Presented by Reliabilityweb.com

Transcription

1 Presented by Reliabilityweb.com

2 Upcoming CRL Workshops Jan 30 Feb 3 Mar Apr May Reliability Leadership Institute Fort Myers, Florida More information:

3 Providers

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5 Sponsors

6 Keynote Reliability Data Management: The Key to a Sustainable Asset Management Strategy by Buddy Lee, Reliability SME, Facilex

7 Rules and Gut Feel, IT, Forensics

8 The BASICS of RDM Why Reliability Data Management? Two basic goals: 1) Eliminate unexpected equipment failure (Eliminate high repair costs of production interruption); 2) Lower total lifecycle costs (Extend equipment MTBF) How: Implement & manage condition monitoring, lifecycle and cost tracking, and failure analysis activities

9 Leadership: If It Is to Be, It Is up to Me 85% of your financial success is due to your personality and ability to communicate, negotiate and lead. Shockingly, only 15% is due to technical knowledge. - Carnegie Institute of Technology

10 The BASICS of RDM

11 Barriers: Over, Under or Through

12 Strategic Data Management 1. Standardization of equipment name, fault description, and severity scale 2. Integration of condition information for assets 3. Communicate results to personnel (Web SAAS, not or pdf) 4. Enforce performance accountability of condition tasks and maintenance 5. Performance metrics: progress toward reliability goals

13 Condition Assessments (Goal #1 Eliminate Failure) 1. Equipment name, fault description, and severity scale standardization 2. Integration of condition information for assets

14 Integrated Condition Status Monitoring (Goal #1 Eliminate Failure) 2. Integration of condition information for assets 3. Communicate results to personnel (Web SAAS, not ) 4. Enforce performance accountability of condition tasks and maintenance

15 Why Lifecycle Tracking? (Goal #2 Extend MTBF) Basic reliability information: 1. MTBF, Root Cause of Failure and Cost of Failure 2. Critical Spares Management 3. Inventory of Equipment 4. Equipment Documents 5. Warranty 6. History - Location and Equipment 7. Vendor Evaluation 8. Program Metrics

16 Why Lifecycle Tracking? Location History Report Basic reliability information: 1. MTBF, Root Cause of Failure and Cost of Failure 2. Critical Spares Management 3. Inventory of Equipment 4. Equipment Documents 5. Warranty 6. History - Location and Equipment 7. Vendor Evaluation 8. Program Metrics

17 Why Lifecycle Tracking? Equipment History Report Basic reliability information: 1. MTBF, Root Cause of Failure and Cost of Failure 2. Critical Spares Management 3. Inventory of Equipment 4. Equipment Documents 5. Warranty 6. History - Location and Equipment 7. Vendor Evaluation 8. Program Metrics

18 General Reliability Metrics World Class Average Average life of electric motors > 15 yrs < 10 yrs Mean time between repairs for pumps > 6 yrs < 3 yrs Average vibration levels < 0.1 in/sec > 0.3 Overtime, percent of total hours worked < 3 % > 10 % Emergency work < 5% > 15 % Total maintenance cost as percent of RAV < 2% > 3% Reliability impacts safety, environmental, quality, service, cost, and CTO Source: Bob Taylor SMRP 2003

19 Reliability Condition Monitoring Metrics

20 Reliability/CM Task Accountability

21 Failure Analysis & Metrics (Goal #2 Extend MTBF) Performance metrics: progress toward reliability goals

22 Corporate RDM Strategy Corporate procedures for asset management and reliability information flow Monitoring - frequency & completion Standardized reliability reporting & metrics (across sites) Communicate accountability for reliability improvement (Web SAAS)

23 Asset Health Report

24 Cost Benefit Tracking

25 Cost Benefit Tracking

26 3 Keys to RDM 1. Standardization of reliability nomenclature 2. Asset location history vs. individual equipment history 3. Broad communication and accountability

27 Contact

28 Tools to Execute Your Reliability Strategy Derek Burley CM RP, CRL (800)

29 3 basic tactical tools Reliability Centered Maintenance (RCM) Includes FMEA as part of the process Preventive Maintenance Optimization (PMO) Quick, less rigorous than RCM Root Cause Analysis (RCA) For when the unexpected happens

30 3 basic tactical tools Reliability Centered Maintenance (RCM) Includes FMEA as part of the process Preventive Maintenance Optimization (PMO) Quick, less rigorous than RCM Root Cause Analysis (RCA) For when the unexpected happens Top 10-15% of most critical systems The next 70-75% of your systems (the bottom 10-15% probably don t matter)

31 3 basic tactical tools Reliability Centered Maintenance (RCM) Includes FMEA as part of the process Preventive Maintenance Optimization (PMO) Quick, less rigorous than RCM Root Cause Analysis (RCA) For when the unexpected happens Top 10-15% of most critical systems The next 70-75% of your systems (the bottom 10-15% probably don t matter)

32 3 basic tactical tools with one thing in common RCM RCA FMs PMO

33 Tools to Execute Your Reliability Strategy Derek Burley CM RP, CRL (800)

34 Educational Session What s Next for Asset Condition Management (ACM)? by Dave Reiber, Senior Reliability Leader, Reliabilityweb.com

35 Dave Reiber CRL / CMRP Currently Senior Reliability Leader at Reliabilityweb.com Recently - Predictive Maintenance Lead for General Motors & Global Training for Maximo Held several leadership positions at General Motors Skilled Trades Supervisor and General Supervisor at 2 GM Sites Maximo Site Project Manager North American Maximo Business Lead Global Maximo Business Lead Member of IBM Maximo Advisory Board for many years Co-Lead for IBM Manufacturers User Group for Maximo Speaker at many maintenance and Maximo conferences Led Maintenance Webcasts for UE and Plant Engineering Magazine Hosted many Maximo & Predictive Webinars for General Motors Certified CMRP from Society of Maintenance and Reliability Professionals Certified CPMM from Association for Facilities Engineering Certified Infrared / Ultrasound

36 Things Are changing fast Did you ever imagine that the information age would open so many doors, so quickly? Do you use some of the new tools that handle large amounts of data fast and efficiently? Are you on the fast track to improvement, or are you waiting to see what happens? If you wait to see what happens, it will be too late. When you do decide to take action, your competition is already moving.

37 What Is Required? New data from many sources real time Asset health monitors real time Quick access to manuals and data gathered Aggregation of the data from all sources fast Auto-generated diagnostics and problem solving solutions Trending and patterning of the data with intelligent software Permanent learnings from past failures. Auto-generated work orders, texts, voice messaging, etc..

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39 Predictive Maintenance Technologies: Vibration Analysis Electric Motor Diagnostics Airborne Ultrasound / Shaft Ultrasound Laser Alignment Fiber Optics / Optivibe Hi-Speed Video Infrared thermography Oil Analysis

40 Predictive Maintenance Condition Based Maintenance Maintenance based on machine condition Scheduled downtime held to a minimum Downtime, spare parts usage, & overtime can be minimized

41 System Depiction Wireless sensors: Some will come right from the supplier, others you will purchase and install

42 Optivibe Measuring Movement 1. The technician takes a measurement without making contact. 2. Vibrations are measured at every pixel in the image. 3. Data is shown as a color-coded image based on the intensity of the vibration.

43 Electrical Motor Diagnostics As more and more studies are done around motor Circuit Analysis, we find that sometimes the most sensitive sensor in the process is the electrical motor. (sewing machine needles)

44 Electric Motor Diagnostics

45 Ultrasound

46 Generic Divisions of Ultrasound ULTRASOUND Pulse/Echo Medical Imaging Flaw Detectors Flow Measurement/Control Power Ultrasonic Cleaners Medical Airborne/ Structure Borne Mechanical Inspection Leak Detection Electrical Inspection

47 Airborne Ultrasonics Is The study and application of high frequency sound waves inaudible to human ears Sound waves above 20,000 Hz (20,000 cycles/second)

48 Sound Penetration Low Frequency Sound Waves Range in size from ¾ to 56 Vibrate solid surfaces Large objects appear transparent High Frequency Sound Waves Range in size from 1/8 to 5/8 Cannot penetrate solid objects Short Weak

49 Typical Applications Leak Detection Compressed Gas Heat Exchangers Vacuum Electrical Inspection Corona Tracking Arcing Mechanical Inspection Leaking Valves Efficiency of Steam Traps Bearing Health Gear Mesh Lubrication Excellence

50 Electrical Inspection Arcing: An arc occurs when electricity is conducted to ground Corona: Voltage on an electrical conductor exceeds the threshold value Tracking: Often referred to as baby arcing, it follows the path of damaged insulation

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52 Condition Based Lubrication When a bearing exceeds 8dB over a baseline, it is scheduled for lubrication. A technician can use the db readout as a guide to determine when to stop applying grease and prevent over lubrication.

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54 Laser Alignment

55 Laser Alignment 3 Disciplines Shaft to Shaft Spindle Belt & Sheave

56 Laser Alignment Methods Laser Indicator Part Quality Tool Life Straight Edge Measuring Precision.010" to.005".002" to.001".0008" to.0002"

57 Remote Sensing/High Speed Video

58 Remote Sensing/High Speed Video Fiber Optics Glass fibers are used to transmit light Glass fibers are used to send an image back Borescopes Rigid instruments for inspection of difficult areas Flexible Video Probes Flexible instruments for access to difficult areas Can be used in conjunction with high speed video High Speed Video Record fast events Review at slow speeds to understand

59 Fiber Optics Fiber optics uses glass fibers to transmit light to the point of inspection and then transmits the image back to the eyepiece.

60 High Speed Video vs. Standard Video High speed video events Sequences normally captured at hundreds or thousands frames per second Standard camcorders/cameras can only capture 25 or 30 frames per second i-speed 33,000fps (1,000fps at full resolution) Information and detail will be missed Understanding high-speed motion is critical in many of today's industries New Go-Pro technologies offer some options for speeding up or slowing down video for better diagnostics.

61 INFRARED THERMOGRAHPY

62 Infrared Thermography What Is It? Takes the invisible and makes it visible Makes infrared visible Able to observe the effects of heat All objects emit heat A form of energy Travels from hot to cold Measure temperature Temperature is crucial The intensity of heat Measured by non-contact Visible light Infrared light

63 Benefits of IR Inspections It is non-destructive Reduces repair costs Extends equipment life Averts catastrophic failures Increases efficiency saving energy $

64 Camera Handling F Focus You must focus carefully before storing an image because you can t refocus later R Range The temperatures you plan to measure must be within the Range you choose for your image D- Distance The Distance to the target cannot be changed in post processing software

65 Infrared Image Test

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67 Why Bearings Fail Storage & Handling Overload Other Improper Lubrication Installation Errors Contamination Lubrication Related In a study conducted by the bearing manufacturer SKF, over 50% of bearing failures were the result of poor lubrication practices.

68 Six Basic Purposes of Lubricants Reduce Friction Reduce Wear Dampen Shock Dissipate Heat Prevent Corrosion Seal Out Dirt and Other Contaminants

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70 Cost Savings / Cost Avoidance

71 Definitions Cost Savings Dollars that are currently spent but will not be spent in the future Cost Avoidance An estimated dollar amount that would be expected to be paid in the future if proactive events did not keep the machine, tooling, or system producing units

72 Questions / Comments Dave Reiber CRL / CMRP Senior Reliability Leader at Reliabilityweb.com - dave.reiber@reliabilityweb.com

73 Questions & Answers

74 Thanks to Our Sponsors

75 Next Webinar Date: Wednesday, January 25

76 WIRAM Series Next Generation Maintenance: The Journey from Calendar-Based Maintenance to Prescriptive Analytics by Rendela Wenzel, Associate Senior Consultant Engineer, Eli Lilly

77 Educational Session Building the Business Case for Maintenance Improvement Made Simple by Susan Lubell, Steppe Consulting Inc.

78 Introducing Soluciones 2.0!

79 Save the Date! April 24-28, 2017 Las Vegas, NV For more information, contact:

80 We d love to hear your feedback! your questions or comments to sean@reliabilityweb.com

81 Thank You for Joining Us!