Presentation 2012

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Maintenance and safety excellence programs

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Presentation 2012

  1. 1. S.C. Kalisz & Associates, LLC Industrial Maintenance & Safety Programs Since 1990 ™ ©S.C. Kalisz & Associates 1994This presentation has automatically preset slide transitions
  2. 2. Our Company History• 1990: Founded by Stan Kalisz, consulting to the nuclear and fossil power plant industry• 1992: Developed OSHA compliant LOTO procedures for the “Big Three” auto manufacturers• 1994: Developed world class preventive maintenance procedures for the auto manufacturers• 1995: Developed total equipment databases to support the maintenance efforts for the auto assembly plants and automotive engineering facilities and test tracks• 1997: Developed predictive maintenance programs for manufacturing and assembly plants• 1998: Began authoring operations, maintenance and safety technical manuals for automated manufacturing systems both domestic and international plants• 2000: Set up maintenance and safety excellence programs at automotive parts distribution centers• 2003: Set up maintenance and safety excellence programs at children’s and heart hospitals• 2004: Set up maintenance and safety excellence programs at open copper mines• 2006: Set up maintenance and safety excellence programs in steel coil slit and rolling tube mills• 2008 to present: Set up maintenance and safety excellence programs in aluminum casting, extrusion and flat rolled plants, lithium hybrid automotive battery plant ©S.C. Kalisz & Associates 1994
  3. 3. The Maintenance Circle of Excellence “Developed and perfected over the past 15 years, this is the roadmap to maintenance excellence” ©S.C. Kalisz & Associates 1994
  4. 4. Bubble 1, SafetyLockout: OSHA 1910.147Our personal interest in safety goes beyondthat of just providing a product.We have researched the laws, accidentarchives and the consequences resulting fromnot having a clear and concise program forsafely locking out equipment to performmaintenance and testing.Ultimately, our procedures are developed andimplemented for the protection of not onlyemployees, but for anyone who can come incontact with equipment.Each and every procedure is designed tocover every aspect of a safe work practice in aVisually Instructive way..Level I and Level II LOTOLevel I LOTO provides a zero energy state to acomplete work cellLevel II LOTO drives further down to createzero energy states for sub components of thecell ©S.C. Kalisz & Associates 1994
  5. 5. Bubble 1, Safety continuedLinks in your CMMSOur LOTO procedures are able to be loadedinto your CMMS (Maximo, SAP, etc.) toautomatically accompany your work ordersand PM procedures. We also offer JSP andSOP authoring, elevated work, confined spaceand mobile equipment safety programs.CAUTION!LOTO placards are not all inclusive for thedefense of your company and employees!Check with your insurance carrier or riskconsultant.A LOTO placard will help you be in compliancewith OSHA BUT provides no documentationthat the procedure was performed properly orin its entirety. We have solutions for concreteprotection....its your life, its your right, its the law! ©S.C. Kalisz & Associates 1994
  6. 6. Bubble 1, Safe Maintenance Procedures Nichols Aluminum Alabama-Maintenance, Paint Line (SPL) Analysis Rating Levels Total RatingReason For Improvement Critical Job Risk Analysis Revision 0, 9/23/2011 1- Minor medical treatment 1- Remotely possible 1- Rare, less than once per year 3 to 4 1 2- No lost 2- Possible in 2- Occasional Decatur, Alabama time, but time between 3 and 5 to 6 2 reportable 12 months 3- Lost time 3- Probable in 3- LikelyA Job Hazard Analysis (JHA) or Job Safety Analysis (JSA) time between 1 and 3 months 7 to 8 3 4- Fatality or 4- Likely to 4- At least onceis an effective tool in breaking down specific job tasks permanent disability occur immediately per month 5- At least once 9 to 10 4 www.sckaliszandassociates.com 11 or higher 5in order to determine the hazards involved in the task System: Cooling towers TASK POTENTIAL LOSS Severity Probability Frequency per week Total Critical Rating Mitigation Step(s) Process water cooling towerand what is required to prevent injuries and/or Remove or install north/south pump motor Cuts, back injury, foot injury, electric 2 2 2 6 2 LOTO, gloves, lifting devices, proper PPE, high voltage toolsaccidents and/or damage to equipment. Remove or install north/south pump shock Cuts, back injury, 2 2 2 6 2 LOTO, gloves, lifting devices, proper PPE foot injury Remove or install cooling fan motor Cuts, back injury, 3 3 1 7 3 LOTO, gloves, lifting devices, proper PPE, fallA formal job hazard analysis is a procedure designed to foot injury, electric shock, fall protection, high voltage tools Need Eng. Eval. for lifting/lowering davit Remove or install cooling fan Cuts, back injury, 3 3 1 7 3 LOTO, gloves, lifting devices, proper PPE, fallstudy the job for any potential hazard caused by the foot injury, fall protection Need Eng. Eval. for lifting/lowering davitmachine, the surroundings, or the worker. Remove or install cooling diffusers Cuts, back injury, foot injury, fall 2 2 1 5 2 LOTO, gloves, lifting devices, proper PPE, fall protection, confined space permit/procedure Remove or install pump gate valves Cuts, back injury, 2 3 1 6 2 LOTO, gloves, lifting devices, proper PPE foot injurySafe Maintenance Procedures (SMP) or otherwise Replace fuses in disconnects Cuts, arc flash 1 2 3 6 2 LOTO, gloves, fuse tool, proper PPE and arc flash protectionknown as Safe Working Procedures are detailed steps Replace motor/pump coupler Cuts 1 2 2 5 2 LOTO, gloves, proper PPEof how to conduct a specific job task. The SMP clearlyoutlines what the task is, steps to execute and Nichols Aluminum Alabama-Maintenance, Paint Line (SPL) Safe Maintenance Procedurecomplete the task, special equipment required. Revision 0, September 25, 2011 Decatur, Alabama www.sckaliszandassociates.com System: Cooling towersConduct a thorough hazard assessment of jobs or TASK Process water cooling tower Remove north/south pump motor Tools, materials, resources Resources required: 2 persons. Work steps 1-Disconnect electrical wires at motor, tape or wire nut ends, secure away from work areatasks, the following three steps are necessary: Develop 1-Perform LOTO steps 2-Ensure proper PPE is in use 3-Inspect lifting devices prior to use Tools required: insulated screwdriver(s) and pliers for electric disconnections, hand 2-Remove motor to pump coupler 3-Remove motor mounting bolts 4-Determine the weight of the motor, select the proper sling from sling rating charta Critical Job Inventory and assess the risk associated 4-Inspect mobile equipment required for lifting prior to use 5-Cordon off work area with safety tape, cones or rope tools, sockets and ratchets, nylon sling, nylon tag rope 5-Using an eye-to-eye type sling, install as a choker around the motor 6-Attach the lifting eye to a lifting device on fork truck, DO NOT wrap the eye around forks or any device with sharp edges 7-Attach a tag line to the motor, guide it to rest point using the tag linewith those jobs. 8-Slowly lift until the sling is taught, inspect the sling for any damage to web 9-Complete the lift separating the motor from the pump 10-When transporting is required, use a cart or pallet that will support the motor weight, DO NOT transport in an elevated position with a fork truck Install north/south pump motor Resources required: 2 persons. 1-When transporting is required, use a cart or pallet that will support the motor weight, DO NOTConduct a Critical Job Risk Analysis (also known as Job 1-Verify LOTO is in place 2-Ensure proper PPE is in use 3-Inspect lifting devices prior to use Tools required: insulated screwdriver(s) and pliers for electric reconnections, hand tools, transport in an elevated position with a fork truck 2-Attach a tag line to the motor, guide it to rest point using the tag line 3-Determine the weight of the motor, select the proper sling from sling rating chartSafety Analysis (JSA) of each of the jobs in the Critical 4-Inspect mobile equipment required for lifting prior to use 5-Cordon off work area with safety tape, cones or rope sockets and ratchets, torque wrench, nylon sling, nylon tag rope, alignment device 4-Using an eye-to-eye type sling, install as a choker around the motor 5-Attach the lifting eye to a lifting device on fork truck, DO NOT wrap the eye around forks or any device with sharp edges 6-Slowly lift until the sling is taught, inspect the sling for any damage to webJob Inventory. 7-Lower the motor to the base and pump, install mounting bolts and properly torque 8-Reconnect coupler and align shaft with laser or dial indicator, record measurements 9-Reconnect electrical wires at motor, remove LOTO, perform post-maintenance test Remove north/south pump Resources required: 2 persons. 1-Remove pump mounting bolts Prerequitie: Motor has been removed Tools required: hand tools, 2-Determine the weight of the pump, select the proper sling from sling rating chart 1-Verify LOTO steps have been completed sockets and ratchets, nylon sling, 3-Using eye bolts with shackles and eye-to-eye type sling, install as a basket rig to the pump 2-Ensure proper PPE is in use nylon tag rope 4-Attach the sling to a lifting device on fork truck, DO NOT loop the sling around forks or any 3-Inspect lifting devices prior to use device with sharp edges 4-Inspect mobile equipment required for lifting prior to use 5-Attach a tag line to the pump, guide it to rest point using the tag line 5-Cordon off work area with safety tape, cones or rope 6-Slowly lift until the sling is taught, inspect the sling for any damage to web 7-Complete the lift of the pump 8-When transporting is required, use a cart or pallet that will support the pump weight, DO NOT transport in an elevated position with a fork truck ©S.C. Kalisz & Associates 1994
  7. 7. Bubble 2, Equipment DatabaseWe can provide a thorough equipment Name/type of equipment: Belco/natural gas fired age oven Vendor informationinventory in your plant and a very Location (column): Belco Industries, Inc. Parent equipment: N/A 115 East Main Streetreasonable cost to you. Serial No.: 34491-01 Belding MI 48809 Model No.: 8-10-54 Tel: 616-794-0410 Fax: 616-794-3424 Type: Natural gas fired billet furnace http://www.belcoind.com/ Reference tech manual: 34491-02The Total Equipment Database is an Electric Motor-Combustion Blower Electric Motor-Recirc fan(s) 1 and 2 Electric Motor-Entrance and Exit Doors Liftelectronic compilation of Motor brand: Motor brand: Motor brand: Model (name): Model (name): Model (name):equipment/component/part Model number: Model number: Model number: Serial number: Serial number: Serial number:description, supplier information and Catalog number: Catalog number: Catalog number: Motor Starter: Square D Integral 18 Motor Starter: Square D Integral 63 Motor Starter: Square D Integral 18lead times, detailed nameplate data Motor HP: 3/4 Motor HP: 40 Motor HP: 1.0 Voltage: 480V Voltage: 480V Voltage: 480Vand exact location of the component Amps: 1.3 FLA Amps: 47 FLA Amps: 1.8 FLA Phase: 3 Phase: 3 Phase: 3in your plant. RPM: 3450 RPM: 1760 RPM: 1200 Frame: 56C Frame: 324T Frame: 145TCZ Stores location: Stores location: Stores location: Main Disconnect Main Disconnect Main DisconnectThe benefits of this program are: Location (column, if available): On wall Location (column, if available): On wall Location (column, if available): On wall• Your planner and purchasing has all Brand: Square D Brand: Square D Brand: Square D Model (name): Disconnect Switch-200 amp Model (name): Disconnect Switch-200 amp Model (name): Disconnect Switch-200 amp Model number: 1494VDNL200 Model number: 1494VDNL200 Model number: 1494VDNL200 the necessary information at their Serial number: N/A Serial number: N/A Serial number: N/A Catalog number: N/A Catalog number: N/A Catalog number: N/A fingertips Voltage: 480V Voltage: 480V Voltage: 480V• Accurate min/max inventories can Phase: 3 Amps: 200 Phase: 3 Amps: 200 Phase: 3 Amps: 200 be defined for your MRO stores Stores location: Stores location: Stores location:• Parts are linked to your assets in the CMMS• MTTR (Mean time to repair) is reduced• Parts kitting for work orders and PMs time is reduced• A foundation is built for the CMMS and optimizing PM procedures ©S.C. Kalisz & Associates 1994
  8. 8. Bubble 3, PFMEAA correctly implemented PFMEA will save future costs and delays to the company by identifying potential failures in theproduction process before they occur. Not identifying potential problems early in the planning stage will lead to costly work lateron.What is it: Potential Failure Modes Effects Analysis (PFMEA) is a planning method that involves thinking about what might gowrong, what are the chances of it going wrong and what might be the consequences of it going wrong, leading to a plan forprevention. PFMEA is a step-by-step systematic approach for identifying all possible failures in a design, a manufacturing orassembly process. PFMEAs help us focus on and understand the impact of potential process risks. A systematic methodology isused to rate the risks relative to each other by ranking & prioritizing the possible causes of failures and eliminating or reducingfailures, starting with the highest-priority ones.Why use it: PFMEAs help us focus on the understanding the impact of the potential process or product risks.1. Identify the relative risks designed into a process.2. Initiate action to reduce those risks with the highest potential impact.3. Track the results of the action plan in terms of risk reduction.The benefits.1- The PFMEA will continue to be a living document in accordance with the TPM "Planned maintenance" pillar.2- The PFMEA revision will launch the "Focused improvement" pillar and provide new opportunities for improvement.3- The revision will support PM and spare parts optimization for focused improvement.4- Identify weak links in the system process and utilize the 80/20 data for KPIs and additional focused improvement.5- Sets the base and pace for your PdM (predictive maintenance) program. ©S.C. Kalisz & Associates 1994
  9. 9. Bubble 3, PFMEA Process Phase I-Review of the past 90 days of : 1- Unplanned breakdown work orders, and 2- Unplanned downtime reports The scores of all equipment and components are adjusted to demonstrate real time activities and ultimately provide areas to focus on further, and/or areas that require less focus.www.sckaliszandassociates.com PFMEA-Potential Failure Mode Effect Analysis, Based on the assumption that all required spare parts are in stock Department: Nichols Aluminum Alabama, maintenance-Champion: Start Date Larissa Garza-Stodgell Aug 23,2011 Facilitator: Stan Kalisz, S.C. Kalisz & Associates, LLC Equipment Score Equip. Additional Score Priority Total Cat Output Utilization Quality Safety/Env Score Freq. Mean D/t Waste Score ScoreSYSTEM MLS Equipment # EQUIPMENT DESCRIPTION FAILURE POTENTIAL A B C D AxBxCxD E F G ExFxG ESxPS A,B or CPaint Line Hydraulics North Hydraulic Skid 0 0 0 Main motor/pump 0 0 0 Motor 3 4 3 1 36 1 4 4 16 576 Dirt, heat, loose, power surge/spike, end of life I/O card cycle failure 3 4 3 1 36 1 3 4 12 432 Dirt, heat, loose, power surge/spike, end of life Starter cycle failure 3 4 3 1 36 1 3 4 12 432 Phase II-Review of the past 90 days of : 1- Unplanned breakdown work orders, and 2- Unplanned downtime reports, and 3- Revised PFMEA scores Identifies spare part (min/max) requirements, downtime costs as a result of spare part inventory deficiencies, adjusts frequencies of and extent of PM’s. If none on hand-hours required to Quantity- contact Cost of Required on Quantity-Part vendor to downtime (est. hand Deviation? Stores System Equipment Part Criticality Rating on hand start up $500.00) Cost of part (min/max) +/- Location Part Shared With? Action? Paint Line Hydraulics North Hydraulic Skid Main motor/pump Motor 576 0 28 $14,000 1 -100% North, paint and south skids This is an example I/O card 432 $0 Starter 432 $0 Transformer 432 $0 Fuses (disconnect) 432 $0 Bearings 432 Not required $0 Coupler 432 $0 Pump 108 $0 Coupler 192 $0 Seals 48 $0 Hoses 432 $0 $0 Recirc motor/pump $0 Motor 9 $0 I/O card 48 $0 Starter 48 $0 Transformer 48 $0 Fuses (disconnect) 48 $0 Bearings 48 Not required $0 Coupler 48 $0 Pump 96 $0 Coupler 192 $0 Seals 48 $0 ©S.C. Kalisz & Associates 1994
  10. 10. Bubble 4, PM OptimizationThe majority of process plant PM’s areexcessive in frequencies and costly in Billet load table and infeed conveyor to furnace-Quarterly PM-Maintenance Mode: Shut down and locked out This is a controlled document; Revision 0, March 3, 2011regards to manpower, parts and supplies. Prerequisites prior to work commencing 1 2 Notify all personnel using P.A. system that equipment is being shutdown for maintenance Verify operator has performed the controlled shutdown 3 Perform lockout/tagout in accordance with procedure, this is a joint LOTO with maintenance and operations Performed by: ________________ Date:__/__/_____ Time:________hours 4 After completing LOTO, it must be independently verified by a qualified employee Verified by: ________________ Date:__/__/_____ Time:________hours 5 Cordon the work area off with "Caution Tape" 6 Receive and sign for the PM kit that includes tools, parts and supplies from the store keeper Performed by: ________________ Date:__/__/_____ Time:________hours 7 Conduct a 5 minute safety tailboard with all personnel working on this equipment Performed by: ________________ Date:__/__/_____ Time:________hoursUtilizing what we have gathered in 8 9 10 All repairs performed shall have a work order generated when complete All work orders generated shall include "5 why" or similar reason for the failure All required PPE is used, including arc flash when requiredbuilding the equipment database and Reference materials provided by storeroom with the PM kit 1 2 LOTO procedure MSDS 3 Safe maintenance procedureresults of the PFMEA we are able to 4 5 Arc flash procedure(s) Noria lubrication guide Required tools, parts and suppliesreduce your: 1 2 3 1/2" drive torque wrench 1/4" drive torque wrench 5/8" socket, 7/16" socket 5 Screwdrivers, pliers, wire cutters 6 Scotchlock wire connector set 7 Flash light 8 24" framing square 9 24" and 48" level1. Required downtime to perform PM’s 10 11 12 1 tube multilith grease #2103 and marked with a "blue dot" and grease gun Penetrant die Rags 13 CRC cleaner2. Manpower requirements 14 15 16 Broom and dust pan Waste rag container Magnifying glass and mechanics mirror 17 FLR filter3. Frequencies of PM’s 18 Step LOTO lock(s) and tag(s) Action to be taken4. Quantity of PM’s Billet load and handling table 1 Table and conveyor structures 1a) Wipe down (dry towel) the entire structure including vertical, horizontal and diagonal supports, pedestal feet and leveling bolts Corrective actions Use approved solvent if necessary Initial 1b) Visually inspect weldments and steel structure for cracks, dents, breakage, twisting and other signs of weakness Use penetrant die for suspected breaks or cracks-grind and weld, repair or replace damaged/twisted framework 1c) Using a 1/2" drive torque wrench, verify all diagonal support fastening bolts are 119 ft/lbs and hash mark aligned, or mark is repositioned as a result of the tightening to required torque Tighten to required torque, position new hashmarks as required 1d) Using a 48" ft level verify the horizontal top of table is level, and vertical supports are plumb Level or straighten as required 1e) Using a 24" framing square, verify that the table is square at each vertical support Level or straighten as required 1f) Using a 1/2" drive torque wrench, verify all leveling bolts are 119 ft/lbs and hash mark aligned, or mark is repositioned as a result of the tightening to required torque Tighten to required torque, position new hashmarks as requiredA fully optimized PM will contain: 2 Billet bundle release cylinder 2a) Wipe down (dry towel) the entire cylinder including mounting clevices, hoses and hose connections Use approved solvent if necessary 2b) Temporarily valve in plant air and listen to verify no air leaks exist at seals, cylinder barrel or hose and hose connections then return to locked out status Mark suspect leaks, resolve then test with plant air again 2c) Visually inspect the cylinder barrel for damage Use penetrant die for suspected breaks or cracks, replace cylinder if found 2d) Visually inspect the rod for pitting, gouging and use a straight edge to ensure it is not bent Replace cylinder 2e) Visually inspect the rod clevices for damage, ensure the connecting pins are in place, properly secured and not damaged Tighten if loose, replace if damaged 2f) Visually inspect the rod seal for damage, dirt or potential breaching Replace cylinder1. Parts, tools, materials and supplies required2. Safety instructions3. Step by step instructions for We have successfully……. completion 1. Reduced the number of PM’s in many plants by as much as 40%.4. Reference documents and 2. Reduced the time to complete PM’s by as much as 30%. information 3. Increased the number of PM’s completed vs. issued to 98%.5. Acceptance criteria 4. Reduced breakdowns with quality PM work.And much more ©S.C. Kalisz & Associates 1994
  11. 11. Bubble 6, MRO StoresWe were contracted to lean out anexisting parts store room in a processplant. After analyzing breakdown workorders we found that the bulk of thedowntime was due to searching forparts, materials or supplies, most non-existent.Utilizing the results of the PFMEA wewere able to determine valid spare partsand their required quantities on hand.1. Obtain an accurate physical count (inventory) of all spare parts currently in the store room2. Catalog (database) parts including Results! name, part number, vendor, descriptive nomenclature, quantity Safety on hand, location in stores. 1. Trip and fall hazards are eliminated 2. Heavy parts are stored on low shelves only3. Layout and execute an organized 3. Infrequently used parts are on top shelves to reduce climbing by technicians and efficient parts storage plan. 4. Dust breathing hazards reduced with cleaning4. Attain a 5S (sorting, straightening, 5. All flammable materials are in an approved cabinet, contents clearly labeled on exterior systematic cleaning, standardizing, and sustaining) status in all the Efficiency 1. Reduced time for finding parts above areas. 2. Reduced duplicate purchases with a clear concise inventory in place • We separated mobile equipment and facilities parts in their own dedicated places from equipment parts to eliminate “mixing”. • Equipment specific parts are in one place. • We gained approximately 2000 square feet of vacant shelving for growth. ©S.C. Kalisz & Associates 1994

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