April 14, 2005
CMMS/EAM Tip
Timely CMMS/ EAM Reporting
Once a company purchases a CMMS/ EAM System, how long it before accurate and informative analysis reports can be produced? The answer depends on how long it takes your company to develop accurate data.
In a recent survey 52 percent of the respondents said it took between 1 to 11 months to make their system fully operational. More specifically, the survey showed that 40 percent of respondents took more than one year to make their system fully operational.
Even before a plant or facility implements a CMMS/ EAM System, the information collected by these companies still will have some value. But until the system is fully utilized, the data will not be accurate. For example, if only certain departments are on a CMMS/ EAM System (a typical pilot implementation problem), then the data from these departments may be accurate. However, in areas where a crossover or combination with another area or craft exists, the data may be incomplete or distorted.
As highlighted in a previous Maintenance Tip, a CMMS/ EAM System should provide a completely integrated data collection system. However, even many mature users are not getting complete—and thus accurate—data from their CMMS/ EAM system. In the referenced survey, 921 respondents were asked about the use of the inventory, purchasing and personnel modules of their systems. Responses showed the majority of the respondents are using less than 70 percent of their system.
When companies fail to fully utilize their CMMS/ EAM System, the data may not be posted accurately in the equipment history. In fact, in most cases, the data is inaccurate or not posted. Thus, the equipment history is incomplete or inaccurate.
For example: When using a CMMS/ EAM system, if the planner does not have access to accurate and timely inventory information, then the planner cannot be sure the stores’ information is accurate. This is especially true if the stores information is updated only once a day or once a week. This situation arises many times when other systems are “interfaced” to a CMMS/EAM system. Planners can waste time looking for a part that is supposed to be in the stores, when, in fact, it was used that part the previous day or shift. This delay may seem inconsequential. However, when downtime can cost $1,000 or even $100,000/hour, these types of delays may mean the difference between profit and loss for the entire company.
The solution to data collection and accuracy will be explained in part 2 of this maintenance tip in 2 weeks.
Tip provided by GenesisSolutions
http://www.GenesisSolutions.com
Tel: (203) 431-0281
iPresentation Invitation: Conducting an Effective EAM/CMMS Training Program (22 Minutes)
April 14, 2005
Alignment Tip
Bolt Bound Solution
I have read many great tips for correcting bolt bound situations and even for calculating the required stationary machine move to allow for correct alignment however we use the following simple procedure with great success, without getting confused as to which way to move what.
When you find your motor is bolt bound simply loosen all the hold down bolts and position the motor in the middle of its available travel. Setup the laser gear with the motor as the stationary machine then calculate the horizontal move required for the pump or go to the live move display. Loosen the pump (or normal stationary machine) hold down bolts and assuming that the plumbing allows the move, slide the pump in the direction indicated on the alignment gear till you have the pump in the approx correct position. Secure the pump, swap the laser gear around and finish the alignment in the normal way by moving the motor. Hope this helps!
Cheers Ross
Reader tip provided by Ross Bowles
Condition Monitoring Australia
http://www.cmaustralia.com.au
Thank you Ross - your Maintenance-Tips hat is on the way!
April 14, 2005
Maintenance costs of unplanned down time
Maintenance costs of unplanned down time are the biggest whale in the water. Training provides the knowledge to transition long term maintenance problems into profit opportunities and raise morale. Outsourcing this responsibility gives someone else the profits. Start with RCM April 12-13, Root Cause Analysis Methods--May 10,11 and Root Cause Analysis Error Reduction, May 12-13, 2005 at the University of Dayton, Center for Competitive Change.
email:
Tel: 937-229-4656
April 14, 2005
Root Cause Analysis (RCA) Tip
In regards to past RCA tips provided by Robert Latino.....I have been a maintenance professional for over 33 years and I agree that CONSEQUENCE is the criteria to decide whether or not to perform and RCA. However, one should look at the CONSEQUENCE to maintenance as well as production equally. Case in point. We had pumps from one manufacture which were continuously breaking down prematurely without impacting production. No one was looking at these pumps as a candidate for and RCA because the repairs were not showing up on any lost production report and the repairs were on several different pumps in different locations. While writing a paper on the importance of maintaining an accurate up to date repair history that can be queried I found these pumps were costing our maintenance about $144,000 every year in parts and labor. An RCA revealed that operations were not operating them properly. Training was performed and the problem now rarely arises. The point is, when a problem arises there could be a maintenance consequence as large or larger than the production consequence.
Reader tip provided by Rick Riles
Vibration Analyst
Georgia-Pacific Paper
Crossett Arkansas
Thanks Rick - your Maintenance-Tips hat is one the way!
April 14, 2005
Vibration Analysis Tip
Always pick two vibration sensors of the same model when measuring Cross Channel Phase. Otherwise, differences in the sensors’ high pass & low pass can influence the phase readings.
Tip provided by LUDECA, INC.
ALIGNMENT * VIBRATION * BALANCING
http://www.ludeca.com
Tel: 305-591-8935
Test your vibration data collection IQ
April 14, 2005
Mark Your Calendar: CMMS-2005
Computerized Maintenance Management Summit
July 26-29, 2005
Indianapolis Indiana
You’re Invited!
Please join us for CMMS-2005, the Computerized Maintenance Management Summit from July 26, 2005 through July 29, 2005 in beautiful downtown Indianapolis Indiana.
CMMS-2005, the Computerized Maintenance Management Summit is the only event dedicated to Computerized Maintenance Management and Enterprise Asset Management, Maintenance Inventory, Maintenance Planning & Scheduling and Maintenance Work Management.
You will take away new solutions for maintenance information management that you can put to immediate use as peers and industry experts share knowledge and experience in a non-commercial environment.
Please request a CMMS-2005 brochure
April 14, 2005
Maintenance Tip
Well written standard jobs can save your company large amounts of time and money on maintenance activities. Standard jobs decrease the task time required for completion of the job, minimize errors, and help insure that the correct parts arrive for the work.
The basic elements of a well written standard job are very much the same as the basic elements of a well written newspaper article. We need to answer the questions of who, what, when, where, and how.
• Who will do the job
• What will be worked on?
• When will the job be done?
• Where will the job be done?
• How will the job be done?
Read more about developing maintenance tasks at the ARMS Reliability Engineers Web Site
April 14, 2005
Reliability Tip
Outsourcing Maintenance? Protect the intellectual property of your asset reliability program
If you are thinking about integrating a maintenance outsourcing model with your asset reliability improvement strategy or have already done so, you need to ensure that you protect the maintenance knowledge and expertise of your assets which are key to plant performance.
Maintenance outsourcing may mean handing over accountability and responsibility for the entire maintenance process to a third party. If externally owned and controlled, knowledge and expertise is not captured and therefore lost when the contracts are up for renewal. Furthermore, it makes it more difficult to continuously improve the performance of your asset base with an interruption of this information. Outsourcing contracts that neglect to capture the intellectual property of the asset reliability program will eventually result in widening the gap in performance, not narrowing it.
Manufacturers, and not Outsource companies, must take ownership of the inherent knowledge that exists in their assets’ reliability programs. This knowledge includes:
• tasks and frequencies required to prevent failure and optimize asset performance
• specific targets for normal and non-normal ranges of condition data, from simple numeric values to more complex rules-based engineering calculations as specified by the expert
• enormous amounts of data critical for tracking and trending
Don’t let that knowledge slip away. If you are outsourcing or considering this option, ensure that you have a process and the tools to capture and retain the intellectual property of your asset reliability program.
With data and information come knowledge and therefore the understanding of asset performance. The ability to have the knowledge and metrics at your fingertips affords you the opportunity to pay for performance – it’s a win/win for you and the outsourcer. Successful companies, who invest in sustainable growth, recognize the strategic impact of capturing maintenance knowledge in all forms.
This tip provided by Ivara Corporation.
http://www.ivara.com
iPresentation Invitation:Capture the Expertise of Your Aging Workforce (4 minutes)
April 06, 2005
Belt Tip
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.
Reader tip supplied by John A. Rumble
Maintenance Technician
Perrys Ice Cream
Akron NY
Thanks John - Your Maintenance-Tips hat is on the way!
April 06, 2005
Airborne Ultrasonic Tips
Vacuum Leaks
Pinpointing vacuum leaks with an ultrasonic detector can be especially challenging since the turbulent ultrasonic hiss produced by the leak is mostly sucked inside the volume being tested. Try using a contact probe or magnetic probe instead of the conventional airborne sensor. Position the probe close to where potential leaks could occur and turn the sensitivity to maximum. Listen for the same sounds that characterize a leak as air rushes turbulently inside the volume.
Tip provided by SDT North America
http://www.sdtnorthamerica.com
Toll free: 1-800-667-5325
Tel: 905-349-2020
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