November 23, 2006
More Maintenance Tips Feedback
Regarding the tip below in your recent Tips: I have known of situations where threaded fasteners have experienced fretting due to vibration. The nut may not move from the original torqued position, but due to thread wear, the nut can be unfastened using only your fingers. The scribe method as described below can not indicate this particular condition.
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Tip for Inspecting bolt/nut tightness
First: Install a nut to proper tightness.
Second: Scribe a line through the nut to the equipment frame around the nut
On PM inspections just verify that the scribed line is unbroken.
Tip provided by Joel Levitt
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Maintenance Tips Feedback provided by Richard Danks
November 23, 2006
The Dirty Dozen: 12 Ways to Wreck Your Maintenance Program
Ignore the Needs of Your Customers (4 of 12)
As maintenance professionals, you interact with other departments and personnel who depend on you to keep their equipment and processes in good condition. If you ignore them, they are helpless, and it can be really funny to observe them jumping around in frustration when they get nothing from you. They may treat you like a servant, but you do have some power over them.
There are many ways to ignore the needs of your customers, but here are a few gems:
• When you get a call for help because some equipment failed, drink one more cup of coffee before you amble down to assess the situation. It’s not like they can call someone else, right?
• When you work on equipment, don’t waste your time communicating that the job is done. If you do, all you are going to get is a bunch of questions, somebody checking your work, and they’ll probably ask you to stick around to assist with startup. No thanks. Fix it fast, and then beat it back to the shop.
• Stay off the floor as much as you can. Someone will call you when they need help. Otherwise, stay out of sight, and keep your head down.
• It’s best to avoid learning at all times. If you gain new skills, the next thing you know, people will expect you to use them. Pretty soon, they will be bothering you constantly. In fact, it’s a good idea to pretend you know even less than you do. That way, if you get a request to help, you can just say, “Sorry, I don’t know much about this. Maybe someone else would be a better choice.” It is a masterpiece if the whole department can do this in unison, so nothing can get done.
Tune in next week as we continue to expose the secret lives of seriously disturbed maintenance “professionals” with The Dirty Dozen Tip #5: Don’t Plan Anything, or Make Rotten, Useless Plans.
“Tip” provided by NoBreakDowns.com
Tel: (218) 327-3114
Web: http://www.NoBreakDowns.com
Receive a complimentary Dirty Dozen: 12 Ways to Wreck Your Maintenance Program electronic poster
November 23, 2006
What is your Balancing IQ?
If everything was balanced as it was built and installed - imagine how much maintenance work could be avoided!
Reliabilityweb.com is proud to announce that Ludeca has launched a new Balancing IQ Quiz to test your knowledge of this valuable precision maintenance technique.
The quiz is self checking and correct answers are displayed if you happen to miss an answer or two.
November 23, 2006
A Global Enterprise Asset and Reliability Management Exchange
RCM-2007 - The Reliability Centered Maintenance Managers’ Forum
Plus
EAM-2006 – The Enterprise Asset Management Summit
2 Learning Events – 1 Price!
Certificate Workshops April 3-4, 2007
Conference and Expo April 5-6, 2007
Sheraton Waikiki Hotel
Honolulu Hawaii
• Proven Asset Management and Reliability Strategies, Techniques and Technologies in a focused learning environment
o RCM-2007 is designed for people who are considering or practicing Reliability Centered Maintenance programs
o EAM-2007 is designed for people involved in implementing or managing physical asset information (CMMS/EAM) including maintenance management for companies and enterprises
o New in 2007 – SAP –Plant Maintenance Track added
A wide selection of workshops, short courses and learning zone sessions ensures a full agenda for beginners as well as advanced maintenance and reliability professionals.
November 23, 2006
Shutdown Tip
Work Validation in Shutdowns
Work Validation is one of the keys to a successful shutdown or outage. Validation is answering a series of questions about all the jobs on the work list.
Its function is to eliminate all unnecessary work, clarify all jobs and eliminate duplications.
Questions to be answered for every job:
• Does the work have to be done during this shutdown?
• Is this a duplicated job or is a small job part of a larger job already on the schedule?
• Is this a job that will be undone by a job later in the shutdown?
• Is this the simplest wording? The work content should be entirely clear.
• Is this routine work being transferred into the shutdown?
• Is this nice-to-do work for which there is no business justification?
• Is there any work done as a custom every shutdown without adequate analysis?
• Is this desperation or blackmail work (that is work added to the list just before start-up)
Three steps of the Validation Process:
• Check: duplication, approval, request is accurate
• Challenge: the need to perform the task either at all or during this shutdown
• Analyze: safety, quality, engineering, material, resource requirements
Important point: Agree on final wording and add to work list (it can make a difference).
Idea for action: What about running a class in how to write up the “work requested” field on the work order? The issue of how work requested is written up is important for day-to-day maintenance jobs and doubly important for shutdowns.
Tip provided by Joel Levitt Author of Lean Maintenance in a Nutshell
November 16, 2006
Motor Tip
When installing Electric Motors on baseplates in order to find shaft center line to match the shaft centerline height for assembly to a pump or other type of rotating equipment.
The formula is as follows on the Motor Frame Size.
Frame Size 182T use the 1st & 2nd digits (18) / 4 = Shaft centerline or the U dimension of 4.5”
Frame Size 324TS (32) / 4 = 8.0”
Reader tip provided by Scott Ginaven, Flowserve Flow Solutions - Seal Group, Burr Ridge Illinois
Thanks Scott!
November 16, 2006
Maintenance Tip
Awareness is the key
In this day and age it is always important to be aware of our surroundings. There are a number of safety concerns to keep in the forefront of our minds while we perform our job duties. A large number of safety provisions have been implemented and enforced in today’s industrial environment, and without a doubt these guidelines have been put in place for the well being of those of us who are exposed to the potential dangers that surround us. Although safety is the most important procedure of our duties it is imperative that we remain aware of potential problems that are outside of our specific job scope.
Many times when we are given a specific job to perform, we get caught up in that particular task that we often become oblivious to any outside issues that might exist. A number of years ago I was conducting an annual electrical thermography inspection at a foundry facility, which I had also performed the previous two years. As the day began to come to a close I found myself inspecting the final piece of equipment which happened to be an arc furnace. As I was inspecting the electrical panels and the bus system a small area with a temperature rise of 5° F caught my attention. Upon initial investigation I made an incorrect assumption. In this particular area there was very little room to move around and I assumed the temperature rise did not exist, but that this was simply reflection. The inspection was completed all that was left was the analysis. Upon analyzing the inspection the following day I noticed a detail that somehow I had overlooked the day before as well as the previous years.
For many years, air-cooled bus was the industry standard. In the 1960s, higher current bus systems became necessary, which led to the development of water-cooled bus applications. When this particular arc furnace was installed, which by the way was seven years prior to this inspection, the industry standard had switched to the water cooled bus system for this type of application. With that being said, I noticed on the digital picture I had taken the day before that the water connections had not been properly made. In fact due one small hose misplacement four bus bars were without water. The analysis was completed and a visit back to site confirmed what the picture indicated. During the next scheduled shutdown the small hose was rerouted and water was now circulating through all conductors. Although this arc furnace had been in operation for seven years with this installation mishap, only time would have told if it would have become a catastrophic issue. When asked why this was not found during the prior two inspections, I had to go back to those pictures and investigate. My answer: I simply was not aware of all my surroundings and how they could contribute to possible anomalies. Although the temperature differences were between 1-2 °F during the previous inspections, careful observations may have revealed this sooner.
Lessons learned: Be safe, be smart, and be aware of potential problems due to your surroundings. For the reliability engineer, consider more thorough acceptance testing.
Tip provided by Chris Colson
Allied Reliability, Inc.
November 16, 2006
Win a Windows Mobile PDA at IMC-2006!
Drop by DMSI’s IMC-2006 booth (N704) for a chance to win a Windows Mobile PDA! While visiting, learn about one of the greatest facilitators of the reactive to PdM change ...Asset Basic Care on Mobile Computers, InspectCE.
See you at IMC booth N704!
http://www.maintenanceconference.com
Please call DMSI at 604.984.3674 or…
If you’re not attending IMC-2006, learn about Asset Basic Care
November 16, 2006
The Dirty Dozen: 12 Ways to Wreck Your Maintenance Program
Keep Maintenance Successes a Secret (3 of 12)
The last thing anyone wants when wrecking a maintenance program are success stories from the proactive maintenance effort. When the maintenance department does something right, any self-respecting team wrecker will do whatever it takes to bury the news, and keep it from being shared.
Good news gets people thinking that they might be able to fix the reactive maintenance mess, and then you will have a real challenge on your hands to get them to give up and accept defeat. Keep in mind that your goal is to erode trust between the maintenance and production personnel, and steer them toward making poor decisions. If everyone is rushing around in a panic, and there is no time to plan their actions, you have them in your grasp. Be negative, and when something good happens, make sure to say it was just luck.
Another excellent approach to crushing any success that is achieved is to broadcast as much bad news as you can. This is an old political trick, and it works like a charm. People love to hear about bad news and scandals. It makes them feel better about their own situation. When people make mistakes or the process fails to work, make it into a major issue. It takes a LOT of good news to offset just a little bad news. Use this leverage to your advantage. The secret to your success is to keep all successes a secret.
Tune in next week as we continue to expose the secret lives of seriously disturbed maintenance “professionals” with The Dirty Dozen Tip #4: Ignore the Needs of Your Customers.
“Tip” provided by NoBreakDowns.com
Tel: (218) 327-3114
Web: http://www.NoBreakDowns.com
Receive a complimentary Dirty Dozen: 12 Ways to Wreck Your Maintenance Program electronic poster
November 16, 2006
Calculating Inherent Reliability Tip
Inherent reliability calculation can be simple if we use the right logic.
The logic is that we can stop some failures happening but there are some we can’t. This means all equipment has inherent levels of reliability or availability based on the design and the operating conditions. When data collection systems are set up, failures should be categorised into expected or unexpected. By reviewing your existing data or after collecting some for a short period you can determine the inherent reliability of your equipment.
Furthermore you can understand which failures are caused by the wrong maintenance and which ones are design or process problems.
For a limited time OMCS is offering free data collection review, improvement kit and training notes. This free offer is only open for two days or the first 200 registrations.
For a free data collection review, improvement kit and training notes click here
