Try this Tool Box Talk to educate your maintenance staff on Failure Modes. Great way to introduce them to Failure Modes and what I call a "Failure Mode Driven Strategy".Great introduction to how maintenance strategies (PM/PdM) are focused on “prevention or early identification of specific failure modes”.

1. Failure Modes Driven Strategy
“MONTHY TRAINING TOPICS – Journey to World Class”
This training is designed for a maintenance manager or reliability manager
to train their staff in known best practices
Failure Modes Driven Strategy is defined as The Objective: (Early ID of a Failure Mode)
maintenance strategies (PM/PdM) focused on
“prevention or early detection of specific 1st: To know how specific equipment fails (failure
failure modes”. modes and their causes) and is typically identified on
critical equipment first
A Failure Mode is the condition that exists that will 2nd: To detect a failure mode early enough to
cause a Functional Failure. correct the Defect (abnormality) before the
equipment fails. An example is high vibration with a
A Functional Failure is the inability of an item (or severity of Low. Planning the job effectively,
the equipment containing it) to meet a specified executing the job using repeatable procedures with
performance standard. specifications/standards. (see PF Curve – Early
Detection)
Example: Motor bearing is failing caused by lack of
lubrication. A Functional Failure would be if a roller
bearing did not rotate. If the bearing is not changed
before it stops rotating other damage within the
motor and coupling could occur.
The Objective: (Prevention of a Failure Mode)
1st: To know how specific equipment fails (failure
modes and their causes) typically on critical
equipment first.
2nd: To prevent a failure mode from occurring
through known best practices such as the right
lubrication at the right time.
3rd: Scheduling the corrective work without
3rd: Equipment runs failure free longer because of
interrupting operations. Corrective work
the application of best lubrication practices.
conducted during “Windows of Opportunity”.
References: Modern Approach to Risk Management Article
FRACAS Slide Presentation
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