May 26, 2005
Maintenance Planning, Scheduling and Coordination by Joel Levitt
Maintenance Planning, Scheduling and Coordination by Joel Levitt
CMMS-2005 Pre-Conference Workshop
Computerized Maintenance Management Summit
July 26-29, 2005
Indianapolis Indiana
Well-planned, properly scheduled, and effectively communicated jobs accomplish more work, more efficiently, and at a lower cost. This work will disturb operations less frequently, and be accomplished with higher quality, greater job satisfaction, and higher organizational morale than jobs performed without proper preparation. The Maintenance Planning, Scheduling Coordination workshop focuses on and deals specifically with the preparatory tasks that lead to effective utilization and application of maintenance resources. It is a vital training course for planners and those to whom planners are responsible. It is also valuable for those who interface with the planning and scheduling function and are dependent upon the many contributions of planning and scheduling operational excellence.
This workshop will:
• Address maintenance management, performance, and control
• Clarify the scope, responsibilities and contributions of the Planner/Scheduler function and the support of other functions to Job Preparation, Execution, and Completion
• Covers the basics commonly contained within world-class programs for effective execution of maintenance work: planning, parts acquisition, work measurement, coordination and scheduling
• Aids organizations that pursue “Maintenance Excellence”— that state of maintenance management and performance that effectively applies the leading edge policies, procedures, systems, structures, methods, and technologies to maintenance
This workshop will:
• Address maintenance management, performance, and control
• Clarify the scope, responsibilities and contributions of the Planner/Scheduler function and the support of other functions to Job Preparation, Execution, and Completion
• Covers the basics commonly contained within world-class programs for effective execution of maintenance work: planning, parts acquisition, work measurement, coordination and scheduling
• Aids organizations that pursue “Maintenance Excellence”— that state of maintenance management and performance that effectively applies the leading edge policies, procedures, systems, structures, methods, and technologies to maintenance
Each workshop participant will receive a hard cover edition of Maintenance Planning, Scheduling and Coordination By Don Nyman and Joel Levitt
Join Joel plus more than 35 other presenters, workshop leaders and learning labs directors at CMMS-2005.
To learn more please call toll free 888-575-1245 or…
May 26, 2005
Cost Effective Predictive Maintenance Solutions
A sponsored white paper by Wilcoxon Research
Vibration Monitoring is a critical component of any sound Predictive Maintenance (PdM) Strategy. Traditionally, data from the vibration sensors is recorded and analyzed using hand-held, walk-around vibration analyzers, or via expensive and elaborate online analysis systems. For an extremely large operations and/or very expensive equipment, these approaches represent cost effective PdM and have repeatedly shown to save money.
In many applications, however, neither of these approaches is cost effective. In recent years we have seen an increased use of 4-20 mA Loop Powered sensors in the market. These sensors have proven extremely valuable, since they can be
tied directly into the existing PLC/DCS Networks and do not require the skilled analyst or the expensive systems. However, these sensors only provide trending information to identify that a potential problem exists, and do not provide the detailed information necessary to determine what the cause of the problem.
A hybrid approach to vibration monitoring provides the best of both worlds to establish a PdM strategy that is not only extremely cost effective but also simple to deploy. More…
Request the Cost Effective Predictive Maintenance White Paper
May 26, 2005
Maintenance Tip
Gland Packing
After spending 15 years in the British Merchant Marine as an Engineer Officer, I cannot over-emphasize the importance of packing pump and valve glands correctly; especially in the Persian Gulf where engine room temperatures are often in the range of 130 degrees F and the humidity is very high.
Packing manufacturers recommend that the packing ring butts should touch each other when installed on the shaft. In the case of pump packing, this method does not permit any expansion of the packing when the unit is in service. When the packing is compressed, the material will tend to bear down upon the sacrificial sleeve on the pump shaft and the resulting friction will lower the viscosity of the impregnated lubricant to the point where the lubricant vacates the packing. This results in the packing becoming abrasive and the packing starts to grind up the sacrificial sleeve causing all of those humps and markings on the sleeve’s surface. Now the sleeve and the packing will have to be replaced.
This scenario can be avoided by simply cutting the butts of the packing rings at a 30 to 40 degree angle and allowing 1/16 inch between the butts. The packing will last ten times longer and be more efficient. It will also help to keep more maintenance money in your pocket rather than the manufacturer’s pocket.
Incidentally, I have always regarded pump stuffing boxes (glands) in the same light as sleeve bearings and have taken vibration signatures off of them over the last thirty years or so. Like sleeve bearings, they require to be lubricated and cooled and, if they are not, they react in the same way as a sleeve bearing when it is deprived of its lubrication and cooling. The resulting vibration signatures give a good indication of the health of the packing.
Reader Tip provided by John C. Robertson, PE/CPE
Thanks John - your Maintenance Tips hat is on the way!
May 26, 2005
Maintenance Tip
When replacing failed bearings take the time to inspect the failed components. There may be evidence of lubrication and or installation problems. This can be seen on the inner and or outer race of the component. An example of this would be a bearing ball path that that crosses from one side of the race to the other. Keep track of what you see and if this type of defect is repeated often some bearing installation training may be needed.
Tip provided by the Reliability Center
http://www.reliability.com
May 26, 2005
Reliability Tip
A Reliability based approach to maintenance uses the probability of failure to select the most effective maintenance strategy. The probability of failure is determined either from past failures, knowledge and experience, or from industry references. Often it is found that existing record systems and logs contain a wealth of data which has not been used to predict future performance. Now with modern computer based tools this analysis is easy.
Many companies are finding that by using a Reliability based approach they can now forecast reliability and plant performance by using computer generated models and running simulation programs on a desktop computer. This means feedback on the effectiveness of alternative strategies is available within hours instead of waiting for years as failure histories are built up. This approach also creates a “what if” environment where asset managers can now structure plans and maintenance budgets based on the probability of failure instead of reacting to failures.
Tip provided by ARMS Reliability Engineers - USA, Inc.
http://www.armsus.com
Phone: 888-673-8360
You can read more about how a Reliability based approach to maintenance works by following this link and downloading the pdf for ...
May 26, 2005
Inventory and Purchasing Maintenance Tip
Inventory and Purchasing Maintenance Tips to
Enhance Maintenance Planning and Scheduling
(Tip 2 of 6 in a series) Archived at
http://maintenancetalk.com/blog.php/tipsblog
Maintenance Inventory and Purchasing Organizational Reporting Structures
While a previous maintenance tip dealt with the geographical structure for maintenance stores locations, this tip will deal with organizational reporting structures. There are two main reporting structures for maintenance inventory organizations. They may report to the maintenance organization or to the procurement organization (which in turn reports to a financial component of the company).
When the maintenance inventory function reports through the maintenance organization, it has some advantages.
First, it allows maintenance to directly control the stocking of spare parts and related issues. Secondly, the maintenance technicians have more ready access to the stores locations and required spare parts. However, there are also several disadvantages with this reporting structure. The first is that very few maintenance managers have the functional background to properly set up and manage a stores and purchasing organization. The second is with the maintenance inventory and purchasing disconnected from corporate purchasing, the ability to negotiate discounts and improved terms with the vendor are reduced.
When the maintenance inventory function reports through the corporate procurement organization, there are some advantages. First, it allows for proper organization and management of the maintenance related spare parts. Secondly, it allows for improved negotiating with the vendors and this usually results in lower prices and improved delivery times. The disadvantages are highlighted when the inventory and procurement organizations fail to understand the unique requirements for maintenance spare parts. This results in lower service levels (less than 95%) and increased work delays due to part shortages or outages. The work delays also result in higher downtime and the related loss of production/ availability.
How can these issues be addressed? It is by clear communication and enhanced understanding of how the maintenance and spare parts functions are related and how they impact the availability and ultimately the throughput of the assets. Without having the proper understanding of the maintenance inventory and procurement function, a company will always sub-optimize their assets.
Tip provided by Terry Wireman
GenesisSolutions
http://www.GenesisSolutions.com
Tel: (203) 431-0281
May 26, 2005
Is your production turning capacity limited by excessive high vibration?
If so, a LORD balancing system could be your answer to increased production. Traditional processes require you to slow down spindle speeds to minimize unbalance, but the LORD balancing system compensates for unbalance and provides vibration-free machining at maximum speeds. The system is permanently mounted and continuously monitors the vibration levels. When an unbalance is detected, the LORD balancing system can make a balance correction during operation.
The proof is in the numbers. A Michigan-based automotive components manufacturer found that they were only able to produce 8 percent of the parts needed to fill a new contract because they had to slow down their spindle speed due to unbalance. They implemented a solution consisting of the LORD balancing system and an indexing chuck. The result is a vibration-free machining environment and an increase in production of more than 1,025 percent while reducing scrap rate by 97 percent.
To find out more about increasing your production capacity, or call 800-929-3218.
Learn more about LORD Balancing online
May 26, 2005
Condition Monitoring Tip
Remember that some of the data collectors on the market allow users to document and log other parameters, not just vibration readings. Some products offer collection of visual data, such as oil levels or foundation condition. When collecting data the user can pick from a list selection showing the gauge is empty, half-full or full. Users can keep track of all the oil levels with their data collector without the need for running a separate route. Other readings, like manual entry allow the user to add numerical entries corresponding to a condition, like pressure. Maximize the productivity of your systems and personnel.
Tip provided by LUDECA, INC.
ALIGNMENT * VIBRATION * BALANCING
http://www.ludeca.com
Tel: 305-591-8935
Request Ludeca’s Condition Monitoring Return On Investment Study for your facility
May 19, 2005
Managing a Computerized Maintenance Management System by Terry Wireman
CMMS-2005 Pre-Conference Workshop
Computerized Maintenance Management Summit
July 26-29, 2005
Indianapolis Indiana
This workshop, by maintenance expert Terry Wireman, is designed to assist anyone investigating the possibility of using a computer in the maintenance function or for people seeking to get more productivity from an existing maintenance information management system.
The workshop provides the information needed to successfully evaluate, select and implement a system. It enables participants to discover how progressive companies are using computer programs to achieve cost reduction and control the maintenance of any facility.
A review of past CMMS benchmarking projects will also be included.
Each workshop participant get a hard cover edition of Computerized Maintenance Management Systems by Terry Wireman
Join Terry plus more than 35 other presenters, workshop leaders and learning labs directors at CMMS-2005.
To learn more please call toll free 888-575-1245 or…
May 19, 2005
Motor Testing Tip
Evaluating the condition of electric motor rotors is not a new concept. Electric motor repair shops have been using techniques such as growler testing, single-phasing, infrared, vibration and/or dye testing as methods used through the repair process. In the field, vibration, analog current tests and inductive testing has been used. Over the past twenty years, a variety of motor circuit analysis and current signature analysis technologies have entered the market providing even greater accuracy in the detection of rotor bars.
Growler testing is performed by applying power to a half-transformer with the rotor resting upon, or near, it. The induced current allows the repair person to check the rotor bars by using metal filings or magnetic paper. The term growler comes from its original purpose of detecting shorts in DC armatures. The power is induced into the armature and a hacksaw blade would be held just above the armature over each slot. If a short exists, the blade would begin to vibrate causing a ‘growling’ sound. The accuracy of growler testing on AC rotors is improved by heating the rotor in an oven to approximately 200 degrees F prior to testing in order to cause expansion of any fractures.
Single phase testing involves the application of approximately 10% of the motor voltage across a single phase (ie: T1-T2), in an assembled motor with a good winding, then rotating the shaft slowly with a current probe attached. If the value stays within 3%, as the rotor is turned, then it is in good condition. This test is considered potentially dangerous to the technician.
Infrared testing is performed by winding a coil of wire through, or around, the rotor and applying a voltage and high current. This causes the rotor to heat and will identify smeared laminations and loose or broken rotor bars. Hot spots, identified with infrared, greater than 10 degrees C above the ambient rotor temperature identify faults.
Vibration analysis is performed with the motor assembled and under load, usually at least 50% of rated load. Signatures of twice line frequency with pole pass frequency and peaks of the number of rotor bars times the running frequency, will indicate rotor bar problems. This normally requires some degree of experience by the operator.
Analog current meters on switchgear/MCC’s, or hand-held analog current meters, can be used by observing the meters for sharp pulsing of the current as the motor operates under load. This ‘ticking’ motion will occur at pole pass frequency and is a strong identifier of multiple broken rotor bars.
Inductance testing can be used by viewing a continuous measurement of inductance or periodic testing of inductance through an arc or full rotation of the motor shaft, of an assembled motor. A repeating pattern indicates a good rotor and impact of the peaks or valleys of a few of the patterns indicate a broken rotor bar problem, impacts on the slopes of the patterns indicate casting voids (in aluminum cast rotors). There should be one pattern per pole of the machine being tested.
Current signature analysis is a classical method for analyzing rotor bars. Side bands of twice slip frequency approaching ’35 dB down’ indicate severe rotor bar conditions, that must be addressed.
Tip provided by Howard W Penrose, Ph.D.
T-Solutions, Inc., Chesapeake, VA
http://www.tsoln-inc.com
