How effective is Repeat failure analysis for terminal equipment’s ?

Repeat failure analysis  means analysis that  handle multiple failures within an item. In a terminal there is a failure occurring on a  same equipment  repeatedly in that particular period ( i.e.  Number of  times the same breakdown happened  which stopped the operations). As equipment failure frequently occurs, therefore a Repeat Failure Analysis is carried out.

How it is useful?

Let’s start an analysis of Quay Crane

  • How many maintenance related failure occurred ?
  • How many times there was a requirement to perform a replacement?
  • The primary thing  here is  how many times did  they fail repeatedly?

For example , in a QC there was a consistent failure every month and 15 times it has to be repaired (Refer below Fig 01 for month of July on an electrical drive) .

The failure was  of an electric drive, we need to analyse how many times a same equipment fail repeatedly in that period, how many breakdown or damage happened  that stopped the operation one after another.


Fig 01

The number of repeat failure in QC where repair has to be done is quite high,now what?

Further analysis is done and the information received  based on repeat analysis is that number of times there is a repeat failure in QC, which needs  to be  repaired  and  it was found many times its maintenance failureFurther analysis is  done in that period to know what was performed action, to understand how the problem is fixed. It was found that terminal has to repeatedly make repair on an electric drive. (Refer below Fig 02)


Fig 02

Whenever Technical  Department  find there is a repeat failure more than  acceptable limit for a particular component  in a month, they have to set-up a corrective maintenance action along with the next two Preventive  Maintenance. Reliability engineers are suppose to execute Corrective Maintenance work orders. These work orders need to be created in ERP application planned along with the maintenance,such Corrective Maintenance work order involves.

  • Conditional checks
  • Ultrasound and other high technology inspection
  • Analyse the RPM (Rotation per minute) check the circuit

(These are specific to an electric drive, for the example being considered.)

The Reliability engineer will also schedule additional Corrective Maintenance  work order for applying the decisions made out of the above analysis, which is either replacement of repeated failure( component replaced) OR a modification of the electric drive is suggested, on all such equipments within the terminal.

By looking at these analytical reports ,by doing a good root cause analysis and by referring  the number a maintenance manager can analyse why there are repeat failure which are maintenance related most of them are electrical failure & have an operational impact ,


  • Increase the bottom line(i.e. to reducing expense in future ) OR
  • Invest in training the employees on doing better maintenance related to electrical circuit and wring the equipment OR
  • Check if there is a requirement  to buy better quality spares and many more.
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Delivery Lead Time, Suppliers Lead Time analysis

In any purchasing/materials management system, the materials, delivery, supplier lead time plays a critical role for the timing and sizing of purchase order decisions. Many purchasing professionals have recognized this importance, and major efforts have been made to accurately predict lead times and to develop strategies for coping with problems created by lead time variations.

The length and reliability of lead time has a significant impact on the total cost of services, because it is important to make tools and spare parts available at right time for prompt response to breakdown, planned maintenance. The recent emergence of time-based management concept attests to this effect.

For example, the lead time length and reliability influence the capacity and manpower requirements, work load, safety stock level, and productivity

Different BI reports helps to analyze time gap between PO release date, delivery lead time, supplier’s lead time and design supply chain strategy.

The main purposes of this report are:

1) To identify and analyze the major characteristics of Supplier and Delivery lead time.

2) To review the potential impacts of supplier and delivery lead time on the system’s performance

3) To suggest several positive strategies for managing supplier and delivery lead time and to make tools and equipment’s available at right time to avoid breakdown of running assets.

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Enterprise Asset Management for Ports and Terminals

Enterprise Asset Management for Ports and Terminals

Enterprise Asset Management (EAM) Solutions, helps in gaining real time visibility into asset usage, better govern assets, manage asset lifecycle, measure and manage energy consumption and improve your return on assets.

The benefits of Enterprise Asset Management are compelling:

* Reduce maintenance costs

* Reduce production costs

* Reduce labor costs

* Increase maintenance productivity

* Help improve your enterprise asset maintenance practices

* Help you comply with applicable regulations

* Minimize equipment breakdowns

* Minimize downtime

Enterprise Asset Management should have well defined ERP processes within itself to fully manage the life cycle of asset and should provide integrated processes in Finance, Procurement, Inventory and Project.

PLAN: Align Asset Acquisitions to corporate strategy. Link each Asset to the organizational budget and Revenue to be realized.


ACQUIRE: Negotiate agreements to maximize value. Huge assets that have longer cycle should be defined as projects, thus managing capitalization with a structured approach and control.


OPERATE: Track Asset Utilization by capturing its Efficiency, Uptime, Downtime and its contribution to the “No of Moves per Hour “and the Overall TEUs achieved. Thus in turn tracking and stream lining your return on investments.


MANAGE: Implement support infrastructure and process to enhance productivity and satisfaction. Establishing a seamless communication between Operations and Maintenance, for Equipment Availability and Optimized Performance is the key to enabling higher productivity.


RETIRE: Analyze the useful life of an Asset by establishing a consolidated view of Assets Current Value, Annual Maintenance Costs and its Performance. Any asset that has an increased liability should be retired, by comparing it with the Replacement Costs.


Enterprise Asset Management in Ports and Terminal, provide uniformity and ease of use across the asset groups and maintenance locations, thus creating efficiencies and reducing operating costs. Port Authority can use the this solution to meet or exceed goals and requirements of this initiative.


EAM, optimize the work flows, funding allocations, and resource utilization resulting in enhanced organizational transparency that facilitates accurate and agile capital planning. This assists Port Authority with better decision making based upon quality information.


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