Euro maintenance2012presentationfinal

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Euro maintenance2012presentationfinal

  1. 1. ©Lubrication Reliability Practices for Improved Equipment Reliability Ian Knight Enluse BV The Netherlands Organized by On behalf of © DOTS © EFNMS vzw ©
  2. 2. Who Are We! © Ian Knight, Australian living and working in Europe, based In The Netherlands. Mechanical trade background, however sales, service and marketing are my key qualifications. 35 years with SKF in Sales, Service and Marketing. Extensive experience in Condition Monitoring, Lubrication and Equipment Reliability. Started Enluse BV in 2003. European importer for Fluid Defense lubrication equipment line. Supply all Lube related equipment from the lube room to the machine. Consult on implementing Lubrication Reliability strategies. ©
  3. 3. ©Over 2 years over 100 replaced bearings were examined €2,300 of Bearing Costs!but €150,000 Maintenance Costs ©
  4. 4. © The ConclusionsOver 60% were due to lubrication issues. 15% were due to poor maintenance issues. 5% were due to ignorance issues. 15% The balance (approx.) were in good condition?? ©
  5. 5. ©The Conclusions Bearings are the rotating core of all equipment . Reduced bearing consumption, is increased equipment reliability. Lubrication accounts for most failures and damage. ©
  6. 6. The Key Conclusion ©A better lubrication strategy, willreduce bearing consumption andincreased equipment reliability . So we should make Bearing Consumption Reduction, a Reliability KPI. ©
  7. 7. © The Reliability KPI’s Down Time Up Time However, detailed Bearing reliability improvements LubeConsumption Consumption should have a package of supporting KPI’s. Inventory Overall Levels Lube Maintenance Cleanliness costs to production levels ©
  8. 8. © Lubrication Reliability ??? We know lubricationIt’s part of our is important. reliability metrics. It’s so important it should be a stand alone Reliability activity. ©
  9. 9. © Lubrication Reliability An effective Lubrication program must consider many points. Can we claim for every machine?  We are using the right lube?  We add lube at the right time?  In the right quantities?  In the right condition?  We are maintaining our lube condition?If so – then you have a reliableLubrication Program.If not – then we will haveproblems. ©
  10. 10. ©Lubrication ReliabilityAll activities to Processes & tools toimprove reliability reduce equipment wear and damage Lubrication Contamination Strategy Control Lubrication Knowledge Data Base and ManagementThe people and Application and Reporting Administration oftheir commitment the work to beto the work done ©
  11. 11. Lubrication Reliability © Activity Maturity Level Lubrication Strategy Asset Efficiency CultureCleanliness andContamination Proactive Control Lubrication Management Data Base Management Lubricationand Reporting Processes Lubrication BasicKnowledge and Requirement Application ©
  12. 12. Lubrication Reliability © Cleanliness & Data Base Lubrication Lubrication Contamination Management Knowledge & Strategy Control and Reporting Application Lube Room Cost verses Basic Dedicated Standards in Data BaseRequirement Resources Existence Investment in Place Uptime Instructions for Procedures for Maintenance Trained Staff Lubrication Reducing Planning Processes the Work on Lubrication Contamination Controls Proactive RCFA on all Integrated inLubrication Oil Analysis and Dedicated Lube Reliability failed Parts Evaluation SoftwareManagement Program Asset KPI’s on Lube Overall Plant Integrated and Measurement of Efficiency Effect to Cleanliness Seamless to Activity Culture Reliability Measurements CMMS Effectiveness ©
  13. 13. Lubrication Assessments ©  Where are we now ?  What do we do wrong ?  What do we need to do better ?Best Practice Solution : Lube Assess . ©
  14. 14. © Lubrication Assessments Coal Fired Power Station Assessment ResultMaintenance Lubrication Cleanliness & Data Base Lubrication Environmental Supply Culture & Strategy Contamination Management Knowledge Practice Control & Reporting Asset Efficiency Not Not Applicable Sure Culture Proactive NotLubrication ApplicableManagemen t Lubrication Do Not Processes Know Basic Maintenance Experience requirement ©
  15. 15. ©10Steps to Lubrication ReliabilityTo enhance Plant & Equipment Reliability and to achieveWorld Class Maintenance 15 A How to guide for Maintenance & Reliability Professionals ©
  16. 16. ©1. Assessment / Benchmarking• Where are we now ?• What do we do wrong ?• What do we need to do better ? Best Practice Solution : Lube Assess . ©
  17. 17. ©2. Organization and Planning• Lubrication Planning• Lubrication Management• Lubrication Management tools Best Practice Solution : Mafuta. ©
  18. 18. © 3. Identification • Multiple types lubricants • Complex Chemistry & Compatibility • Avoiding errors • TPM, ISO22000, OSHA, IFSBest Practice Solution : LABEL SAFE . ©
  19. 19. © 4. CLEANLINESS CONTROL• Contamination is a major source of failure• Clean lubricants in operation• Lubricant Cleanliness Control Centres• Safe & Clean storage-conditioning / transfer Best Practice Solution : Lubristation Luberooms . ©
  20. 20. © 5. LUBRICANT DISPENSING Dispensing equipment needs to be : • Safe & Clean & Closed • Efficient & user friendly • Adapted to application • Multi colored identification • Rust freeBest Practice Solution : Oil Safe . ©
  21. 21. © 6. GREASE LUBRICATION • Best practice tools • Efficient & practical • Color-codedBest Practice Solution : Grease Safe, Mobilube . ©
  22. 22. © 7. CONTAMINATION CONTROL • ISO4406 check • On line /Off line filtering • Lubricant protectionBest Practice Solution : Air Sentry, Magnum, Decolube ©
  23. 23. © 8. OIL ANALYSIS • ISO 4406 monitoring • Lubricant life extention (chemistry) • Cleanliness managementBest Practice Solution : Oil Analysis services, sampling tools ©
  24. 24. © RELIABILITY/CLEANLINESS LEVEL 30 RESULTS OF DTI SURVEY 1984 25 20ISO CODE 15 >3um >5um 10 5 >15um 0 MEAN TIME BETWEEN FAILURES (hours) ©
  25. 25. © BEARING LIFE Ref Dr. D.P. MacPhearson of Westland Helicopters Ltd. 14 6.6To Fatigue Failure 12Millions of Cycles 10 8 3.6 6 4 1.3 1 2 0 0 3 6 10 20 25 30 40 50 Filter Rating (Particle size, µm, where Beta = 200) ©
  26. 26. ©9. ENVIRONMENTAL CONTROL• Maintenance strategies : 5S• World Class Manufacturing• Environmental protection• Efficiency tools Best Practice Solution : Fluid Defense Absorbents ©
  27. 27. © 10. KNOWLEDGE MANAGEMENT • Reliability Lubrication training • Reliability Technician • Custom in-plant training, all levels Vision Interactive style Feedback Fun Blogs Motivating Forums Meaningful E MailsRecognizable Cartoons Transfer Cartoon Strips Engaging Cartoon characters Best Practice Solution : Reliability Institute bv ©
  28. 28. LUBRICATION RELIABILITY © BAD Practice ©
  29. 29. ©LUBRICATION RELIABILITY BEST Practice ©
  30. 30. © The Reliability InstituteChange Management Requirements To Achieve World Class Maintenance Stephen Thomas 22 module online learning program with dialogue / interaction to Stephen. 7 ©
  31. 31. ©Lubrication Reliability10 steps to Improved Production Reliability and World Class Maintenance THANK YOU - QUESTIONS 31 ©

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