FRACAS Analysis

[octane]

What exactly is Failure Report Analysis & Corrective Action System (FRACAS), and where it is used when compared to FMEA?

[tiror]

FRACAS happens only after a failure is happened. The phase is entirely different, happens once we are in operation, and face a failure. FMEA application is to avoid a failure, analyze carefully what can actually happen and result into something unacceptable. FMEA is preferred at design stage where all the failure modes are identified, and effects are analyzed.

[octane]

Do you have any case done with FRACAS, just for reference purposes?

[tiror]

Actually it stays very simple.
Just taking an example of a centrifugal pump high vibration and abnormal noise during operation.
Start listing down like;
Operational Impact: Reduced pump efficiency and risk of seal failure
Immediate Action Taken: Pump isolated and standby pump started
Root Cause Analysis Method: 5-Why Analysis
Root Cause Identified: Bearing lubrication failure due to blocked grease line
Corrective Action: Replace bearings and clean lubrication line
Preventive Action: Add periodic lubrication inspection and install grease filter
Responsible Department Maintenance
Target Completion Date: 2026-02-20
Actual Completion Date: 2026-02-18
Status: Closed
Lessons Learned: Lubrication monitoring is critical for rotating equipment reliability

See how can intensely this technique if applied frequently can help.