8.2.1 Failure Reporting,
Analysis and Corrective Action System (FRACAS)
The purpose of FRACAS is to collect failure data, provide
procedures to determine failure cause, and document corrective action taken.
It requires the contractor to have a system that collects, analyzes and
records failures that occur for specified levels of assembly prior to
acceptance of the hardware by the procuring activity.
Failure reporting and analysis is necessary to ensure that a
product’s reliability and maintainability will be achieved and sustained. The
FRACAS program is a key element in “failure
recurrence” control for newly developed and production equipment. A FRACAS
program must include provisions to ensure that failures are accurately
reported and thoroughly analyzed and that corrective actions are taken on a
timely basis to reduce or prevent recurrence.
An in-plant FRACAS determines the
basic causes of failures associated with design or manufacturing, and provides
a closed-loop method of implementing corrective action. The system should
emphasize the investigation and analysis of all failures, regardless of their
apparent frequency or impact, and classification of failures according to
categories of design/part procurement, manufacture, or assembly and
inspection. It is well known that the most economical repair of a failure
occurs at the component part level. A conventional rule of thumb is that a
repair action at the subassembly level costs an order of magnitude more than
at the part level, and a repair at the product level costs an order of
magnitude more than a repair at the subassembly level.
Data on electronic equipment
malfunctions can be obtained from any or all of the following types of data
(1) Design verification
(3) Production tests