XFRACAS is a highly configurable, web-based Failure Reporting, Analysis and Corrective Action System (FRACAS).
Depending on how you configure your implementation, this can include incident/failure reporting, failure analysis on returned parts, part tracking for serialized systems, root cause analysis, team-based problem resolution and tracking the completion of assigned actions.
- Easy web access for collaboration and deployment across multiple sites, suppliers and customers
- Highly configurable to fit your organization’s specific processes
- Flexible, scalable and able to grow with your needs
- Innovatively bridges the gap between addressing individual failures and managing efforts to understand, contain and resolve the underlying problems
- Streamlines incident reporting and problem resolution activities
- Captures data for reliability, quality, safety, risk management and other analyses
- Builds a “knowledge base” of lessons learned that can be shared throughout the organization
- Provides a closed-loop system for managing corrective actions
- Contributes to design improvements, faster product release, better service and enhanced customer satisfaction
Highly Configurable to Meet Your Needs
XFRACAS can be implemented with a single entity (where all users share the same configuration settings and data) or with multiple entities (where different business units have their own separate settings, data and permissions). You can:
- Turn features on or off
- Configure built-in fields and preferences
- Create your own custom fields
- Define security groups for different access levels
The optional Go-Live Service includes an on-site visit from an XFRACAS implementation specialist, training for up to 10 “power users” and assistance to configure your implementation to meet your particular processes and needs.
Personalized Portal for Each User
For each user, the XFRACAS home page provides a customizable, at-a-glance view of all the issues you need to work on, such as:
- Actions you need to complete
- Incidents, Problems or Projects you need to work on
- Reports that you frequently use
- Global or local announcements and links
Incident (failure) Reporting
In XFRACAS, each “incident” deals with a single instance of a failure, suggestion or other event so you can track how it was addressed and capture sufficient detail for reliability and related analyses.
- Fully describe the incident and link or attach relevant files
- Identify the responsible part(s) and notify owners
- Record the operating time/usage when the failure occurred
- Assign responsibility for specific actions and track their completion
Capture Findings from Failure Analysis on Returned Parts
If parts are removed/replaced and returned for more in-depth failure analysis, XFRACAS can capture additional details, such as the RMA number, sales order number or work order number, findings from the visual inspection and detailed analysis, fault history or sensor data, or other test results.
Part tracking for Serialized Systems
If you are tracking specific systems by serial/TAG number, XFRACAS can capture a detailed history for each piece of equipment, such as:
- Installation details
- Reported incidents
- Operating time or usage
- Exact system configuration as parts are repaired and replaced over time
- Current status of the system (running, waiting for part)
Track Completion of Assigned Actions
Throughout XFRACAS, you can assign actions to system users and track the progress and completion.
- Fully describe the assignment and link or attach relevant files
- Automated e-mail notifications for the person responsible and other users who need to monitor or approve the actions taken
- Reports and charts to track progress and completion
Root Cause Analysis and Team-Based Problem Resolution
In XFRACAS, a “problem” is a larger issue that may require a team-based approach to understand the root cause and implement improvements that will prevent similar issues from occurring again in the future.
- Use any method from 4 to 8 steps (8 Disciplines, Six Sigma DMAIC, DCOV, CAPA)
- Fully describe the problem and link or attach relevant files
- Link to all related incident reports
- Capture findings from root cause analysis
- Assign responsibility for specific actions and track their completion
- Track review and sign-off by a Failure Review Board (FRB)
Track Stats for a Group of Incidents and Problems
In XFRACAS, a “project” groups multiple problems together and provides quick access to high-level statistics for all associated incidents and problems, such as:
- How many issues are open/closed?
- How long has each issue been in the system?
- What is the status for open issues?
Flexible Queries and Reports
XFRACAS provides a large selection of built-in “standard” reports as well as a flexible Report Builder to create your own custom reports or run custom SQL statements. Tabular results are displayed directly in the web browser, where it is easy to:
- Filter and sort within the results
- Export to *.xlsx, *.rtf, *.csv, *.pdf
- Link, “watch” and share with other users
Charts, Dashboards and Custom XSLT
XFRACAS provides built-in tools to create graphical charts for any set of results.
- Bar charts, pie charts, area charts, step charts, scatter charts, line charts
- Highly customizable
- Full drill-down capability
- Configurable dashboards
For even more customized output, you can:
- Output results to XML, which can be used as a web-based data source in a variety of third-party reporting tools (e.g., Get External Data > From Web feature in Microsoft Excel)
- Define your own custom XSLT style sheets (Extensible Stylesheet Language Transformations)
Extract Data for Reliability Analysis
The incident reporting process in XFRACAS can result in clean, usable data for reliability analysis in ReliaSoft Weibull++/ALTA and RGA.
If data entry is based on fully serialized systems, you can extract complete time-to-failure and suspension data by system, subsystem and component.
Integration with FMEAs
When your organization uses ReliaSoft XFMEA, RCM++ or RBI for failure modes and effects analysis (FMEA), you can:
- Synchronize the generic system configurations (“bills of materials”)
- Use an FMEA to define the failure modes that can be assigned to incidents, problems or failure analysis reports in XFRACAS; or use failure modes defined in XFRACAS as input to an FMEA
- Use the quantity of incidents, problems or failure analysis reports in XFRACAS as input to calculate RPNs in an FMEA
Use XML to Import or Export Data From External Systems
XFRACAS uses XML to import or export data to other external systems, such as an asset management system or work order tracking system.
XFRACAS includes a Windows service that runs on the web server and can be configured to automatically import XML files on a scheduled basis. Alternatively, you can develop your own custom application to extract data into the required format and use the XFRACAS web service to trigger the imports.
For “bill of materials” data, XFRACAS also supports import via Excel (*.xlsx) template, or synchronizes with the system hierarchies in XFMEA, RCM++ or RBI.
Implement XFRACAS and SEP Together
The Synthesis Enterprise Portal (SEP) provides web-based access to key analysis and project management details from ReliaSoft desktop applications such as Weibull++, ALTA, RGA, XFMEA and BlockSim, as well as the XFRACAS actions and incidents that are relevant for each user.
SEP also provides a way to share selected data and results with customers and suppliers who don’t have direct access to your XFRACAS implementation.
Scalable and Distributable Web-Based Architecture
Whether you have 15 users or 15,000 users, XFRACAS is scalable and easy to distribute with no client software to install for each user. Your team can access the site with their preferred web browsers (such as Internet Explorer, Chrome, Firefox or Safari) from a variety of devices (laptop, tablet, etc.).
The website can be public or private, encrypted or unencrypted, using Windows Authentication or Single Sign-On (SSO).
If you plan to host the database and website on the same server, you will need:
- Windows 2008 R2 or newer
- .NET 4.6
- IIS with support for serving ASP.NET
- SQL Server (2008 or newer) or Oracle (10g or newer)
Data Encryption and Secure Communication
In both Oracle and SQL Server, your organization can choose to enable Transparent Data Encryption (TDE) on your database server (“data at rest”). For an Oracle implementation, you can also configure the database to require encryption for the connection between the application and the database (“data in transit”).
New in Version 2018, we’ve added the option to encrypt communication between the application and a SQL Server database.
Web Service to Import Data
If you have some basic programming knowledge, you can use the XFRACAS web service (“XFRACASImport”) in your own custom application. Introduced in Version 11, the web service provides a faster and more flexible way to trigger data import for specific XML files, or to process all files in the XFRACAS import queue.
New in Version 2018, the service now includes functions to insert time/usage data for serialized systems.
Custom Fields for Serialized Parts
XFRACAS uses generic System Templates to identify the parts that may be used in a system (e.g., “Bill of Materials”). If applicable, you can also use Serialized Systems to track the specific parts in a particular piece of equipment.
New in Version 2018, you can configure your own custom fields (called “details”) for serialized system parts. This provides more flexibility for equipment operators and other organizations who want to define the general type of component in the template and capture more specific details for the part used in a particular system (such as the part number, man tag, supplier serial number, MAC address, etc.).
If you configure XFRACAS to track incidents and part repairs/replacements for specific serialized systems, you will be able to capture time/usage data that can be used for reliability data analysis. There will always be one primary metric and you can choose to enable up to two additional fields if desired (e.g., hours, miles, kilometers, cycles, etc.). In Version 2018, the following features now support all three metric fields.
- Serialized Systems – When you define a new serialized system, you can enter the starting age if the part was previously used before being added to the system.
- Repair and Replace Parts – For serialized incidents, you can enter the usage of the failed part at the time when it was repaired/replaced, if it is different than the system. You can also enter the starting age of the replacement part if it was previously used.
- Extract Data to Weibull++/ALTA or RGA – When you use the Synthesis Data Warehouse (SDW) to extract data for analysis in ReliaSoft desktop applications, you can choose any of the metrics captured in XFRACAS.
Custom Fields for Data Extracted to Weibull++/ALTA or RGA
In the Synthesis Data Warehouse in Weibull++/ALTA and RGA, a wizard guides you through the steps to select the XFRACAS part(s) you want to analyze and specify your preferences for building a data set for life data analysis or reliability growth analysis.
The extracted data set can include standard fields such as part number, failure mode, occurrence date, etc. New in Version 2018, we’ve added the ability to include your own custom fields with any of the following “detail types”: Alphanumeric Input Box, Check Box, Company, Contacts, Currency, Date, Numeric Input Box, Users, Yes/No Button, or Select List, Administrative Controlled.
History of Changes to System Status Field
In an incident report for a serialized system, users can record the current operational status of the system (e.g., “Running,” “Down – Waiting on Parts,” etc.). This may change over time as you take steps to address the failure. Starting in Version 11.1.1, we’ve added the ability to view the history of all system statuses saved for the incident.
In Version 2018, we’ve also added the option to hide or show the System Status field in “part incidents” that are not associated with a particular serialized system.
More Info When You Retire a Template Part
If a template part is used in an incident, problem or serialized system, it can be retired but not permanently deleted. When you attempt to delete a part in Version 2018, the interface now provides information about where the part is used so you can decide whether to leave affected records unchanged (and retire the part) or remove all associations to existing records (and permanently delete the part).
“Print Preview” Enhancements
XFRACAS’s flexible Print Preview feature uses *.xslt templates to enable your organization to customize the print-ready output for incidents, problems, projects, failure analyses and customer support records. Starting in Version 11.1.3, any image files attached to the record (*.gif, *.jpg/jpeg or *.png) will display as pictures, and URL attachments will show as clickable links.
You can also configure Print Preview Detail fields that display as clickable links within the record and generate your own completely customized output based on the record’s data. For example, you can use this flexible feature to create your own dashboard of the particular metrics you’re tracking via Problem reports, or to present data captured in a particular section of your Incident reports. New in Version 2018, you can now view these links in any list of records generated from the Reports page. This saves time when you want to go directly to the specialized output without first opening each XFRACAS record.
Number of Lines for Description fields
XFRACAS provides extensive options to configure user interfaces to capture data that’s relevant for your particular products and processes. New in Version 2018, we’ve added the ability to specify the number of lines for text description fields. You can set a default height that’s appropriate for most descriptions, and also set different heights for specific fields.
Set “From” Address for E-mail Notifications
XFRACAS provides many flexible options for generating e-mail notifications to alert users when action may be required. By default, e-mails are sent from the address of the user who performed the action that triggered the notification. We’ve added the option to specify a single “From” address for all e-mails, which may be useful for implementations where XFRACAS users are both internal and external to your network.
Set “Close date” for Problems
Your organization can configure the XFRACAS Problem page to facilitate any team-based problem resolution method with 4 to 8 steps (such as 8D, Six Sigma DMAIC, IDOV, MDOV, etc.). The application tracks the completion date and approval for each step.
New in Version 2018, we’ve added the ability to set the “Close date” for the final step. This enables an authorized user to manage closed records while still maintaining correct dates for when work was performed.