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Prevent Unplanned Downtime With Proactive Maintenance
- 1. 100 10 1
- 2. You shouldn’t have to be here… …for unplanned stops
- 3. How come that there always seems to be money available to fix failures…
- 4. …but never enough to prevent them from happening in the first place?
- 6. What are the most common reasons for unplanned stops of your equipment?
- 7. It is generally not…
- 8. …big rocks
- 11. But rather…
- 12. …small grains of sand
- 16. and cavitation
- 18. causing sludge
- 21. …and all of that is generally caused by the 3 I’s…
- 22. …Incompetence
- 23. …Ignorance
- 24. and Indifference
- 25. and never underestimate the tremendous impact of a bad driver
- 27. Dust in the engine’s inlet air causes…
- 28. Leading to reduced machine performance …increased engine wear Accelerating the engine wear Resulting in increased fuel consumption
- 29. Genuine air filter Good spurious air filter 99.99% filtration 99.9% filtration 10 X more wear!
- 30. Dirt in the hydraulic system causes…
- 33. Increased mechanical wear Slower operation Increased fuel consumption
- 34. Increased mechanical wear Slower operation Increased fuel consumption Increased oil consumption
- 35. Dirt in the fuel system causes…
- 36. Wear on injectors and fuel pumps
- 38. Shorter engine oil life
- 39. and reduced engine life
- 40. Dirty Air/Oil affects your entire operation as it…
- 42. …reduces your output …increases your operating cost
- 43. …reduces your output …increases your operating cost …decreases your profit
- 44. Facts:
- 46. Dirt spirals wear Wear particles causes shorter oil life
- 47. Dirt spirals wear Wear particles causes shorter oil life Dirty oil is a main reason for leakage, causing further increased wear
- 48. 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
- 49. 100 The cost to fix a catastrophic failure.
- 50. 10 The cost to fix a catastrophic failure. The cost to filter the system clean.
- 51. 1 The cost to fix a catastrophic failure. The cost to filter the system clean. The cost to keep the dirt out.
- 52. The risks are huge… …but remedies straight forward. Or?
- 54. Set cleanliness targets Train your staff at all levels
- 55. Set cleanliness targets Train your staff at all levels Choose high quality/genuine oil
- 56. Set cleanliness targets Train your staff at all levels Choose high quality/genuine oil Store it well
- 57. Set cleanliness targets Train your staff at all levels Choose high quality/genuine oil Store it well Keep filling area dustfree when changing oil
- 58. Use only genuine filters
- 59. Use only genuine filters Maintain your breathers
- 60. Use only genuine filters Maintain your breathers Rectify leakages immediately
- 61. Use only genuine filters Maintain your breathers Rectify leakages immediately Frequent and regular oil analysis
- 62. Use only genuine filters Maintain your breathers Rectify leakages immediately Frequent and regular oil analysis Monitor and modify
- 63. “If you think education is expensive, try ignorance” Benjamin Franklin
- 64. Reactive maintenance Repair on failure No pre-planning Erratic operation Costly failures Sh…t happens Bigger fleet than required
- 65. Predictive maintenance Repair before catastrophic failure Significant pre-planning Smoother operation Lower cost per failure Cheaper sh…t happens More accurate fleet size
- 66. Proactive maintenance Root cause analysis Change incorrect behavior Well-run operation Longer time between failures Sh…t happens, but rarely Optimum fleet size
- 67. Don’t rely on luck…
- 68. … start working proactively
- 71. Benefits, Proactive Service: Early detection and correction reduces your cost
- 72. Benefits, Proactive Service: Early detection and correction reduces your cost Detect root cause to avoid repetition
- 73. Benefits, Proactive Service: Early detection and correction reduces your cost Detect root cause to avoid repetition Better uptime and production through smoother operation
- 74. 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
- 75. ...you just have to get started.
- 76. 100 10 1
- 77. The choice is yours