Incorporating a predictive maintenance strategy has been proven to provide savings. Learn how to use your pressure and temperature gauges as part of your initiatives.
Predictive Maintenance vs Preventive MaintenanceMobility Work
Whether your business is small, medium or large, effective equipment maintenance is crucial. The CMMS market is flooded with solutions promising cost and time savings but also demanding a solid investment. Every maintenance professional will tell you that predictive and preventive maintenance are absolutely worth it and of highest importance for asset management.
But how to choose the right maintenance strategy for your equipment according to your budget?
Predictive Maintenance vs Preventive MaintenanceMobility Work
Whether your business is small, medium or large, effective equipment maintenance is crucial. The CMMS market is flooded with solutions promising cost and time savings but also demanding a solid investment. Every maintenance professional will tell you that predictive and preventive maintenance are absolutely worth it and of highest importance for asset management.
But how to choose the right maintenance strategy for your equipment according to your budget?
Quality Maintenance is an "advanced" pillar of TPM and aims to assure zero defect conditions. Also known as Hinshitsu Hozen in Japanese, it does this by understanding and controlling the process interactions between the 4Ms - manpower, material, machines and methods that could enable defects to occur. The key is to prevent defects from being produced in the first place, rather than screening them out through inspection systems after they have been produced. Controlling quality through its causes is the essence of Quality Maintenance.
Developed by our JIPM-certified TPM Instructor, this presentation teaches the key concepts, principles and philosophy of Quality Maintenance, the 4M conditions that are essential for defect-free production, as well as the step-by-step process for Quality Maintenance.
LEARNING OBJECTIVES
1. Understand the key concepts, principles and philosophy of Quality Maintenance
2. Acquire knowledge on the 4M conditions and the prerequisites for promoting Quality Maintenance
3. Describe the 8-step process of Quality Maintenance and the key analytical tools and techniques
CONTENTS
1. Key Concepts & Philosophy of Quality Maintenance
2. 4M Conditions - The Determinants of Quality
3. The 8 Steps of Quality Maintenance
4. Key Tools & Techniques for Quality Maintenance
5. Towards Excellence in Quality Maintenance
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
Total Quality Managment - TPM - final year B.E.cs - Presented by DR. K. BARANIDHARAN, SAIRAM INSTITUTE OF MANAGMENT STUDIES (sims) SRI SAI RAM INSTITUTE OF TECHNILIGY (sit) CHENNAI
Guide to delivering maximum equipment uptime (Reliability / Availability) at the lowest possible cost!
At ARM & Associates (+00 353 873104712) we provide the following professional Maintenance Excellence services.
1) Facilities Planned Maintenance (PM) Frequency extension:
Our unique guaranteed “No Win no Fee” approach means there are no up-front costs. We only invoice for our services after you have approved our reliability analysis recommendations for increasing your PM frequencies. For example at Astellas Pharma’s Kerry and Dublin sites we have reduced the cost of facilities PM maintenance by 200%. (Intro to Maintenance Effectiveness and Efficiency)
2) Reliability Centered Maintenance (RCM) studies on new and problem (bad actor) equipment:
Clients include: DePuy Synthes, Janseen Pharmaceutical, Sanofi Genzyme, and Sigma-Aldrich. (RCM Video)
3) Computerised Maintenance Management System (CMMS) Maintenance Best Practices Benchmarking Audit:
Clients include: Astellas Pharma.
4) eMentoring & Coaching:
Don’t know where or how to get started on your journey towards Maintenance Best Practices?
Wasting time making all the mistakes yourself, trying to figure out what works and what doesn’t?
Wish you had an affordable way of accessing the professional training, help and support you need?.
Want to develop your career by becoming a Maintenance Best Practices Champion?
eMentoring & Coaching is a professional maintenance best practices service delivered using WebEx calls; capable of training, guiding and supporting Maintenance/Facilities Managers, Supervisors, Planners and Reliability Engineers on their daily journey towards Maintenance Excellence. Subjects covered include but are not limited to: - Criticality Assessments, LEAN Maintenance, TPM, RCM, FMEA, RCA, CMMS Data & User Competency Benchmarking, PM reviews, Condition Monitoring, Work Prioritisation, Competency Assessments and Productivity Studies. Work Flow KPI development and monitoring etc.
John Day developed a proactive maintenance process in 1978 and manage maintenance and engineering at Alumax Mt. Holly and later at Alcoa Mt Holly for over 20 years. These are the slides he presented at the 1997 SMRP Conference. Great slides with great information. If you would like the slides and not PDF send me an email at rsmith@maintenancebestpractices.com. I worked for John Day back in the early 1980s which started my journey in Proactive Maintenance.
Planned Maintenance is a proactive approach to maintenance that focuses on minimizing the downtime and costs associated with machine breakdowns. As one of the key pillars of the TPM Excellence framework, the goal of Planned Maintenance is to have trouble-free equipment that produce defect-free products.
Planned Maintenance achieves and sustains availability of machines at an optimum maintenance cost, reduces spares inventory, and improves reliability and maintainability of machines.
In this presentation developed by our JIPM-certified TPM Instructor, you will learn how to plan and organize the Plan Maintenance activities to strengthen the capabilities of your Maintenance department. It clarifies the roles of the Operations and Maintenance departments in supporting the TPM initiative and provides step-by-step guidance on the implementation of the Planned Maintenance pillar.
LEARNING OBJECTIVES
1. Understand what is Planned Maintenance and why it is important in TPM implementation
2. Acquire knowledge on how to plan and organize Planned Maintenance activities
3. Describe the seven implementation steps of Planned Maintenance
4. Gain knowledge on the JIPM TPM Excellence Criteria for Planned Maintenance
CONTENTS
1. Introduction to Planned Maintenance
2. What is Planned Maintenance?
3. Planning & Organizing for Planned Maintenance
4. The 7 Steps of Planned Maintenance
5. JIPM TPM Excellence Criteria for Planned Maintenance
To download this complete presentation, goto:
https://www.oeconsulting.com.sg/training-presentations
In order to prevent a breakdown or a sudden failure of the equipment in the workplace, organization need to monitor the maintenance of equipment's and prevent problems before it occurs.
It refers to a regular examine and routine maintenance, which helps in keeping equipment up and running.
It is a planned maintenance of the plant and equipment's which is designed to improve equipment life and avoid any sudden failure.
It includes painting, lubrication, cleaning, adjusting and component replacement to prolong the useful life of the production equipment.
This presentation outlines the processes and benefits of applying enhanced maintenance planning techniques such as Reliability Centred Maintenance at your place of work. Please go to www.simenergy.co.uk for more information.
A survey by Schneider Electric in the US revealed that predictive maintenance services can lead to 25% reduction in cost. Learn about industrial IoT framework that enables PdM
Quality Maintenance is an "advanced" pillar of TPM and aims to assure zero defect conditions. Also known as Hinshitsu Hozen in Japanese, it does this by understanding and controlling the process interactions between the 4Ms - manpower, material, machines and methods that could enable defects to occur. The key is to prevent defects from being produced in the first place, rather than screening them out through inspection systems after they have been produced. Controlling quality through its causes is the essence of Quality Maintenance.
Developed by our JIPM-certified TPM Instructor, this presentation teaches the key concepts, principles and philosophy of Quality Maintenance, the 4M conditions that are essential for defect-free production, as well as the step-by-step process for Quality Maintenance.
LEARNING OBJECTIVES
1. Understand the key concepts, principles and philosophy of Quality Maintenance
2. Acquire knowledge on the 4M conditions and the prerequisites for promoting Quality Maintenance
3. Describe the 8-step process of Quality Maintenance and the key analytical tools and techniques
CONTENTS
1. Key Concepts & Philosophy of Quality Maintenance
2. 4M Conditions - The Determinants of Quality
3. The 8 Steps of Quality Maintenance
4. Key Tools & Techniques for Quality Maintenance
5. Towards Excellence in Quality Maintenance
To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations
Total Quality Managment - TPM - final year B.E.cs - Presented by DR. K. BARANIDHARAN, SAIRAM INSTITUTE OF MANAGMENT STUDIES (sims) SRI SAI RAM INSTITUTE OF TECHNILIGY (sit) CHENNAI
Guide to delivering maximum equipment uptime (Reliability / Availability) at the lowest possible cost!
At ARM & Associates (+00 353 873104712) we provide the following professional Maintenance Excellence services.
1) Facilities Planned Maintenance (PM) Frequency extension:
Our unique guaranteed “No Win no Fee” approach means there are no up-front costs. We only invoice for our services after you have approved our reliability analysis recommendations for increasing your PM frequencies. For example at Astellas Pharma’s Kerry and Dublin sites we have reduced the cost of facilities PM maintenance by 200%. (Intro to Maintenance Effectiveness and Efficiency)
2) Reliability Centered Maintenance (RCM) studies on new and problem (bad actor) equipment:
Clients include: DePuy Synthes, Janseen Pharmaceutical, Sanofi Genzyme, and Sigma-Aldrich. (RCM Video)
3) Computerised Maintenance Management System (CMMS) Maintenance Best Practices Benchmarking Audit:
Clients include: Astellas Pharma.
4) eMentoring & Coaching:
Don’t know where or how to get started on your journey towards Maintenance Best Practices?
Wasting time making all the mistakes yourself, trying to figure out what works and what doesn’t?
Wish you had an affordable way of accessing the professional training, help and support you need?.
Want to develop your career by becoming a Maintenance Best Practices Champion?
eMentoring & Coaching is a professional maintenance best practices service delivered using WebEx calls; capable of training, guiding and supporting Maintenance/Facilities Managers, Supervisors, Planners and Reliability Engineers on their daily journey towards Maintenance Excellence. Subjects covered include but are not limited to: - Criticality Assessments, LEAN Maintenance, TPM, RCM, FMEA, RCA, CMMS Data & User Competency Benchmarking, PM reviews, Condition Monitoring, Work Prioritisation, Competency Assessments and Productivity Studies. Work Flow KPI development and monitoring etc.
John Day developed a proactive maintenance process in 1978 and manage maintenance and engineering at Alumax Mt. Holly and later at Alcoa Mt Holly for over 20 years. These are the slides he presented at the 1997 SMRP Conference. Great slides with great information. If you would like the slides and not PDF send me an email at rsmith@maintenancebestpractices.com. I worked for John Day back in the early 1980s which started my journey in Proactive Maintenance.
Planned Maintenance is a proactive approach to maintenance that focuses on minimizing the downtime and costs associated with machine breakdowns. As one of the key pillars of the TPM Excellence framework, the goal of Planned Maintenance is to have trouble-free equipment that produce defect-free products.
Planned Maintenance achieves and sustains availability of machines at an optimum maintenance cost, reduces spares inventory, and improves reliability and maintainability of machines.
In this presentation developed by our JIPM-certified TPM Instructor, you will learn how to plan and organize the Plan Maintenance activities to strengthen the capabilities of your Maintenance department. It clarifies the roles of the Operations and Maintenance departments in supporting the TPM initiative and provides step-by-step guidance on the implementation of the Planned Maintenance pillar.
LEARNING OBJECTIVES
1. Understand what is Planned Maintenance and why it is important in TPM implementation
2. Acquire knowledge on how to plan and organize Planned Maintenance activities
3. Describe the seven implementation steps of Planned Maintenance
4. Gain knowledge on the JIPM TPM Excellence Criteria for Planned Maintenance
CONTENTS
1. Introduction to Planned Maintenance
2. What is Planned Maintenance?
3. Planning & Organizing for Planned Maintenance
4. The 7 Steps of Planned Maintenance
5. JIPM TPM Excellence Criteria for Planned Maintenance
To download this complete presentation, goto:
https://www.oeconsulting.com.sg/training-presentations
In order to prevent a breakdown or a sudden failure of the equipment in the workplace, organization need to monitor the maintenance of equipment's and prevent problems before it occurs.
It refers to a regular examine and routine maintenance, which helps in keeping equipment up and running.
It is a planned maintenance of the plant and equipment's which is designed to improve equipment life and avoid any sudden failure.
It includes painting, lubrication, cleaning, adjusting and component replacement to prolong the useful life of the production equipment.
This presentation outlines the processes and benefits of applying enhanced maintenance planning techniques such as Reliability Centred Maintenance at your place of work. Please go to www.simenergy.co.uk for more information.
A survey by Schneider Electric in the US revealed that predictive maintenance services can lead to 25% reduction in cost. Learn about industrial IoT framework that enables PdM
Digital Transformation through Product and Service Innovation - Session Spons...Amazon Web Services
Today large enterprises are under pressure to innovate faster than ever, drive down costs, and deliver increased value to their organisations through more responsive and flexible IT. Organisations that are shifting to a data-driven, insight-powered culture will be in the best position to defend, differentiate and disrupt in their respective industries, potentially expanding their business with new products and revenue sources. Learn how some leading companies are leveraging data – from IoT sources, social sources, enterprise, partners, competitors, and consumers – to unlock new sources of insight.
Speaker: Amit Bansal, Digital Delivery & Analytics Lead, APAC, Accenture
A Leading Industrial Automation, Process Control and Instrumentation Company, Serving Since 1996.
This presentation is about S V Controls work in pharmaceutical domain. S V Controls is serving prestigious clients like Serum Institute, Sun Pharma, Emcure, Cipla etc. in pharma domain.
For More details about S V Controls visit https://www.svcontrols.com/industries-served/
In the Nanoprecise, industrial preventative maintenance is a crucial aspect of ensuring the smooth operation and longevity of your machinery. Finally, by investing in proper preventive maintenance, you can save money in the long run while increasing overall production output. So don't wait any longer; start implementing these tips today!
Nanoprecise Data Services Pvt. Ltd.IndiQube- Edge Service CentreKhatha No. 571/630/6/4,(Sy No.6/4), Ambalipura Village,Outer Ring Road, Varthur Hobli,Bangalore-560103
Talk to our experts
at solutions@nanoprecise.io
Asia - +91 75681 21121
The Science of Predictive Maintenance: IBM's Predictive Analytics SolutionSenturus
Overview of IBM’s Predictive Maintenance and Quality (PMQ) solution. View the webinar video recording and download this deck: http://www.senturus.com/resources/science-predictive-maintenance/.
We show you the PMQ solution can keep manufacturing processes, infrastructure and field equipment running to maximize use and performance, while minimizing costs.
We show how you can use powerful analytics and data integration to help: Anticipate asset maintenance and product quality problems, Reduce unscheduled asset downtime, Spend less time solving production machinery and field asset problems, Improve asset productivity and process quality, Monitor how assets are performing in real-time and predict what will happen next.
Senturus, a business analytics consulting firm, has a resource library with hundreds of free recorded webinars, trainings, demos and unbiased product reviews. Take a look and share them with your colleagues and friends: http://www.senturus.com/resources/.
Spumaint is a generic software to service any industrial sector. Has Asset Maintenance Module to record any number of machinery with spares inventory,special tools, etc. Preventive Maintenance Module for scheduling multiple time pop-ups as well as condition based. Analytical tools also found in breakdown n reporting module
Arrelic end-to-end Reliability Management allows you to;
Identify and rectify equipment problems before they happen, Reduce maintenance costs and unplanned downtime.
RCM is used to develop scheduled maintenance plans in an efficient and cost-effective manner that will provide an acceptable level of operability and risk. It focuses on processes and systems to reduce the overall cost to maintain and operate assets. Arrelic Consulting assists industries in integrating assets and increasing return on investment by enhanced asset performance and reliability.
Maintenance strategy development and optimisation through Critical Asset Ranking, RCM Approach and cost benefit analysis ensures you the best maintenance plan.
I was wondering if there were any Industry 4.0 opportunities at PAR Formulation
Intellithink is a young company based out of Chennai and Bangalore that offers comprehensive solutions in real-time productivity monitoring (including energy) and maintenance, condition-based monitoring.
The challenges facing in pharmaceutical maintenanceMANUEL PACINI
Maintenance strategies for the pharmaceutical industry.
Maintenance and service-related items are often the second-largest budget element in a laboratory after salaries and benefits
DIVA is a selflerning maintenance software where you can control your machines based on availability. Thanks to decades of research the software is optimizing the intervalls for maintenance and inspections. With this CMMS you can reduce the risk of downtimes, increase productivity and save maintenance costs. DIVA can be used on a local basis, in addition with a mobile app and via cloud. This maintenance program has a modular structure and can be used within all branches independend from the size of the company.
BearingPoint's predictive maintenance approach supports clients to optimize asset availability, reduce failure rates and minimize downtimes. Clients will be able to predict breakdowns and initiate tangible actions to avoid them.
The Evolution of Proactive Maintenance:
How maintenance teams are using tiered maintenance, wireless tools, condition monitoring system, CMMS software platform and IIoT data management to get around barriers to predictive maintenance implementation.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfKamal Acharya
The College Bus Management system is completely developed by Visual Basic .NET Version. The application is connect with most secured database language MS SQL Server. The application is develop by using best combination of front-end and back-end languages. The application is totally design like flat user interface. This flat user interface is more attractive user interface in 2017. The application is gives more important to the system functionality. The application is to manage the student’s details, driver’s details, bus details, bus route details, bus fees details and more. The application has only one unit for admin. The admin can manage the entire application. The admin can login into the application by using username and password of the admin. The application is develop for big and small colleges. It is more user friendly for non-computer person. Even they can easily learn how to manage the application within hours. The application is more secure by the admin. The system will give an effective output for the VB.Net and SQL Server given as input to the system. The compiled java program given as input to the system, after scanning the program will generate different reports. The application generates the report for users. The admin can view and download the report of the data. The application deliver the excel format reports. Because, excel formatted reports is very easy to understand the income and expense of the college bus. This application is mainly develop for windows operating system users. In 2017, 73% of people enterprises are using windows operating system. So the application will easily install for all the windows operating system users. The application-developed size is very low. The application consumes very low space in disk. Therefore, the user can allocate very minimum local disk space for this application.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Vaccine management system project report documentation..pdfKamal Acharya
The Division of Vaccine and Immunization is facing increasing difficulty monitoring vaccines and other commodities distribution once they have been distributed from the national stores. With the introduction of new vaccines, more challenges have been anticipated with this additions posing serious threat to the already over strained vaccine supply chain system in Kenya.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
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2. Predictive Maintenance www.WIKA-FAST.com 2
51%
Plant, property and equipment
make up the majority of their
total investments
Maintenance Challenges:
How do you maintain your company’s most
important assets?
Source: IDC Energy Insights, 2010
3. Predictive Maintenance www.WIKA-FAST.com 3
Three Most Common Approaches to Maintenance
Approach Technique Needed Human Body Parallel
Reactive Maintenance Large budget
Unplanned loss of
production
Stroke or heart attack
Preventive Maintenance Periodic component
replacement
Bypass or transplant
Predictive Maintenance Monitoring of heat,
vibration, pressure, flow,
alignment and other
indicators
Detection with regular
check-ups, EKG or other
monitoring
4. Predictive Maintenance www.WIKA-FAST.com 4
Predictive Maintenance: Impressive Cost Reduction
Statistics compiled by the U.S. Department of Energy and the Federal Energy Management Program
provide valuable insight into the need for predictive maintenance programs:
5. Predictive Maintenance www.WIKA-FAST.com 5
Maintenance and Reliability
Joined at the Hip
Many companies have moved to a Predictive
Maintenance approach to monitor “critical”
process equipment, such as large compressors
and turbines
However, monitoring second-tier, “essential”
equipment – such as small compressors,
pumps, blowers, pipes, or cooling towers – may
be deemed too cost-prohibitive
Yet, failures of these essential assets represent
the majority of unplanned slowdowns and
slowdowns (see Figure 1)
And can comprise 70% of your maintenance
budget (see Figure 2)
SOURCE: “Improve reliability with essential asset monitoring,” InTech, May/June 2012.
http://www.isa.org/InTechTemplate.cfm?template=/ContentManagement/ContentDisplay.cf
m&ContentID=89645
0%
5%
10%
15%
20%
70% of total maintenance
budget consumed by only 7
asset classes
Figure 1
Figure 2
6. Predictive Maintenance www.WIKA-FAST.com 6
Predictive Maintenance
Need for Early Identification
So how do you become more predictive?
One key is reading the warning signs so you can act before unplanned downtime
happens
A vast majority (81%) of
companies using Predictive
Maintenance have instituted
“alerts and alarm management”
as a core functionality*
* Source: Aberdeen Group
8. Predictive Maintenance www.WIKA-FAST.com 8
“An Ounce of Prevention…”
What do all companies like yours
have that are relatively inexpensive
and can support predictive
maintenance efforts?
Gauges, which can:
Help you protect “essential”
equipment
Serve as a relatively low-cost alert
to potential problems, including
downtime
9. Predictive Maintenance www.WIKA-FAST.com 9
Gauges & Reliability
A mechanical gauge can serve as a low-cost,
mechanical back-up for your monitoring software
Or, it can serve as entry point to Predictive
Maintenance if you don’t have monitoring software
You can use gauges to:
Detect signs of degradation in process
performance
Diagnose causes of system and production
disruptions
Predict how long a piece of equipment can be
safely and economically run
Identify potential loss of process or loss of
containment
10.
11. Challenge
•A gauge in a large chemical manufacturing plant that transfers a brine/salt water solution ruptured and released media Solution
•WIKA examined gauge and found root cause of failure was overpressure
•Brine solution became diluted and froze, causing pressure system to expand and rupture—when ambient temperature warmed, media poured out from the gauge
Results
•WIKA recommended customer investigate the installation to determine cause of overpressure situation
•Pressure gauge served as early warning system for much bigger problem with
•potentially disastrous results
•Company identified freezing issue before it ruptured the piping system
Case Study
13. Predictive Maintenance www.WIKA-FAST.com 13
Where’s the Expertise?
“As many as 40% of
U.S. petroleum
engineers currently
employed by the
industry will retire by
2015.”
IDC Energy Insights
“The Role of Predictive Analytics in Asset
Optimization for the Oil and Gas Industry”
October 2010
To start using gauges as predictive indicators,
you first need the right gauges in the right
places…and that takes expertise
You may not know a lot about
instrumentation…or even care to learn more
Or maybe your engineers have retired…
15. Predictive Maintenance www.WIKA-FAST.com 15
Let us be your gauge experts
Full Audit Service Team
Gauges, if used properly, can help you
identify an issue before costly problems
develop
Our Full Audit Service Team (FAST) will
take care of your gauges to help
o Lower inventory costs
o Improve reliability
o Reduce gauge maintenance costs
And best of all, FAST is the only solution
you need—a total care services program
at no additional cost to you
17. Predictive Maintenance www.WIKA-FAST.com A Full Suite of
Services at Zero Cost
17
FAST Program
Instrument
Audit
Turnaround
Instrument
Planning
Instrument
Failure Analysis
Instrument Safety
Training
WIKA’s Instrument
Audit provides expert
analysis and solutions
form our FAST
engineers who help you
put the right gauges in
place for your
applications to improve
reliability and lower
costs.
Our team performs an
Instrument Audit,
standardizes the
instruments you need
and sends the products
to you when you need
them... before your
turnaround begins so
you can avoid delays.
Send us your failed
gauge, and our
engineers will conduct
a root cause analysis.
By understanding the
mode of failure, our
FAST engineers can
recommend a reliable
solution.
Our FAST engineers
train your team to look
for signs of instrument
failure when completing
a scheduled evaluation
of your instrumentation.
18. Predictive Maintenance www.WIKA-FAST.com 18
FAST Instrument Audit
Visual inspection of pressure, temperature gauges to build a
comprehensive record of gauge installations and rate problematic
conditions
Data analysis to provide engineering-based recommendations that
improve, standardize and consolidate your population
Implementation support, including ERP imports, MOC
documentation, and Easy Order Guides
Improves reliability, and decreases inventory and maintenance costs
year after year
Establishes a Sustainable Gauge Maintenance
Program
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25%
20%
30%
Average FAST Audit Savings
$51,171Ɨ in first year savings,
Ongoing annual savings of $21,073ƗƗ
Less gauge failures and
less time to replace
Correct gauges for
processing
conditions
Standardize on full
scale ranges, options
for gauges
Decrease
Maintenance Costs*
Reduction in
Inventory*
Increase in
Reliability*
First year savings only includes engineering resources for physical audit, storeroom review, data
compilation, and implementation support. Based on average audit of 1,000 installations, requiring
two instrumentation engineers for one week
ƗƗ Ongoing annual savings. Inventory savings based on industry averages for overhead, inventory
management, shrinkage, obsolescence, inventory tax, and cost of capital
*Based on results from more than 250 WIKA instrument audits
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Our team performs a full Instrumentation
Audit and standardizes what
instruments you need...before your
turnaround actually begins
With this advanced preparation, we
ensure that the right instruments are at
your plant at the exact time you need
them – eliminating the risk of delay
Action plan with part number, IOM and
data sheet for each installation
FAST Turnaround Instrument Planning
Ensure the Right Instrumentation for
Start-up
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FAST Instrument Failure Analysis
Getting to the Root of the Problem
If you have gauges that are continually
failing, then send them to us
Our FAST engineers will perform a root
cause analysis
Can alert you to problems with more
expensive equipment
Reduces likelihood of downtime and
decreases maintenance costs
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FAST Instrument Safety Training
Education and training are best tools to
maintain operational efficiency and
employee safety in your plant
Our Instrument Safety Training will teach
your team to look for warning signs
Held at your site or ours, the training helps
reduce maintenance costs and wrench
time
22
FAST FACT
U.S. process plants lose more than $10 billion per year
from abnormal situations caused by human error.
Source: Abnormal Situation Management Consortium
FAST Instrument Safety Training
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Years of testing culminated in premiere
process gauge that:
Reduces downtime from regularly replacing
worn-out instruments
Improves safety and efficiency
Produce most precise measurements with
its Swiss-made movements
Exceeds pressure gauge standards ASME
B40.100 and EN 837-1 (mandatory
performance testing)
Fire-resistant case with flammability rating
according to UL 94, V-0 test procedures
XSEL®: The Process Gauge You Helped Design
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XSELTM Process Gauge
Best-in-Class for Process Industry
XSEL Process Gauge
Culmination of German Engineering, Swiss Precision and
American Manufacturing…
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All-Welded System
For the Most Extreme Environments
Diaphragm seal and pressure gauge
permanently welded together to create a
sealed pressure measurement system
Removes all threaded connections to
eliminate potential leak paths
Helium leak tested
Helium is the smallest stable gas
molecule, so if we can contain it, we
can contain your gases
Complies with EPA’s Dual Containment
Requirements
Removes possibility of misapplication or
tampering
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Potential Leak Point
WIKA welds its stainless steel case to its
stainless steel socket
Other manufacturers screw the socket
into the gauge with a rubber O-ring,
which is prone to wear out and create a
leak point
With thousands of gauges in your
plant, it’s impossible to monitor
each one
That’s why WIKA has developed
solutions to protect against leaks
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Liquid Filled Gauges
Longer Lifetimes and Greater Accuracy
Liquid filling absorbs vibration and
pulsation, which stabilizes pointer
Liquid filling shields internal components
from corrosion, moisture, icing, and shock
Liquid filling lubricates and cools moving
parts, dramatically reducing wear
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Direct Drive Gauges
Give Us Your Worst
One moving part – a helically-wound
Bourdon tube
A tube made of Inconel X-750 alloy,
highly resistant to temperature
extremes with excellent oxidation
and corrosion properties
No gears, linkages or springs to
wear or break
Direct Drive Gauges
Give Us Your Worst
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Temperature Gauges
Performance Plus Peace of Mind
Silicone free and available in temperature
ranges not possible with case fill
Eliminates the need for case fill that can
leak or discolor under extreme
temperatures
All angle swivel connection allows
mounting in a variety of positions
World’s first dampened movement thermometer
eliminates pointer flutter caused by vibration
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How much could you gain with a
FAST Audit?
Contact us to Learn More about WIKA’s
FAST Services.
1-855-651-FAST
info@wika-fast.com