February 08, 2007
Root Cause Analysis (RCA) Tip
CONTRARY TO POPULAR BELIEF…A common paradigm in industry is that if I cannot obtain “management support”, I cannot be successful in my RCA efforts. If people actually believe this, then their RCA effort will never be successful. Sure, full management support would make it easier for us to be successful, but is it a deal breaker? Only if we let it be. If we have the will and desire to conduct RCA’s on events where it is the RIGHT THING TO DO, then we will be successful despite the barriers placed in front of us. If we lead an effort to conduct a thorough RCA that ultimately nets a quantum amount of returns for the corporation, then those in the “ivory tower” will take notice and start to inquire how those returns were realized. You are in control of your own destiny, not management!
Tip provided by Bob Latino
The Reliability Center Inc.
http://www.reliability.com
Find out more about the PROACT Logic Tree Knowledge Management Templates
February 08, 2007
Vibration Analysis Tip
Testing for accelerometer failure
Not sure if your accelerometer is working?
Here are a few quick test to help you determine if your vibration sensors is functioning properly:
• Lightly shake the accelerometer next to your ear. Do you hear a rattle? No accelerometers are made with loose parts! If you hear anything when you shake it, internal parts are loose.
• Connect the accelerometer to your data collector, and check for a reading. Many people simply shake the accelerometer to test for vibration measurements, but even on a working accelerometer this typically does not produce a sufficient reading. A better technique is to enclose the sensor in your hand and gently hit your hand on the table. NEVER bang the accelerometer on the table – grip it in your fist so that only your hand impacts the table. Unlike shaking it, this allows you to create high enough g-level vibrations to be read, without inflicting fatal damage to the sensor.
• Using your data collector, check the BOV level of the sensor. If the BOV reading is more than 4Volts off the nominal specifications provided by the manufacturer (above or below), the sensor has likely suffered permanent damage. A sensor BOV reading will detect virtually all internal electronic circuit failures.
If it fails these simple tests, it’s time to replace your accelerometer.
Tip provided by Wilcoxon Research
http://www.wilcoxon.com
Learn more about troubleshooting accelerometers at Wilcoxon’s online knowledge desk
February 08, 2007
Welcome to Commtest - The Revolution
Commtest is dedicated to providing the world’s best value in vibration analysis products. Products include vibration data collectors, portable analyzers and permanent machinery surveillance systems, sharing a common interface: Ascent software.
Commtest expectations are high. We take pride in our products service and support network. We respect customers’ needs and work toward mutually beneficial relationships. The book, “Second to None”, contains Commtest’s guiding business principle. Author Dr. Ian Brooks states: “Partners are customers who believe you are so important to their own success that they cannot imagine being in business without you”. That is how we strive to be regarded.
Phone: 865-588-2946
February 08, 2007
The Dirty Dozen: 12 Ways to Wreck Your Maintenance Program
Walk Away From the Challenge (12 of 12)
Over the past 3 months, we have shared The Dirty Dozen: 12 Ways to Wreck Your Maintenance Program, poking a little sarcastic fun at the dark side of the maintenance profession. The idea for approaching maintenance excellence from the worst-case point of view came from our observations of extremely reactive maintenance organizations struggling, and often failing, to become proactive.
We wondered what would happen if we featured a model for bad behavior instead of the usual “This is what you should be doing” approach, exposing the damage that is viewed as normal just because it is familiar. Would it be possible to create an environment where it isn’t OK anymore to waste money, talent and production to fight fires continuously? Could we shout out that the emperor wears no clothes, and generate the energy to help the toughest cases become proactive?
Imagine being a person who has been a Master of the Dirty Dozen for years. Maybe you don’t have to imagine it? Everyone could see that your behavior was deadly to the well being of the operation, once they were made aware of it. This common vision would allow us to work together to learn and change. It’s not about firing people who made mistakes, or placing blame. Those who have damaged the process in the past have tremendously valuable insight into fixing problems in the future, once they understand the stakes.
The last of the Dirty Dozen ways that you can wreck your maintenance program is to walk away from the challenge to do something differently today. If you are dealing with equipment failures and emergencies on a daily basis, that is proof that your process is broken. It doesn’t have to be that way. Don’t let anyone tell you different.
“Tip” provided by NoBreakDowns.com
Tel: (218) 327-3114
http://www.NoBreakDowns.com
Receive a complimentary Dirty Dozen: 12 Ways to Wreck Your Maintenance Program electronic poster
February 01, 2007
EAM-2007 Workshop
The Enterprise Asset Management Summit
April 3-6, 2007
Sheraton Waikiki Honolulu Hawaii
Workshop 10B
EAM Failure Coding and Functional Hierarchy Development by Bill Keeter
One of the most important parts of EAM/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 minute presentation 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.
Seating is limited so register early. Early bird conference and hotel discounts end Feb 15.
Call +1 (305) 735-3746 or…
Find out more about workshops and case studies at the EAM-2007 web site
February 01, 2007
Maintenance Planning Tip
BACKLOG BOARDS
Excerpt from John W. Rushton’s book: Effective Maintenance Management Using Planned and Preventive Maintenance.
Any good planned maintenance program can become significantly better by installing and using backlog boards. In fact, we doubt that any group can become a first class maintenance organization without boards. If you question the quality of your program, installing boards is the single quickest way to find out just how good your program really is.
The backlog board is primarily a communications tool, and makes it easier for more people to get involved in the planning effort. Backlog boards make it easy for a vice president or plant manager to walk into a planning office and immediately know the health of the planned maintenance program. They make it easy for a production supervisor that perceives a need for maintenance work to quickly find out if there is a work order written. He can then initiate a job request, adjust priority and suggest a schedule in a matter of seconds.
The use of a computer cannot currently duplicate the function of a backlog board. If the planner does not keep the board up-to-date, everyone knows that the planner is not doing his job. This differs from the computer, where a planner can be behind for weeks or months before anyone realizes that the information in the maintenance computer is of little, if any, use in planning maintenance work. Most foremen like the lack of accountability that a poor system creates, and will gladly assign their people as they feel the need, and allow the planner to keep score after the fact. Backlog boards create accountability.
Boards can be purchased from almost any school or office supply company. We prefer a slick, white surface, and you should check to make sure the board is magnetic. Size and number of boards is determined by the size of the active backlog and the number of areas that need to be scheduled.
Tip provided by Rushton International
http://www.rushtonintl.com
For more information on implementing backlog and scheduling boards, please visit
February 01, 2007
Data shows proactive techniques and leaders create asset uptime of 92% and return of invested capita
Reliabilityweb.com, an online community of over 50,000 maintenance and reliability professionals, recently partnered with the Aberdeen Group to encourage members to participate in a study titled “Collaborative Asset Management Strategies”.
Aberdeen’s analysts and researchers Mark Vigoroso and Michael Israel have uncovered significant characteristics of “best practice” companies. According to the recently issued report these “organizations reap substantially larger benefits from improved maintenance practices than do average and laggard establishments, including:
• Significantly improved asset reliability,
• Greater asset uptime and availability,
• Lower costs of servicing assets,
• Fewer unexpected downtimes and outages, and
• A higher return on invested capital.”
February 01, 2007
V-Belt Tip
QUESTIONS ON V-BELTS?
When it comes to v-belts there is more to just throwing them on and walking away. Unfortunately in most cases this is exactly what is done. Another misconception is that v-belts do not need to be replaced until they have completely broken and will not function at all. V-belts will stretch and start slipping long before they will break. V-belt dressing will buy you some short term time but is not the answer. A quality preventive maintenance program may include automatically replacing vbelts every six months depending on equipment run time.
Proper v-belt installation is very important when it comes to getting maximum life and efficiency from your v-belts. Take time to insure that your v-belt pulleys are properly lined up with a strait edge and that they are not worn and cutting into the v-belts. Proper v-belt tension should be set with a v-belt tension tool and reset again after the first week or so of operation to allow for v-belts that stretch, and all v-belts will stretch. Most of the stretching takes place in first hours of operation so it is very important to re check belt tension after the belt has had some run time.
Tip provided by HVAC Maintenance & Supplies
http://www.mainsupplies.com
February 01, 2007
Transformer Tip
Condition Assessment of Large Oil filled Power Transformers
The aging population of power transformers needs to be monitored closely to avoid unexpected failure. The fact is that failure occurs as equipment ages, the difference is knowing when to trend, when to repair and when to place and order for a replacement. The tips below will aid this process.
1. Treat the transformer and its support systems as you would any other critical plant system.
2. Create a level 2 condition assessment plan.
3. Select a dedicated team to man this process.
4. Obtain the test equipment to provide the needed data.
5. Gather baseline data on all subject transformers.
6. Monitor and trend.
These six steps will not only provide the information to the PdM coordinator to maintain these aging giants, but will uncover many anomalies that would lead to premature failures in their support systems.
Tip by Jon Giesecke
JLG Associates
http://www.powerpd.net
February 01, 2007
CMMS/EAM Tip
In order to get good analytical data from your EAM/CMMS it is good to have standard data fields to select and sort your data. One way to accomplish this is to establish and use predefined codes for documenting what component failed, what caused the failure, and what action was taken to repair the equipment. Most all EAM/CMMS systems have the ability to use standard codes for this information. It may take effort to get these codes establish and used on a routine basis but the results will well worth the effort.
Tip provided by AssetPoint
http://www.assetpoint.com
iPresentation Invitation: Use Maintenance Data to Solve Production Problems
