July 14, 2005
5th EPRI Conference on Maintenance
Hosted by PSE&G
August 8 - 10, 2005
Jersey City, NJ, USA
The electricity generation industry is continuing the rapid changes of the last five or more years from a stable, predictable past, to a future of competition, changing ownership, and dynamic new business goals. Adding to this new challenge, we are faced with the loss of long-term employees along with their knowledge. Many companies have mortgaged their human assets hoping to succeed in bridging the gap in knowledge and training without having developed a contingency plan.
The Electric Power Research Institute (EPRI) has structured this conference to provide some of the latest work being accomplished in the area of business evolutionary ideas, technology updates to forge ahead with more effective and efficient methods of completing maintenance work, as well as the ability to more accurately project what work has to be accomplished and when. This conference is structured for both the tactical maintenance needs as well as strategic ideas for focusing the future changes to be more successful.
July 14, 2005
Maintenance Metrics Tip
LEADING AND LAGGING INDICATORS
It seems that Leading and Lagging indicators are a mystery to many organizations. Organization that are operating without leading and lagging indicators operate similar to driving a car with the windshield painted black (you really cannot see where you are going).
Dr. Deming stated that “you cannot improve something you cannot measure”.
Most people agree with Dr. Deming but do not know how to develop leading indicators (which directly impact lagging indicators). I have heard many times, “I wish I could have seen this problem coming” or “I wish I could identify the root cause of my problems”. I am telling you here is the solution to most of your problems. A great example of a lead indicator is PM compliance (like everything else PM compliance is all in the definition). PM compliance is the measurement of the percentage of PMs that are completed in a specified period of time (watch future issue for my iPresentation about the 10% rule of Preventive Maintenance which defines PM compliance in a more rigid fashion). If your PM compliance is low it will directly impact your emergency labor hours which we would call a lagging indicator. Another example would be maintenance scheduled compliance (leading indicator) directly impacts production capacity (lagging indicator). The reason I used these examples is because I have seen these indicators provide great results in many plants I have visited so I know they work. I believe leading and lagging indicators must be developed from the maintenance crew level to plant management level. Clear away the black paint from your windshield and set up leading and lagging indicators for your operation.
When I was in maintenance management, “I wish I knew then what I know now”. “Knowledge is Power”.
Tip provided by Ricky Smith, CMRP
MAXZOR Corp.
July 14, 2005
Airborne Ultrasonic Tip
Acoustic Bearing Analysis:
When listening to bearings for analysis it is not recommended to solely go on “sound alone”. Decibels or the incremental changes/differences in the bearing over a period-of-time, is best. One bearing reading 58 db and low on grease can sound very much like a bearing with adequate wear that may warrant a removal/replacement.
Tip provided by Jim Hall
Ultra-Sound Technologies
(770) 517-8747
http://www.Ultra-SoundTech.com
July 07, 2005
Generating Failure Codes for CMMS Implementation by Bill Keeter
CMMS-2005 Learning Zone Session
Computerized Maintenance Management Summit
July 26-29, 2005
Indianapolis Indiana
One of the most important parts of CMMS implementation is the generation of failure codes for the craftsmen to record. Picking good codes means that you will have information that is useful for continuous improvement activities. Picking inadequate codes means that crafts people will soon grow tired of carefully entering codes that are not perceived to generate value for the organization.
In this session Bill will show you how to use Failure Modes and Effects Analysis to generate useful codes that will provide a path forward for continuous improvement. You will see how good codes can help you generate useful failure statistics so that you can forecast future failures and develop preventive/predictive activities that will minimize the business impact of failures.
Join Bill 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…
July 07, 2005
Belt Tip
Belt Tip dated 04/07/05 was state below:
When removing belts from multiple belt pulleys, mark with chalk or crayon the order and the direction to the motor or drive they are coming off. 1,2,3,4,5,6 with an in or out arrow.
After all, that is why you bought a matched set. Putting them back on helter skelter any where will lead to vibration and possible bearing failure down the road.
My suggestion:
Since belts are no longer sold in matched sets, when replacing belts in multiple groove pulleys they should be vulcanized together under one backing, such as the Gates Powerband belts.
When removing Powerband belts mark the direction of rotation to the motor or drive they are coming off of with chalk or crayon and install it in the same orientation.
Reader tip provided by Rich Holland
Maintenance Planner
Noranda Aluminum, Inc.
New Madrid MO
Thanks Rich - your Maintenance-Tips hat is on the way!
July 07, 2005
Airborne Ultrasound Tip
Vacuum or In-Leakage Detection
Vacuum (in-leakage) leaks are internal and sometimes these leaks can be found using isopropyl alcohol, de-mineralized water or a liquid agent your system can accept and applying it to the piping surface or suspect area while using an ultrasonic contact probe touching the suspect area. The sound will be that of bubbles popping or a “Rice-Krispies” sound. This application is great on autoclaves, sterilizers, condensers, etc…
Tip provided by Jim Hall
Ultra-sound Technologies Inc.
Vendor Neutral Ultrasound Training
http://www.ultra-soundtech.com
July 07, 2005
Distance Learning Infrared Thermography Courses
Infraspection Institute
Distance Learning Infrared Thermography Courses
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Become an Infraspection Institute Certified Infrared Thermographer®. Complete 32 hours of Distance Learning and take your certification exam at one of our convenient locations.
July 07, 2005
Alignment Tip
Laser System Lens Cleaning
Always use an optical quality micro-fiber lens cleaning cloth to avoid scratching the polarized coatings of your sensor lens. These are also ideally suited at sucking fingerprints and dust right off the lens surface.
Avoid using lint-laden cotton cloths or tissues.
Tip provided by LUDECA, INC.
ALIGNMENT * VIBRATION * BALANCING
http://www.ludeca.com
Tel: 305-591-8935
July 07, 2005
Inventory and Purchasing Maintenance Tip
Inventory and Purchasing Maintenance Tips to
Enhance Maintenance Planning and Scheduling
(Tip 5 of 6 in a series) Archived at
http://maintenancetalk.com/blog.php/tipsblog
Spare Parts Storage – Proper Storage Locations
While a previous maintenance tips dealt with identifying storage locations, this tip will focus on the right type of location. Many companies fail to give the storage condition of spare parts the proper consideration. When they are ready to use the spare parts, they find that they are either defective or have been sufficiently damaged in storage and they will no longer deliver their full service life. Comfier one common example: rolling element bearings. While, many companies rely on supplier arrangements to eliminate storing bearings, they will still find bearings stored in the storeroom in major spares such as pumps, gear cases and motors.
• When examining the storage conditions for bearings, what is found in the storeroom?
• Are the locations, clean and humidity controlled?
• Are the bearings still sealed in the original containers?
• Are the bearings located in an area that is free from external sources of contamination and vibration?
In many cases, the bearings have been opened and checked by someone who was not sure of the OEM number and wanted to physically compare the bearings. In this case, unless the bearings are re-packaged, they are being damaged. The exposure to atmospheric conditions, acid in the skin of the technician, and other conditions will quickly deteriorate the life of a bearing. Even if the bearings are stored as part of a component in a spare part assembly, they will incur damaged if the storage conditions are not monitored. For example, if the bears are stored, mounted under load and not rotated, external vibration may cause a problem with false brinnelling.
Other power transmission components, such as v-belts, roller chain and gears also must be stored under proper conditions to insure their full service life when installed.
It is only when spare parts are stored in easy to find locations, where they are properly stored and protected that they will deliver their design life expectancy, keeping maintenance spare parts cost at a minimum level.
Tip provided by Terry Wireman
GenesisSolutions
http://www.GenesisSolutions.com
Tel: (203) 431-0281
