Análise de falhas por meio do método fracas

Abstract

This paper discusses the analysis of failures in a sugar-alcohol plant, Raízen Energia S/A. Within this branch of industry, which is very vast in Brazil, failures are evident and must be dealt with quickly if companies are to be competitive and develop. In this sense, the aim of this monograph is to provide a foundation for failure analysis, highlighting its main methods, the tools used within them and how they were used to give rise to Raízen's failure analysis system, R-FRACAS, as well as demonstrating its application in two different real cases within the company's production process. The system is based on the FRACAS method and is structured around failure notification, failure analysis and appropriate actions. The cases studied are of different complexities and were dealt with from the beginning, when the fault is noticed, to the end, when actions must be taken to correct/prevent it. One of the cases analyzed was a problem in the decanting of juice, which resulted in the purchase of a new operational pH meter, the calibration of the industrial pH meter and the development of a route to inspect its electrodes, the development of point-by-point lessons (LPP) to ensure that the operators followed the procedures correctly, a review of the screen material of the rotating sieves and the inclusion of the decanters, more specifically their internal components, in the maintenance plan for the next harvest. In the other case, related to maintenance on a grinder, the action was summarized in the purchase of a new system for the asset, which was more modern and facilitated maintenance and control. The causes that lead to failures in a process of this magnitude are numerous, of different classes and complexities, but a good failure analysis system ensures that these are increasingly mapped, so that they can be anticipated or solved efficiently, guaranteeing the integrity of the assets, the process and the good development of the business.