Original Date: 04/20/1998
Revision Date: 01/18/2007

Previously, ITT Aerospace/Communications Division (A/CD) used a labor-intensive system for handling failures, analyses, and corrective actions of units. Documentation consisted of paper travelers for unit configurations; log sheets for test failures; and failure report and analysis forms for failure causes. This information was then compiled and manually entered into a database. Reliability personnel used this database to perform reliability trend analyses, identify critical failures, and develop corrective actions. In addition, the Failure Review Board manually tracked pattern failures and corrective actions. This time-consuming system lacked flexibility, was difficult to control, offered no relationship between configuration histories and failure reports, and failed to keep up with production increases. ITT A/CD resolved this situation by developing the Failure Reporting, Analysis, and Corrective Action System (FRACAS).

The FRACAS is an automated system. Unit configurations are now entered into the computer system by scanning a barcode, and valid part numbers are loaded by reference designator from released parts list. Since test stands are tied into the system, all failures will automatically cause a failure report to be generated. If an open reject exists on a unit, the next automated test cannot be performed. In addition, the final test program will flag any missed tests. Reliability personnel use the FRACAS database and programs to automatically generate trend information and failure percentage rates.

Since implementing the FRACAS, ITT Aerospace/ Communications Division reduced its data entry and analysis time from several weeks to a few seconds. In addition, the company eliminated the need for manual data entry; established a relationship between configuration histories and failure reports; and can capture accurate failure history data.

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