ICQI2002

Pakistans Seventh International Convention on Quality Improvement October 26-27, 2002 , at Marriott Hotel, Karachi

A Yielding Technical Investigation is also a Quality Contribution

Author
Wing Commander (Retd) Nadir Ali Shah Principal PIA Training Centre Karachi - Pakistan

E-mail: khigtpk@piac.com.pk

Pakistans Seventh International Convention on Quality Improvement (ICQI2002)

A YIELDING TECHNICAL INVESTIGATION IS ALSO A QUALITY CONTRIBUTION

by

Wing Commander (Retd) Nadir Ali Shah Principal PIA Training Centre Karachi - Pakistan

PRELUDE

e work in technologically advanced environment which has enabled us to provide required output from minimum input. The tools & machines available at our disposal are expensive and require total productive maintenance for optimum production efficiency. And yet, these machines, equipment occasionally fail demanding a technical investigation which yields or, unveils the cause. And that is indeed a contribution towards improved quality. This paper proves the fact logically. THE PURPOSE OF A TECHNICAL INVESTIGATION 2. As we operate the production system with utmost care, we encounter less equipment downtime which means delivery schedules will consistently be met. A failure should ultimate be targeted at finding the true causes. The purpose of the technical investigation is to device methods which would prevent recurrences. However, this is not any easy task. From the Reliability and the Maintainability Engineering view, it is pertinent to examine and monitor the production system on a continuous basis, so that failures are identified and arrested before they occur. The need to arrange a technical investigation will, either not occur, or be minimized. LIFE CYCLE OF A PRODUCTION SYSTEM 3. Every production system is seen as a combination of machines and processes with a finite life-cycle. Whether it is an aeroplane, a machining centre, a cement plant, or, a car; all have an aging sequence. The famous bath-tub-curve tells us how the brand new equipment enters a service chain with almost no failures in early age until it is not economically viable to retain it any more. But here we wish to develop a simple life-cycle model to illustrate uptime and downtime.

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Pakistans Seventh International Convention on Quality Improvement (ICQI2002)

Downtime

Dt1

Dt2
Bath-Tub Curve

Dt3

Downtime consumed by Tech. Investigation

Failures
Planned Inspection Random Failure

Failure as a result of Major Breakdowns (Compulsive use)

Time in service

(T)

Equipment is inducted

(T0 )

(I1 )

(F1 )

Tn

(F2 ) Fig 1

4. Whenever planned inspections are carried out, downtime like; Dt1 are caused. These are unavoidable. With good planned maintenance invoke, small random failures, F1 will occur, provoking downtimes as depicted by Dt2. As we continue with our production system, we tend to become complacent with its reliability. We ignore squeaky noise, high-oil consumption, blunt tools, loose tool-posts, inappropriate torques, poor heat-transfer and, submit to tight schedules and production deadlines. So, we end up with accidents. Technical Investigations are ordered to find out the true cause(s) of such major failures. As depicted at F2, the investigating team, will consume a downtime Dt3. And this may not still restore the machine/equipment back to production state; may be due to a breakdown which is irreversible. 5. The effect of improved technology, the Total Productive Maintenance and the latest shop-floor emphasis on Health, Safety & Environment (HSE), has considerably reduced the onset of catastrophic failures. However, in large production enterprises, like; PIA, PAF, Process Industries, we are still called upon to formally investigate a technical failure. Thus, Lifecycle Time = Scheduled Inspection Downtime + Random failures Downtime + Technical Investigation downtime (caused by compulsive use or major breakdowns) i.e. T LS = Dt1 + Dt2 + Dt3 + U t (the Uptime)

While planned Inspections, Is, generate DtI = Dt1 the random failures F1 generate DtF = Dt2 The Dt1 are visible and subject of continuous improvement, the Dt2 are invisible.

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Pakistans Seventh International Convention on Quality Improvement (ICQI2002)

QUALITY AS ENABLER 6. A Continuous Improvement Doctrine (CID) invoke at any shop-floor, Airline PAF, process industry available in the shape of respective Quality Standards, enable us to improve upon Dt1 & Dt2 Q 1 Dt1 1 Dt2

7. Since random failure downtime Dt2 is identifiable through Mean-time-to-repair; MTTR, we can say that a good surveillance offered by a Quality System invoke, will not only minimize MTTR but may also intelligently reduce the planned maintenance inspection downtime Dt1.

Life cycle Time (TLS)

Planned Maintenance Downtime (Dt1 )

Random Failure Maintenance Downtime (Dt2 )

Assuming no major breakdowns (Dt3 ) Fig 2 Combining Eq.1 and Eq.2, we can say that Q = J Dt1 + Dt2 3

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Pakistans Seventh International Convention on Quality Improvement (ICQI2002)

8. When human endeavors in terms of focused attention or joint attempt, J, is available on a continuous scale throughout the system operating life, Dt1 and Dt2 will be reached to minimum because J will stay imposing as a big numerator in the equation of downtimes. The quality Q, or the productivity p will become synonymous. We will have all the uptime, Ut, to stay competitive. THE MAJOR BREAKDOWNS / ACCIDENTS 9. As we would not like to fly an aged aircraft endlessly, so should be the case with any other man-made production system. We can not continue to expect our production system produce the good output without endangering ourselves and deprive the society of the benefit of the prosperity. So, we must change the aged production system before a catastrophic failure occurs. 10. The continuous improvement doctrine (CID) or, the Quality system invoke, will enable us to change when it is due for change. Should we ignore the warning signs the major accidents become highly probable.

Life cycle Time (TLS)

Planned Maintenance Downtime (Dt1 )

Random Failure Downtime (Dt2 ) Fig 3

Major Breakdowns Downtime (Dt3 )

A YIELDING TECHNICAL INVESTIGATION 11. A good technical investigation yields the true cause of failure. The effects of a major incidence are, to initially inflict on our production system; a downtime Dt3 and then render us almost incapacitated on that system which is not available for the production. A redundancy, may help us to continue with the business but we will nevertheless be demoralized until we overcome the shock. 12. A technical investigation is basically a reactive approach to identify and then contain the recurrence of failure. Yet, professionally-done the technical investigation eliminates Downtime Dt3 from showing up again. The quality system available and the joint effort J

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Pakistans Seventh International Convention on Quality Improvement (ICQI2002)

inherent in the continuous improvement doctrine (CID), makes major accidents in the longterm a non-entity. So, J Dt3 limit = 0 Q (Quality)

13. Quality Q, is therefore, a dominant contributing factor in the wealth of an enterprise. A yielding Tech. Investigation facilitates quality to stay invaluable. It makes quality Q infinitely available, giving us all the uptime Ut that we want to stay upfront in the business. Wing Commander (R) Nadir Ali Shah Principal PIA Training Centre Tel: 92-21-4577832 Fax: 92-21-45794363 e-mail: khigtpk@piac.com.pk

16th October, 2002

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