in equipment?

A functional failure occurs when equipment cannot perform its intended function to the required standard. This could be due to complete breakdowns or minor deviations from normal operation.

Why is it important to monitor functional failures?

Monitoring functional failures is crucial because it allows for early detection of issues, preventing significant damage and unplanned downtime. It also enables the implementation of predictive maintenance strategies, which can save costs and extend the equipment's lifespan.

How can organizations effectively manage functional failures?

Organizations can manage functional failures by creating a detailed condition monitoring program, documenting functional failures throughout the asset lifecycle, and categorizing failures based on severity. Engaging with all relevant employees to understand equipment functions and potential failures is also essential.