Failure Analysis and RCA Flashcards

Overheated grease, bluish discoloration, and smeared rolling elements in a failed bearing most strongly suggest:

Answer: Inadequate lubrication or lubricant starvation

Heat discoloration and smearing come from metal-to-metal contact caused by poor or missing lubrication.

Evenly spaced washboard-like grooves across a motor bearing race usually indicate:

Answer: Electrical discharge damage (fluting) from shaft currents

Fluting is a regular groove pattern caused by electrical current passing through the bearing, often from VFDs.

Shallow indentations at rolling-element spacing on a bearing from equipment that sat idle near vibrating machinery are called:

Answer: False brinelling

False brinelling is wear at rolling-element spacing caused by vibration while the bearing is stationary.

Which statement best describes a 'failure mode' as used in FMEA and RCA?

Answer: The manner in which an item fails to perform its intended function

A failure mode is how an item fails, such as a bearing seizing or a seal leaking.

In a Failure Reporting, Analysis and Corrective Action System (FRACAS), what is the key purpose of closing the loop?

Answer: Verifying that corrective actions were implemented and actually prevented recurrence

Closing the loop means confirming the action worked, which is what makes FRACAS a learning system.

An RCA concludes the root cause was 'operator error.' What is the most appropriate response from a reliability leader?

Answer: Keep asking why the error happened and what system conditions allowed it

Human error is usually a symptom of deeper system issues like procedures, training, design, or workload.

Which metric best shows whether an RCA program is delivering value?

Answer: Reduction in repeat failures and related costs over time

RCA value shows up as fewer repeat failures and lower losses, not as activity counts.