II. A. Basic Concepts Quiz
I. C. Ethics, Safety, and Liability Quiz
I. B. Reliability Program Management Quiz
I. A. Strategic Management Quiz
Discussion Forums Introduction
You have Questions
Questions about the material, about specific concepts, tools or techniques. If anything is not clear in the course you could spend hours reading, researching, and sorting out a solution. Or, you can post your question to a discussion forum and in a few hours, maybe a day, get back on track with learning the course material.
Discussion Forum Options
You have many options given the many platforms and sites discussing reliability engineering. But, specific to this course there are two good options.
First, a private discussion forum just for those enrolled in this course on Accendo Reliability.
The private forum provides a convenient and safe environment for you to ask any question you have concerning the body of knowledge or the course. Please also add comments, ideas, and suggestions to improve the course.
I’ll be monitoring the private discussion forum and providing responses or finding responses as soon as I can. I tend to check at least daily and have it set up to alert me via email with any new posting. Hopefully, you and other students will chime in to help each other, too. That is one of true benefits of a private forum.
Private CRE Preparation Discussion Forum
Second, a public discussion group, the Linkedin CRE Preparation group.
It is free (need to be a member of Linkedin) and is a great place to post a question about the CRE body of knowledge or the exam that over 500 group members may see your note. Typically for a good question, you may start a discussion or receive a couple useful responses to help you resolve the question.
Public Linkedin CRE Preparation Group
So, you have a couple of options to find the support you need to resolve your questions or open a discussion on a topic of interest.
Plus, you can always just send me (Fred Schenkelberg, fms@accendoreliability.com) an email directly and I’ll respond as soon as I possibly can (generally within a day, sometimes longer depending on what else is happening around here.)
Exam Day Bonus
VII. C. 2. Failure Reporting, Analysis, and Corrective Action System
VII. Data Collection and Use
C. Failure analysis and correction
2. Failure reporting, analysis, and corrective action system (FRACAS) (Apply)
Identify reporting, analysis, and corrective action system (FRACAS) demonstrate the importance of a closed-loop process that includes root cause investigation and follow up.
It is a process that starts when a failure occurs and ends when confirmed fixed.
Additional References
FRACAS (article)
Quick Quiz
1-66. Arrange the following failure data steps in the proper sequence from start to finish.
I. Verify the failure.
II. Report the fail.
III. Investigate the failure.
IV. Identify and control the failure.
V. Provide corrective action and follow up.
(A) I, III, IV, II, V
(B) II, I, IV, V, III
(C) IV, II, I, III, V
(D) IV, II, I, V, III
(C) IV, II, I, III, V
In part this is common sense as is a systematic failure reporting and corrective action system (FRACAS). The basic steps in a closed loop FRACAS may include:
- Identify a problem
- Control or contain the problem (also safety steps)
- Report the failure
- Log any associated data
- Conduct failure analysis
- Determine and implement short and long term corrective/preventative actions
- Determine effectiveness of corrective actions, monitor preventative actions.
1-72. Identify all the aspects of a comprehensive failure analysis and corrective action feedback loop.
I. determining what failed
II. determining how the item failed
III. determining why the item failed
(A) I and II only
(B) I and III only
(C) II and III only
(D) I, II, and III
(D) I, II, and III
The question is asking you to judge each option on whether it is part of a FRACAS or not. They all are, not the list is not all encompassing. The basic steps in a closed loop FRACAS may include:
- Identify a problem
- Control or contain the problem (also safety steps)
- Report the failure
- Log any associated data
- Conduct failure analysis
- Determine and implement short and long term corrective/preventative actions
- Determine effectiveness of corrective actions, monitor preventative actions.
1-74. Identify all the correct statements concerning failure data collection, analysis, and corrective action (FRACAS).
I. FRACAS is a requirement of MIL-STD-785.
II. FRACAS should be conducted by competent staff using a computer.
III. FRACAS always pays for itself in the long run.
(A) I only
(B) II only
(C) I and III only
(D) I, II, and III
(A) I only
Being familiar with MIL-STD-785 is essential here to know this answer. On the other and the two other options can be logically ruled out. FRACAS does require compentent staff, yet does not require a computer (in some projects a database application is certainly helpful). Also, the word “always” limits the correctness of the last option.
1-75. For a FRACAS to be effective, how many failures should be allowed to pass before corrective action should be taken?
(A) 1
(B) 2
(C) 10
(D) It depends on the expected reliability.
(A) 1
A failure is “gold”, it is the product telling you that there is an opportuntity to prevent future problems. The key word in this question is “should” as in practice for a complex system, given the volume of failures considered, not every issue will receive attention or corrective actions. The aim to do so, none the less.
1-78. Identify the most important role of a failure reporting and corrective action system.
(A) determining responsibilities for failures
(B) identifying, investigating, and analyzing failures
(C) recording costs associated with corrective action
(D) defining the goals of the FRACAS team
(B) identifying, investigating, and analyzing failures
Of the options (B) is best. (A) if done to assign ‘blame’ should not be part of a FRACAS. (D) is a good thing to do, yet not necessary as part of a FRACAS. I would say the primary role of FRACAS is to effectively implement correction/preventative actions that reduce failures rates. (B) has essential elements for an effective FRACAS.
VII. C. 1. Failure Analysis Methods
VII. Data Collection and Use
C. Failure analysis and correction
1. Failure analysis methods (Understand)
Describe methods such as mechanical, materials, and physical analysis, scanning electron microscopy (SEM), etc., that are used to identify failure mechanisms.
Determining the root cause permits the team to find and implement the right solution. It often takes a very careful examination of materials, assemblies, and processes.
Additional References
Electronics Failure Analysis Done the Right Way (article)
SOR 028 Failure Analysis Best Practices (podcast)
Failure Analysis: The Key to Learning From Failure (article)
Quick Quiz
Failure Analysis and Correction Introduction
VII. C. Failure Analysis and Correction
VII. B. 3. Measures of Effectiveness
VII. Data Collection and Use
B. Data Use
3. Measures of effectiveness (Evaluate)
Use various data analysis tools to evaluate the effectiveness of preventive and corrective actions in improving reliability.
Once an action or experiments is set in motion, you need a way to determine if it’s working or not.
Additional References
Quick Quiz
VII. B. 2. Preventive and Corrective Actions
VII. Data Collection and Use
B. Data Use
2. Preventive and corrective action (Evaluate)
Select and use various root cause and failure analysis tools to determine the causes of degradation or failure, and identify appropriate preventive or corrective actions to take in specific situations.
Let work to avoid issues and if something does fail take steps to learn and prevent future similar failures.
Additional References
Two Approaches to Reliability (article)
Quick Quiz
1-64. Of the following tools, which is not classified as a structured root cause analysis tool?
(A) Failure mode and effects analysis
(B) 7D, 8D, or 9D problem solving
(C) management oversight and risk tree analysis
(D) human performance evaluation system
(A) Failure mode and effects analysis
FMEA is a risk identification and prioritization tool and may be a useful tool as part of root cause analysis.
8D is Eight Disciplines (7D and 9D are variations) a structured problem solving process developed and used widely in the automotive industry and beyond.
Management oversight and risk tree analysis is “a comprehensive analytical procedure that provides a disciplined method for determining the causes and contributing factors of major accidents.” [Mort User’s Manual US Department of Energy, SSDC-4 Revision 3, February 1992 http://www.osti.gov/scitech/servlets/purl/5254810/]
Human performance evaluation system is “a resource for U.S. Nuclear Regulatory Commission inspectors to use when reviewing licensee problem identification and resolution programs with regard to human performance.” [ The Human Performance Evaluation Process: A Resource for Reviewing the Identification and Resolution of Human Performance Problems (NUREG/CR-6751) http://pbadupws.nrc.gov/docs/ML0209/ML020930054.pdf]
1-65. Arrange the following action steps in a root-cause analysis in proper sequence from start to finish.
I. Define and Implement Corrective Actions.
II. Develop Interim Containment Plan.
III. Define and Implement Corrective Actions.
IV. Verify Permanent Corrections.V. Describe the Problem.
(A) I, V, II, IV, III
(B) V, I, II, III, IV
(C) V, II, IV, III, I
(D) V, IV, II, I, III
(C) V, II, IV, III, I
The phases are from the 8D or eight disciplines model, which is a structured problem solving process. The disciplines are:
D0: Plan: Plan for solving the problem and determine the prerequisites.
D1: Use a Team: Establish a team of people with product/process knowledge.
D2: Describe the Problem: Specify the problem by identifying in quantifiable terms the who, what, where, when, why, how, and how many (5W2H) for the problem.
D3: Develop Interim Containment Plan: Define and implement containment actions to isolate the problem from any customer.
D4: Determine, and Verify Root Causes and Escape Points: Identify all applicable causes that could explain why the problem has occurred. Also identify why the problem was not noticed at the time it occurred. All causes shall be verified or proved. One can use five whys or Ishikawa diagrams to map causes against the effect or problem identified.
D5: Verify Permanent Corrections (PCs) for Problem will resolve problem for the customer: Using pre-production programs, quantitatively confirm that the selected correction will resolve the problem. (Verify that the correction will actually solve the problem.)
D6: Define and Implement Corrective Actions: Define and Implement the best corrective actions.
D7: Prevent System Problems: Modify the management systems, operation systems, practices, and procedures to prevent recurrence of this and all similar problems.
D8: Congratulate Your Team: Recognize the collective efforts of the team. The team needs to be formally thanked by the organization.
1-69. When trend analysis is used in a corrective action system, what aspect is most important?
(A) short-term problem status
(B) cyclical components of a time series
(C) long-term movement
(D) seasonal variations
(C) long-term movement
Keep in mind the purpose of corrective action is to systematically and conclusively solve problems and keep them from happening in the future. A long term solution is the goal.
1-70. In is a structured corrective action approach, in the problem definition segment there is a reference to “is data” and “is not data”. This is a technique advocated by:
(A) Kaoru Ishikawa
(B) Kepner-Tregoe
(C) Deming’s PDCA cycle
(D) Kaizen principles
(B) Kepner-Tregoe
“Is”/”Is Not” is a method to clearly define a problem by describing the problem boundaries using what issues/elements are part of the problem and which are not.
