August 24, 2006
Business Improvement through PMO (PM Optimisation)
Heard about PMOptimisation?
Perhaps you could ask yourself these questions before proceeding ...
Are you suffering more breakdowns than you should and does your PM program need more focus?
Are you caught in or approaching the Vicious Cycle of Reactive Maintenance?
Have you considered using RCM but been put off by the high cost and resources required?
Would you invest in a program providing the same results as RCM but at 20% of the resource cost and elapsed time?
Would you benefit from having a maintenance strategy that was fully documented and justified, could be easily changed in a controlled manner and fully involved the shop floor personnel by using their experience and knowledge?
Learn the basics of PM Optimization with Steve Turner, one of the pioneers of this widely used reliability strategy. PMO2000 is a PMO program designed to rationalize existing maintenance programs and develop a plan to eliminate or greatly reduce functional failures. The PMO2000 reliability concept was originally developed in Australia but is now spreading throughout industrial plants everywhere” This training session is just over 35 minutes.
August 24, 2006
Skilled Workforce Tip
In 2005, direct cost for industrial and manufacturing maintenance in the United States was approximately $200 Billion. The indirect costs or all types of maintenance, from facilities to power plants and automotive to manufacturing, was approximately 20% of the annual GDP for the USA, which was ~$49 Trillion. This means that all costs, including lost opportunity, within the USA directly attributable to maintenance of all types, was just under $10 Trillion (published estimates range from $2 Trillion direct industrial and manufacturing up to $10 Trillion). This leaves a tremendous opportunity for business to act on an area that can generate huge opportunities for improvement. Yet present executive training does not include work on these opportunities.
The “Skilled Workforce in the 21st Century” study developed by ReliabilityWeb and SUCCESS by DESIGN reviews the history of the skilled workforce and how reliability and maintenance is impacted, explores the premises published within other domestic and international studies, the ReliabilityWeb workforce survey and conclusions on how to exploit the opportunities from both the R&M professional and management standpoints.
“The future holds great promise for knowledge workers in the field of maintenance and reliability. As the shortage of both high level and lower level skills becomes more pronounced, the competition to hire or contract with these knowledge workers will intensify. Companies that use cost to drive maintenance decisions rather than best practices will lose knowledge workers and will see costs skyrocket. Companies that attract knowledge workers and implement best practices will see increased profits through higher availability and increased output, lower scrap rates, higher quality product, and finally lower maintenance and labor and material costs.
Companies that hire and retain the right maintenance and reliability workforce, create an environment that empowers the knowledge worker, and leverage available technologies will reap the rewards. The companies that wait to read about the Reliability Revolution on the front pages of national and international news media will be far to late!” – “Skilled Workforce in the 21st Century” Study.
August 24, 2006
Maintenance Tip
One of the most basic fundamentals that causes rework in my experience is very simple: Make sure the equipment is running!!!
I have gotten back in the office and downloaded the route only to find that the worse piece of equipment to get to was down when the readings were taken.
Reader Tip provided by Aubrey Green
International Paper
Thanks Aubrey - Your Maintenance Tips hat is on the way.
August 24, 2006
Balancing Tip
Rotor mass unbalance is one of the most common causes of excessive vibration levels in most rotating equipment. The primary symptom of rotor mass unbalance is a high 1X vibration level. Rotor mass variation leading to an unbalanced condition can be caused by a variety of factors including material build-up or fouling, wear, and thermal changes. Excessive amounts of rotor mass unbalance can have several detrimental effects on rotating equipment. The primary concern is the long-term fatigue-inducing beating forces incurred by running at elevated vibration levels. Excessive amounts of rotor mass unbalance can also amplify other vibration conditions, such as a loose bearing cap or instability in a foundation. By monitoring vibration levels and keeping rotating equipment in a well balanced condition, you can extend the operating life of your equipment and also increase the operating capacity and efficiency of your plant by keeping your valuable assets running.
Tip provided by:
LORD Corporation
http://www.lord.com
Tel: 1-877-ASK-LORD
August 24, 2006
Human Error Tip
To minimize the risk of human error in conditions where someone is doing a task for the first time:
a. Have procedures in place which will provide guidance in how to perform the task properly (Rules)
b. Train the person in how to apply the procedure (Knowledge)
c. Ensure that the person demonstrates the application of their new training (Skill)
d. Hold periodic sessions where “what-if” scenarios are discussed
e. Identify conditions which are appropriate to start the task and alarm conditions in which should prevent the task from proceeding
Tip provided by Reliability Center Inc.
http://www.reliability.com
August 24, 2006
Tips feedback
Taken from one of readers comments:
“Maintenance is the only organization in manufacturing that has a responsibility to the assets being used and the responsibility to ensure they will be usable tomorrow.”
Everyone in the organization has or MUST HAVE this responsibility.
I realize that maintenance department’s closer ,more frequent, contact with the assets make this feeling surface.
As a minimum all manufacturing departments must be on same level. Maintenance should not be part of (under) production and should an equal voice in decision making.
Joe Cannatelli
Con Edison
NYC NY
Leave it to a New Yorker to tell it like it is! Thanks Joe - Your Maintenance Tips hat is on the way!
August 17, 2006
Time is running out to register for PdM-2006
The Predictive Maintenance Technology Conference
September 12-15, 2006
Chattanooga TN
Learn everything you need to begin a Machinery Condition Monitoring Program in just 4 days at PdM-2006
PdM Manager’s Sessions
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• Managing a successful condition monitoring program by Jason Tranter
• Why Leadership, Proactive Maintenance Strategy and PdM are important - Keys To Success in Condition-based Maintenance by Phillip Pinkston, Allied Reliability and Chris Hein, Cargill Sweeteners
• Southern Company Condition Based Maintenance (CBM) Case Study by Steven Newton
• Understanding and Implementing Predictive Maintenance Excellence by Kenneth D. Peoples, The Boeing Commercial Airplane Company
Motor Testing Sessions
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• Elements of an effective motor maintenance program by Jerry Honeycutt Tennessee Valley Authority
• The Story of Dofasco Steel’s Motor Management: Past, Present and Future by Vlad Djuric, CMRP, Dofasco
• What to Do When a Major Motor Dies Prematurely - Case Study with Multiple Issues by Jack Nicholas Jr.
• A Proven Electric Motor Re-greasing Program used in the Nuclear Power Industry by Jerry Honeycutt, Tennessee Valley Authority
• Alcoa Motor Circuit Testing Case Studies by Jim Zuidema, Alcoa
• Dynamic Electric Motor Testing of DC Motors by Noah Bethel, PdMA
• Motors The Past is Present by Howard Penrose
Infrared & Electrical Application Sessions
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• Getting Started with Infrared Thermal Imaging by John Snell
• Avoiding Flashover in Medium Voltage Switchgear by Chuck Humphrey Highvec Canada
• Electrical Inspections with the use of Thermography & Ultrasound
• Ultrasound War Stories: Electrical Inspection by Jim Hall
• Infrared Surveying and NFPA 70E Mock Trial by Greg Stockton, ISPoT and cast
• Techniques for Accurate infrared Temperature Measurement by Jim Seffrin, Infraspection Institute
• Infrared Windows Case Studies by Darren Billings
Lubrication and Bearings Sessions
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• Lubrication Excellence by Ken Peoples, The Boeing Commercial Airplane Company
• A comparison of detecting bearing problems using ultrasound and vibration by Tom Murphy
• Oil Analysis basics by Ray Thibault
• Pump Bearings and Lubrication by Ross Mackay
• Acoustic Bearing Lubrication by Jim Hall
• A Proven Electric Motor Re-greasing Program used in the Nuclear Power Industry by Jerry Honeycutt, Tennessee Valley Authority
Many more real world case studies plus the Business Case for Predictive Maintenance Keynote address.
2 Day - 3 Day - 4 Day Passes to meet any schedule and budget!
Hotel discounts only available till August 28!
Please make plans to attend PdM-2006 today and meet the Uptime Magazine PdM Program of the Year Winners. Group discounts are also available by calling toll free (888) 575 1245. Be sure and ask how you can win an Alienware Laptop!
August 17, 2006
Vibration Analysis Tip
Acquisition and storage of Time Waveforms can be useful in ways that many vibration analysts may not have considered. Most PdM trending platforms will store the TWF (and FFT) in a digital format that may not include re-processing capability. Many newer PC based acquisition systems give the user the option to store a TWF “clip” in an individual file. These files can be post-processed multiple times and/or in multiple ways without having to collect additional data sets. Storing a 10-12 second TWF will allow fairly high FFT spectral resolution, without impeding speedy data collection, or enormous data storage problems. Consider the possibilities:
• High Resolution Overall Amplitude Levels
• Computing Crest or Form Factors on the Original TWF signal
• High & Low FFT Spectral Range Analysis
• Signal Re-processing: Resolution, Averaging, Windowing
• Transient Waterfall, Cascade Maps of data.
• Retaining TWF Phase relationships (with Reference)
Granted that these functions may be beyond the capabilities of most trending software platforms, but are easily within the realm of most PC based data acquisition systems.
Tip from Dan Ambre, P.E., Full Spectrum Diagnostics, PLLC,
http://www.fullspec.net
Don’t miss Dan’s Introduction to Vibration Analysis Workshop at PdM-2006
August 17, 2006
Infraspection Institute -Distance Learning Infrared Thermography Courses
Now you can receive infrared training wherever and whenever it’s convenient for you.
Infraspection Institutes broad range of Distance Learning Courses includes Certification Prep, Applications, and Industry-Specific courses. All courses are taught by expert Level 3 instructors utilizing dynamic, multi-media resources.
Become an Infraspection Institute Certified Infrared Thermographer. Complete 32 hours of Distance Learning and take your certification exam at one of our convenient locations.
August 17, 2006
Oil Analysis Tip
The key to quality sampling is to pull the samples the same way each and every time. Write a procedure for each piece of equipment stating the exact location with a very descriptive procedure to follow. One of the best ways is to install a pitot tube if that is possible for the equipment in your facility. If plastic tubing is used to obtain the sample, use a permanent marker to mark the depth the tubing should be inserted to get a representative sample in the same part of the gearbox/equipment each time. Each system or application may be different, just set up a procedure that each employee pulling samples will be able to follow. This is the only way that trending conditions will be accurate.
Reader tip provided by Jerry Weeks, Monsanto, Soda Springs ID
Thanks for entering the Maintenance-Tips Challenge Jerry - Your PdM-2006/LubricationWorld Proceedings CD and Maintenance Tips hat will be shipped as soon as the CD is published.
