100 10 1 Why Proactive Service Can Save you a Lot of Money

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Repair on failure is very costly. Repair before cost you a lot less. But preventing the situation from happening in the first place can save you a fortune.

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100 10 1 Why Proactive Service Can Save you a Lot of Money

  1. 1. 100 10 1
  2. 2. You shouldn’t have to be here… …for unplanned stops
  3. 3. How come that there always seems to be money available to fix failures…
  4. 4. …but never enough to prevent them from happening in the first place?
  5. 5. >75% avoidable
  6. 6. What are the most common reasons for unplanned stops of your equipment?
  7. 7. It is generally not…
  8. 8. …big rocks
  9. 9. …forces of nature
  10. 10. …or even overload
  11. 11. But rather…
  12. 12. …small grains of sand
  13. 13. causing abrasive wear
  14. 14. …droplets of water
  15. 15. causing corrosion
  16. 16. and cavitation
  17. 17. …microscopic bacteria
  18. 18. causing sludge
  19. 19. …and excessive heat
  20. 20. causing oxidation
  21. 21. …and all of that is generally caused by the 3 I’s…
  22. 22. …Incompetence
  23. 23. …Ignorance
  24. 24. and Indifference
  25. 25. and never underestimate the tremendous impact of a bad driver
  26. 26. Dust in the engine’s inlet air causes…
  27. 27. Leading to reduced machine performance …increased engine wear Accelerating the engine wear Resulting in increased fuel consumption
  28. 28. Genuine air filter Good spurious air filter 99.99% filtration 99.9% filtration 10 X more wear!
  29. 29. Dirt in the hydraulic system causes…
  30. 30. Increased mechanical wear
  31. 31. Increased mechanical wear Slower operation
  32. 32. Increased mechanical wear Slower operation Increased fuel consumption
  33. 33. Increased mechanical wear Slower operation Increased fuel consumption Increased oil consumption
  34. 34. Dirt in the fuel system causes…
  35. 35. Wear on injectors and fuel pumps
  36. 36. Increased fuel consumption
  37. 37. Shorter engine oil life
  38. 38. and reduced engine life
  39. 39. Dirty Air/Oil affects your entire operation as it…
  40. 40. …reduces your output
  41. 41. …reduces your output …increases your operating cost
  42. 42. …reduces your output …increases your operating cost …decreases your profit
  43. 43. Facts:
  44. 44. Dirt spirals wear
  45. 45. Dirt spirals wear Wear particles causes shorter oil life
  46. 46. Dirt spirals wear Wear particles causes shorter oil life Dirty oil is a main reason for leakage, causing further increased wear
  47. 47. Dirt spirals wear Wear particles causes shorter oil life Dirty oil is a main reason for leakage, causing further increased wear Dirty oil increases filtration cost
  48. 48. 100 The cost to fix a catastrophic failure.
  49. 49. 10 The cost to fix a catastrophic failure. The cost to filter the system clean.
  50. 50. 1 The cost to fix a catastrophic failure. The cost to filter the system clean. The cost to keep the dirt out.
  51. 51. The risks are huge… …but remedies straight forward. Or?
  52. 52. Set cleanliness targets
  53. 53. Set cleanliness targets Train your staff at all levels
  54. 54. Set cleanliness targets Train your staff at all levels Choose high quality/genuine oil
  55. 55. Set cleanliness targets Train your staff at all levels Choose high quality/genuine oil Store it well
  56. 56. Set cleanliness targets Train your staff at all levels Choose high quality/genuine oil Store it well Keep filling area dustfree when changing oil
  57. 57. Use only genuine filters
  58. 58. Use only genuine filters Maintain your breathers
  59. 59. Use only genuine filters Maintain your breathers Rectify leakages immediately
  60. 60. Use only genuine filters Maintain your breathers Rectify leakages immediately Frequent and regular oil analysis
  61. 61. Use only genuine filters Maintain your breathers Rectify leakages immediately Frequent and regular oil analysis Monitor and modify
  62. 62. “If you think education is expensive, try ignorance” Benjamin Franklin
  63. 63. Reactive maintenance Repair on failure No pre-planning Erratic operation Costly failures Sh…t happens Bigger fleet than required
  64. 64. Predictive maintenance Repair before catastrophic failure Significant pre-planning Smoother operation Lower cost per failure Cheaper sh…t happens More accurate fleet size
  65. 65. Proactive maintenance Root cause analysis Change incorrect behavior Well-run operation Longer time between failures Sh…t happens, but rarely Optimum fleet size
  66. 66. Don’t rely on luck…
  67. 67. … start working proactively
  68. 68. Cost? Close to nothing
  69. 69. Potential saving: Immense
  70. 70. Benefits, Proactive Service: Early detection and correction reduces your cost
  71. 71. Benefits, Proactive Service: Early detection and correction reduces your cost Detect root cause to avoid repetition
  72. 72. Benefits, Proactive Service: Early detection and correction reduces your cost Detect root cause to avoid repetition Better uptime and production through smoother operation
  73. 73. Benefits, Proactive Service: Early detection and correction reduces your cost Detect root cause to avoid repetition Better uptime and production through smoother operation Improved net profit
  74. 74. ...you just have to get started.
  75. 75. 100 10 1
  76. 76. The choice is yours

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