Siemens Solar Industries (SSI)Pdm Analysis on Equipment

1. Siemens Solar Industries and Shell
Solar Industries Wire Saws Improved
Productivity Through Vibration
Analysis
A Case Study
M Miskus Director FM&E (2001-
2004)
Siemens SI and Shell SI

2. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis
A Case Study
M Miskus Director FM&E (2001-2004)
Site Background on SSI
 The increasing demand for renewable forms of energy is making photovoltaic
(PV) products an important part of the energy supply future.
 The costs of producing photovoltaic modules have been significantly reduced
during the last 15 years as manufacturing costs per watt have dropped from
over $6 per peak watt to less than half of that value now.
 Condition monitoring (vibration analysis) used in PV manufacturing has
contributed to this reduction.

3. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis
A Case Study
M Miskus Director FM&E (2001-2004)
 Crystal growth improvements, both in yield and machine design, have reduced
the PV manufacturing energy consumption by a factor of 3 and improved silicon
utilization by 40%.
 Wafer slicing process changes have resulted in 66% more wafers being
produced for a given amount of silicon.
 Cell production improvements in both automation and improved efficiency have
reduced the labor cost contribution by over 40% per watt.

4. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis
A Case Study
M Miskus Director FM&E (2001-2004)
 Larger modules and better materials have added another 10% reduction in the
cost to produce photovoltaics.
 These improvements have contributed to a better energy payback time,
reducing it from over 5 years to approximately 3.
 Reductions in cost and improvements in energy efficiency have made
photovoltaic products a commercially viable alternate energy source.

5. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis
A Case Study
M Miskus Director FM&E (2001-2004)
Why?
How?

6. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis
A Case Study
M Miskus Director FM&E (2001-2004)
 Introduce Predictive Maintenance Practices
 Subject Matter Expert – Miscon Associates
Mannheim
 Identify high risk assets and failure modes
 Correct application of sensors
 Adequate data acquisition

7. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis
A Case Study
M Miskus Director FM&E (2001-2004)
 Interpretation of data via report
 Action to prevent breakdown

8. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis
A Case Study
M Miskus Director FM&E (2001-2004)
 Identify Asset/Equipment for Pdm
 Survey Asset/Equipment for sensor
 Pre survey data for baseline
 Install sensors, preliminary data
 Review Data Collection Intervals

9. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis
A Case Study
M Miskus Director FM&E (2001-2004)
 Review Data for Abnormalities
 Review Baseline Data
 Determine Asset Pre Failure
 Run time to Failure

10. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis
A Case Study
M Miskus Director FM&E (2001-2004)
 Scientific Maintenance
 Life Cycle Cost Reduction
 Increase Overall Equipment Effectivity
 Operational Productivity Enhancement
 Lean Manufacturing

11. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis
A Case Study
M Miskus Director FM&E (2001-2004)
 Develop and manage five-year strategic plan
for equipment reliability through reliability
based maintenance. SOP review.
 Implement predictive maintenance
technologies and interval based actions
 Manage utility energy usage for Camarillo
Campus and Vancouver, WA

12. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis
A Case Study
M Miskus Director FM&E (2001-2004)
 Manage long term utility energy use plan for
equipment
 Manage routine review for ISO compliance
on all equipment preventive maintenance
procedures effectiveness

13. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis
A Case Study
M Miskus Director FM&E (2001-2004)
 Manage performance based projects to
exceed PM/Downtime ratio for all areas –
measured 3.5/1
 Establish OEE measurement for equipment
performance reviews

14. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis
A Case Study
M Miskus Director FM&E (2001-2004)
 Develop Five-year strategic plan for
equipment reliability through reliability based
maintenance and introduction of sound
methods and systems
 reduce $15MM expense budget by 15% per
year for 3 year period 2001-2003.

15. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis
A Case Study
M Miskus Director FM&E (2001-2004)
 Integrate computerization with technical staff for on line equipment
status.
 Achieve uptime average of 96% from 60% in 2.5 years.
 Administer review of all equipment preventive maintenance
procedures
 effectiveness. Manage ISO 9000 compliance for manufacturing
support role.
 Develop talent pool optimization for technical support of production
areas.
 Established OEE measurement for equipment performance reviews.
 Exceeded PM/Downtime ratio for all areas – 3.5/1 from .5/1 in 2003.
 Reduced redundant parts in maintenance stores and establish critical
spares.

16. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis
A Case Study
M Miskus Director FM&E (2001-2004)
 Developed talent pool optimization for
technical support of production areas.
 Established OEE measurement for
equipment performance reviews.
 Exceeded PM/Downtime ratio for all areas –
3.5/1 from .5/1 in 2003.
 Reduced redundant parts in maintenance
stores and establish critical spares.

17. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration
Analysis
Solar Power Supply Chain

18. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration
Analysis
 Wire Saw Technology

19. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration
Analysis
(Typical Equipment)

20. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration
Analysis
(Typical Equipment)

21. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration
Analysis
(Typical Equipment)

22. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration
Analysis
(Typical Equipment)

23. Siemens Solar Industries Wire Saws Improved Productivity Through Vibration
Analysis
(Typical Equipment)