The Awakening(Rev1)

879 views

Published on

This presentation talks about the Economic Crisis we face and what each maintenance and reliability manager can take a stand and make change which could save jobs in their company.

Published in: Technology, Business
0 Comments
3 Likes
Statistics
Notes
  • Be the first to comment

No Downloads
Views
Total views
879
On SlideShare
0
From Embeds
0
Number of Embeds
3
Actions
Shares
0
Downloads
0
Comments
0
Likes
3
Embeds 0
No embeds

No notes for slide

The Awakening(Rev1)

  1. 1. The AWAKENING Copyright 2008 Allied Reliability, Inc.
  2. 2. The AWAKENING The AWAKENING Ricky Smith, CMRP Copyright 2008 Allied Reliability, Inc.
  3. 3. The AWAKENING How bad are things? • Over 100 Plants in the US Close their doors every month • Over 500,000 people added to unemployment in November alone • When will you know when your plant is shutting down or organization will have a layoff? • How many of you are willing to do something NOW? Copyright 2008 Allied Reliability, Inc.
  4. 4. The AWAKENING “It Isn’t What You Know That Will Kill You, It Is What You Don’t Know That Will” • Competition lowering their cost – selling below your cost! • How does a company decide which plant to close? • Labor says their operation will never close • Today you have a job, tomorrow you don’t Vibration Analysis and Infrared Thermography 156.9°F 118.9°F 140 110 119.1°F 100 120 153.1°F 90 100 80 80 74.5°F 75.3°F SHM - 200 Hp Vertical Turbine Pump SHM - 150 Hp Vertical Turbine Pump 200 Hp VT -M1V Motor #1 Bearing - Vert 150 Hp VT -M1V Motor #1 Bearing - Vert 1.4 1.4 Route Spectrum Route Spectrum RMS Acceleration in G-s RMS Acceleration in G-s 1.2 1.2 25-Jun-03 09:03:12 25-Jun-03 09:05:36 OVERALL= .4624 V-DG OVERALL= .3255 V-DG 1.0 1.0 RMS = 2.39 RMS = .4796 LOAD = 100.0 LOAD = 100.0 0.8 0.8 RPM = 1784. (29.74 Hz) RPM = 1800. (30.00 Hz) >SKF 29422E 0.6 0.6 A=FT 13.14 F: 0.4 0.4 0.2 0.2 0 0 2400 2700 3000 3300 3600 3900 0 1000 2000 3000 4000 5000 Frequency in Hz Frequency in Hz 10 10 Route Waveform Route Waveform CF ALARM 25-Jun-03 09:03:12 25-Jun-03 09:05:36 Acceleratio n in G-s Acceleratio n in G-s RMS = 2.74 RMS = .4763 5 5 PK(+/-) = 8.53/7.86 PK(+/-) = 1.85/1.60 CREST 3.12 F= CREST 3.88 F= PK ALARM PK ALARM CF ALARM 0 0 CF ALARM PK ALARM PK ALARM -5 -5 CF ALARM -10 -10 Freq: 3207.1 0 40 80 120 160 200 240 280 320 0 40 80 120 160 200 240 280 320 Ordr: 107.83 Time in mSecs Time in mSecs Spec: .256 Dfrq: 13.16 Copyright 2008 Allied Reliability, Inc.
  5. 5. The AWAKENING Market Survivor Model Market Price Unit Cost = Cost Capacity Market Share Source: The RM Group, Inc., Knoxville, TN 060417 ©2006 Allied Reliability Copyright 2008 Allied Reliability, Inc.
  6. 6. The AWAKENING Copyright 2008 Allied Reliability, Inc.
  7. 7. The AWAKENING Eleven Major Losses Planned-shutdown losses 1. No production, breaks, and/or shift changes 2. Planned maintenance Downtime Losses 3. Equipment failure or breakdowns 4. Setups and changeovers 5. Tooling or part changes 6. Start-up and adjustment Performance efficiency losses 7. Minor stops (less than six minutes) 8. Reduced speed or cycle time Quality Losses 9. Scrap product/output 10. Defects or rework 11. Yield or process transition losses Copyright 2008 Allied Reliability, Inc.
  8. 8. The AWAKENING Here are the Facts • Most companies spend 20-30% too much on maintenance of their assets • Companies in the US experienced the largest layoff rates in 2008 than anytime in the past 10 years • Why? Copyright 2008 Allied Reliability, Inc.
  9. 9. The AWAKENING A Few Quick Questions 1. Do you consider your maintenance department to proactive or reactive? 2. What percent of your assets are identified in your CMMS/EAM? 3. Is your equipment hierarchy established effectively? 4. Have you ranked your assets based on criticality? 5. Are your current PMs mapped to Failure Modes or Regulatory Compliance? • What is your PM Compliance? 6. What percent of your labor hours are focused on emergency work each week (average)? 7. Does your company identify their losses in all areas? Copyright 2008 Allied Reliability, Inc.
  10. 10. The AWAKENING How many know and understand the PF Curve? Copyright 2008 Allied Reliability, Inc.
  11. 11. The AWAKENING Failure Patterns Initial Break-in period Bathtub Pattern D = 7% Pattern A = 4% Random Pattern E = 14% Wear Out Pattern B = 2% Time Time Fatigue Infant Mortality Pattern C = 5% Pattern F = 68% Age Related = 11% Random = 89% Source: John Moubray, Nolan & Heap Copyright 2008 Allied Reliability, Inc.
  12. 12. The AWAKENING Can you reduce Infant Mortality and do you have a plan to make it happen? Pattern F... 68% 6% Page M - 12 Copyright 2008 Allied Reliability, Inc.
  13. 13. The AWAKENING Random Failure Patterns Number of Failures Page M - 13 Source: SKF Copyright 2008 Allied Reliability, Inc.
  14. 14. The AWAKENING Self Induced Failures • 70-80 % of equipment failures are SELF-INDUCED – Reliability • Over-lubricated motors • Align motor couplings with “straight edges” • Specifications and procedures not defined (torque) • Putting hydraulic fluid into a reservoir without filtering it • Welding on equipment without grounding properly • PM Procedures stating “Check the Pump, Seals, etc” Copyright 2008 Allied Reliability, Inc.
  15. 15. The AWAKENING Extending Equipment Life – Is it part of your Maintenance Strategy? Copyright 2008 Allied Reliability, Inc.
  16. 16. The AWAKENING What do you think? • It is time to be; AWAKENED Copyright 2008 Allied Reliability, Inc.
  17. 17. The AWAKENING What is Maintenance? • To Maintain an Asset --- – Keep in existing condition – Keep, preserve, protect Copyright 2008 Allied Reliability, Inc.
  18. 18. The AWAKENING What to Stop Doing! • Applying the Run to Failure (RTF) Maintenance Strategy • Doing the same thing over and over again and expecting a different outcome • Stop perform PM that is not effective • Stop looking for easy solutions • Take charge and Lead from the Front – Inspect what you expect – Lead by Example – Treat people with respect – Listen to your people – Walk the fence when needed Copyright 2008 Allied Reliability, Inc.
  19. 19. The AWAKENING “If your actions inspire others to dream more, learn more, do more and become more, you are a leader“ - John Quincy Adams 1785 Copyright 2008 Allied Reliability, Inc.
  20. 20. The AWAKENING There are no Silver Bullets – We are sold out! Copyright 2008 Allied Reliability, Inc.
  21. 21. The AWAKENING Lesson 1: Stop/Reduce self induced failures • Develop Effective Work Procedures – Lubrication – Corrective Maintenance – Preventive Maintenance – Operator Care • Ensure rebuilds are performed to standard – Stop making parts in your machine shop – Begin inspecting vendor rebuild shops • Effective Work Procedures • Clean Environment • Testing • Begin measuring Rework Copyright 2008 Allied Reliability, Inc.
  22. 22. The AWAKENING Defect Severity – Let’s look at what we know Copyright 2008 Allied Reliability, Inc.
  23. 23. The AWAKENING Lesson 2: Ensure your PM Program is effective • Evaluate your PM Tasks based on the following: PM Task Action % of Man-Hours # of Tasks Recommendation Tasks Represented Non-Value Added 1,640 8.2% 6,661 (Delete) Reassign to 1,380 6.9% 5,605 Operator Care Reassign to Lube 2,856 14.3% 11,600 Route Replace with PdM 6,437 32.2% 28,222 Re-Engineer 5,200 26.0% 26,221 No Modifications 2,487 10.4% 8,987 Required Totals 20,000 100.0% 87,297 • Begin Measuring PM Compliance using the 10% Rule • Begin Comparing PM Vs EMER Labor Hours Copyright 2008 Allied Reliability, Inc.
  24. 24. The AWAKENING Lesson 3: Develop a Key Performance Indicator Scoreboard • Begin posting some basic metrics – Mean Time Between Failure (MTBF) – PM Compliance using the 10% Rules of Critical Assets – PM Labor Hours Vs EMER Labor Hours – % of Planned Work – Scheduled Compliance – Number of Interruptions to Schedule “You cannot manage what you cannot control and you cannot control what you do not measure” - Peter Drucker Copyright 2008 Allied Reliability, Inc.
  25. 25. The AWAKENING Lesson 4: Build an Effective Maintenance Program which provides “Optimal Reliability at Optimal Cost” Copyright 2008 Allied Reliability, Inc.
  26. 26. The AWAKENING Current State / Future State Current State Future State “Maintenance Issues” “No Maintenance Issues” Optimizing Maintenance creates a Major Shift in Culture Copyright 2008 Allied Reliability, Inc.
  27. 27. The AWAKENING “The significant problems we face cannot be solved with the same level of thinking we were at when we created them.” - Albert Einstein Copyright 2008 Allied Reliability, Inc.
  28. 28. The AWAKENING Save Jobs NOW – Make Something Happen Copyright 2008 Allied Reliability, Inc.
  29. 29. The AWAKENING Questions? Ricky Smith smithr@alliedreliability.com Cell: 843-725-8378 Copyright 2008 Allied Reliability, Inc.

×