March 10, 2005
Knowledge Management Tip
Capture the expertise of retiring workers and ensure the continuing viability of your organization
Is your company concerned about retaining the enormous amount of knowledge that will soon be lost as experienced maintenance workers retire? If the answer is yes, you are not alone; capturing the expertise of retirees is an urgent challenge facing many companies today. These workers collect a wealth of knowledge during their many years on the job, but this information is almost never formally documented or transferred to others. Their expertise includes asset prioritization, asset condition and performance targets, inspection knowledge and general know-how pertaining to the maintenance of critical assets. Turning in the little black book as they walk out the door just doesn’t cut it.
Companies that understand this issue are turning to asset reliability software that captures, stores and disseminates asset health information where and when it is needed, and leverages knowledge long term. By taking this action these companies will help to ensure the continuing viability of their operation.
This tip provided by Ivara Corporation
http://www.ivara.com
Benchmark Your Workforce Knowledge Capture (5 minute survey)
March 10, 2005
Infrared Tip
Consistency is King.
Thermography is a very powerful tool and can be used for numerous applications. In order to have a complete thermography program it is important to have consistent methodologies in collecting data, classifying problems, and reporting.
There is a science behind the technology to make accurate temperature measurements. While most cameras are very easy to operate, there are issues such as emissivity, reflectivity, spot size to distance ratios, and others that can affect the measurements. It is highly recommended that all thermographers attend some level of training to best understand what these elements are.
It is easy to get confused with emissivities and such. Of course, you could use the “correct” method of inputting unique emissivity for every material, but this can be difficult as many of these materials may be in different levels of oxidation or wear.
Therefore, it may be best to establish a simple set of criteria that you work with on a daily basis and stick with that. An example, taken from one utility, is to use one emissivity value for all things painted or plastic, one item for all things copper, one for aluminum, and another for ceramic. Everything else falls into one of those categories.
Classification of problems also needs consistency. It is best for each organization to establish classification criteria that is best for its own. Whether you create your own “rules” for problem classification or you use an amalgam of accepted values, be consistent. Most likely you will have a set of criteria for electrical equipment (various) and also mechanical equipment. Perhaps in your facility, you have determined that any connection hot spots <30ºC above ambient are not critical. Perhaps that value is lower, or higher. Be consistent.
Finally, it is a good idea to use consistent reporting formats. It is probably best to select a single format report, or a few formats, so that the personnel reading the reports will gain a familiarity. Fortunately, most thermography reports are generated in Word so choosing the best form/fit that suits your requirements can be relatively simple.
Consistent collection of data, classification, and reporting will insure consistent results in a thermography program.
This tip provided by Electrophysics
Manufacturer of EZTherm and EZTherm Pro Cameras
http://www.electrophysics.com
Tel: 973-882-0211
Check Out The Technology Overview for Ferroelectric focal plane arrays by Electrophysics
March 03, 2005
Gear Tip
Gear Backlash: The measurements of backlash may vary in the same pair of gears, depending on the accuracy of manufacture and assembly. Change of backlash at different phases of the tooth action will be caused by incorrect tooth profiles. Eccentricity could cause a great difference between minimum and maximum backlash at different positions around the gear.
It should always be remembered that simply making allowances on tooth thickness does not guarantee the minimum amount of backlash that will exist in actual gears when they are assembled.
Tip provided by Daniel Jenkins
Jenkins Maintenance Technology Inc.
Mount Mourne NC
Thanks Daniel - your Maintenance-Tips hat is on the way!
March 03, 2005
Computerized Maintenance Management System (CMMS) Tip
How to avoid CMMS/EAM System Failures
Failure #10:
Misjudging data collection time
Failure #10 is related to Failure #8. However, it is enough of a problem to warrant a stand-alone mention. Just ask yourself, how long does it take to gather and load the equipment, PM and inventory information into CMMS? The typical project will require one hour per record. So, if you have 10,000 equipment, inventory and PM records, it will take about 10,000 hours (roughly 5 man-years) to load the data.
This holds true whether the software vendor loads the data or you load the data yourself. Improper estimates of the time or cost to load the data has caused many projects to fail. Just be sure you know what the total cost and time will be for your project. Occasionally, companies have other failures, but the elimination of these 10 common failures would produce many more satisfied users of CMMS/ EAM systems—Managers who did it right the first time.
Tip provided by GenesisSolutions
Tel: (203) 431-0281
http://www.GenesisSolutions.com
CMMS-2005, the Computerized Maintenance Management Summit - July 2005
March 03, 2005
Infraspection Institute’s Online Distance Learning
Infraspection Institute’s Online Distance Learning thermography courses enable you to take your infrared training wherever and whenever it’s convenient for you.
With Infraspection Institute’s Distance Learning,
you get the same quality course content for which we are famous.
• We utilize state-of-the-art web servers and dynamic multimedia resources
to provide a unique, quality educational experience.
• Our Distance Learning courses are based upon our Level 1, 2, and 3 courses and meet all ASNT training requirements for the certification of NDT personnel.
• All courses are taught by Infraspection Institute Level 3 Certified Infrared Thermographers™, each having over 20 years of professional experience.
• Infraspection Institute’s Distance Learning courses are divided into narrated one-hour online infrared lecture training units allowing you to work at a pace that’s convenient for you.
• Each course unit is designed to build upon the previous units of the course.
You may return to individual online course units at any time for review.
March 03, 2005
Airborne Ultrasonic Tip
Electrical Panels – Electrical faults in low, medium, and high voltage switchgear almost always produces some level of ultrasonic noise that can be detected with ultrasonic detectors. Frequent ultrasound inspection should compliment infrared scans. While safety is still a concern, there is no need to open panels to perform an ultrasonic inspection. One of the best methods is to use a magnetic probe directly on the outside of the panel. Position the sensor to the center of the steel door and listen to what is going on inside. This practice is not unlike what your family doctor would do to listen inside your lungs or chest. Take a decibel reading on each switchgear panel and record it to the data collector. Panels are typically quiet (0-3 dBµV) if no problem exists. Early stage arcing and tracking produce between 10 and 15 dBµV. If you record these higher values the problem must be tagged and investigated by electrical staff immediately.
Tip provided by SDT North America
http://www.sdtnorthamerica.com
Toll free: 1-800-667-5325
Tel: 905-349-2020
March 03, 2005
Motor Testing Tip
Low Load and High Current Imbalance
An unloaded motor can create a 10-15% current imbalance yet be perfectly healthy. This is a normal design response caused by unbalanced flux in the core iron between phases at low loads. When performing power or current analysis on three-phase induction motors, verify the percent loading at which the motor is operating. If possible, increase the load on the motor to determine the validity of a high current imbalance. A normal current imbalance for healthy motors operating at or near design load is 3% or less.
Tip provided by PdMA
http://www.pdma.com
Tel: (813) 621-6463
Learn more about the 2005 Motor Reliability Technical Conference
March 03, 2005
SAP intensifies focus on Enterprise Asset Management (ADV)
SAP intensifies focus on Enterprise Asset Management (ADV)
Software giant SAP (sap.com) is intensifying its focus on the Enterprise Asset Management (Maintenance Management) market.
With the broadest solution for EAM currently on the market, SAP and partners are introducing new functionality in the areas of:
• Planning and Scheduling
• RCM support and integration with the Work Identification – Execution cycle
• Fully integrated Maintenance Cost Budgeting and analysis
• Role-based intuitive portals ensuring easy transaction and information access with visibility on asset condition
• EAM Business intelligence solutions
SAP’s Service and Asset Management unit is taking an aggressive approach to push SAP’s market leadership in this area. As they have shown in CRM (where SAP has now toppled Siebel as market leader), when SAP focuses its attention on a market, its only a matter of time.
Evidence of this new intensity comes in the SAP-centric EAM conference running in Tucson, AZ from March 20-23, 2005 [ http://www.sap-centric-eam.com ]. Organized by event experts Functional Asset Solutions in conjunction with SAP, this event features impressive content from SAP customers in North America, updates on strategic plans from SAP’s Service and Asset Management Unit and showcases new EAM functionality from SAP and its technology partners – NRX, Meridium, Impress and more. The show is rounded out with the key service providers around this space – the “globals” - Accenture and IBM and specialist players such as New Dimension Solutions.
One senses that the SAP juggernaut is rolling in EAM. EAM business processes run across the enterprise – work management touches financials, HR/HCM, materials management/SCM, customer service/CRM and really every part of the enterprise making SAP’s vaunted integration all the more important. SAP’s best-of-breed competitors have relied on slinging mud around usability and esoteric maintenance/reliability functionality. Given these new offerings it appears that SAP has closed any apparent chinks in its armor in these areas and offers huge advantage to new and existing customers in the depth and breadth of value in terms of license fees.
We suggest you kick the tires and the winter blues in Arizona in March – this looks like a very interesting event in a lovely corner of the country (especially in March!)
For more information please visit the conference website at http://www.sap-centric-eam.com or call us at 914-509-5355.
March 03, 2005
Vibration Tip
If you are having trouble determining if looseness is truly causing the vibration in your machinery, take a look at each component individually.
For example, take vibration readings on the machine foot, baseplate and the base, then compare the amplitude and phase readings. If the equipment is not experiencing any looseness, the phase readings should be relatively close. If looseness is actually the issue, the phase and amplitudes of each component will be considerably different.
Tip provided by LUDECA, INC.
Distributor of the new VIBXPERT data collector/vibration analyzer
http://www.ludeca.com/vibxpert.htm
Tel: 305-591-8935
Download the Taking Accurate Vibration Measurements Case Study at Ludeca.com
March 03, 2005
Maintenance Tip
It pays to take the time to evaluate your preventive maintenance work orders carefully. Many times, they get initiated by emotional priorities when equipment has special case problems. When the operational issue is resolved, the PM remains. The end result is a recurring activity that consumes time for little or no benefit. Make sure your preventive maintenance work is preventing something!
Tip provided by Dave Krings, CMRP
http://www.masteringmaintenance.com
Tel: (888) 230-5280
Learn more about the 5 Pillars: Maintenance & Reliability Professional Review Course
