Resources for maintenance and reliability

Electrivert Introduces Manufacturing System Analysis

2012-02-09T10:26:54-06:00

Electrivert Inc. recently introduced a new cabling and termination (C.A.T.) scan process to help customers achieve increased efficiency, reliability and serviceability.

The four-phase process is an in-depth analysis of a company's machines, systems and processes that identifies opportunities for improvements in the following key areas:

Cabling selection and consolidation
Connector selection and consolidation for a more modular design
Streamlined build processes
Reduced manufacturing and installation costs
Increased reliability
Greater serviceability
Modifications to meet UL and NFPA regulations

"The Electrivert C.A.T. scan enables us to help our customers streamline their designs, reduce costs and improve overall efficiencies," said Jody Williquette, Electrivert’s business development manager. "Our services identify ways to improv

Reliability Reduces Waste of Time, Talent and Resources

2012-02-06T08:45:11-06:00

Waste is seen in many different forms in manufacturing. Some of these wastes include physical, time and talent.

Physical waste is anything that is left over from the process that has to be discarded, recycled or sold. For every process, there is an expected amount of waste that is unavoidable. However, the waste that we will focus on is the excess waste that is produced because of equipment or process reliability issues. There are many processes that are a one-shot process, where if it is interrupted during the process, all of the materials become waste.

Time waste also directly relates to equipment and process reliability. Any time that the system is down for unplanned maintenance, that means there is extra time required to make up the work, idle manpower and manpower required to correct the deficiency. In many cases, the extra time required to make up the work falls into overtime or extra shifts.

Talent waste is the use of time and education to repair or cor

Get More Maintenance Work Done with Proper Planning

2012-01-30T11:43:23-06:00

Famous financier Bernard Baruch was often quoted as saying, “Two and two still and always will equal four.” This, some would say, quaint concept has fallen out of favor more and more in recent years, as clearly the restrictiveness of basic arithmetic is not something that should continue to bind us in today’s brave new world.

It’s much more useful if two and two can equal:

Whatever analysts are expecting it to be (or better).
Whatever your boss wants it to be.
Whatever will make this current project justifiable.

Keeping this in mind, some odd-looking math that actually works in plant maintenance is the rule that:
“10 minus 1 equals 16.5.”

This rule is a huge help with another rule that is always pretty much true:
“In most plants, there are never enough maintenance people.”

If I have 10 maintenance mechanics and

Ultrasound World VIII to be Held in Florida

2012-01-26T08:46:59-06:00

Ultrasound World, a forum for ultrasound technology, has been scheduled for May 14-17, 2012, at the Clearwater Hilton in Clearwater Beach, Fla. Entering its eighth year, Ultrasound World has grown into one of the top conferences for reliability and energy conservation. This year’s program will feature presentations and short courses by users of ultrasound technology and will cover a wide range of topics for condition monitoring and energy conservation.

Among the presentations offered include “No More Equipment Failures! Can You Say That?” by Todd Fraser of Procter and Gamble, who will describe how his department dramatically reduced bearing failure incidents using ultrasound technology. The short course “Clean, Green and Reliable” will explain how equipment reliability delivers low-cost, energy-efficient assets at plants around the world. Other important topics, such as effective energy conservation practices and detecting and a

Solving Maintenance Problems with Mobile Collaboration

2012-01-25T08:41:27-06:00

Time is money. For companies with operations spread across the globe, delays in equipment maintenance issues or production line problems can kill the bottom line. If the most skilled engineer is located in New York or Detroit and the most important machinery is in Mexico or China, costs mount quickly when decisions are delayed. Typically, the expert (or a whole team of experts) would board a plane to go and try to solve the problem, causing further delays and incurring expensive travel costs. With mobile collaboration, no one leaves their desk, let alone the country.

Secure Mobile Video

The standard form of video collaboration facilitates face-to-face meetings in video-conferencing boardrooms. However, for manufacturers, the heart of their business is often the plant floor —

Boeing to Close Wichita Facility

2012-01-06T08:36:44-06:00

The Boeing Company recently announced that the Boeing Defense, Space and Security (BDS) facility in Wichita, Kan., will close by the end of 2013. The facility currently employs more than 2,160 employees.

"The decision to close our Wichita facility was difficult, but ultimately was based on a thorough study of the current and future market environment and our ability to remain competitive while meeting our customers' needs with the best and most affordable solutions," said Mark Bass, vice president and general manager for BDS' Maintenance, Modifications and Upgrades division. "We recognize how this will affect the lives of the highly skilled men and women who work here, so we will do everything possible to assist our employees, their families and our community through this difficult transition."

Boeing Wichita is the base for the company's globa

5 Time Wasters for Reliability Engineers to Avoid

2012-01-05T08:19:19-06:00

You’ve heard the catch phrases. You’ve read the success stories. You’ve seen the return on investment (ROI) calculations and the positive trending that reliability engineers bring. You’ve even lobbied upper management. Your argument has been so convincing that you’ve secured approval in this year’s budget to hire a reliability engineer. The hiring process has begun, and you can’t wait for the results: more reliable equipment, fewer failures and increased availability and production.

If only it were that easy. Building a reliability program led by competent professionals takes work. It requires setting expectations properly. Most of all, it requires time. How do you accelerate the process to ensure the maximum benefit in the shortest time? Avoiding these top five time wasters could help.

Lack of Vision

No, we aren’t talking about whether your reliability engineer could have been a fighter pilot or whether

Lockheed Martin Awarded Operations and Maintenance Contract

2011-12-16T10:50:19-06:00

Lockheed Martin has been awarded work by the U.S. Army's Product Manager, Joint-Automatic Identification Technology organization to provide operations and maintenance for the Radio Frequency In-Transit Visibility (RF-ITV) system. If all options are exercised over the course of five years, the contract is valued at $126 million.

RF-ITV sites exist worldwide in support of combatant commands and must be maintained at optimal levels of operational readiness to support joint forces. Through RF-ITV technology, the system provides last-known locations and in-the-container visibility for shipments that have active RF tags attached to pallets, containers or equipment.

"With the government's and Lockheed Martin's focus on affordability, the RF-ITV system is critical to manage military shipments such as cargo, supplies and unit movement," said DeEtte Gray, Lockheed Martin IS&GS-Defense vice president for enterprise IT solutions. "The Lockheed Martin t

Using Dynamic Electric Motor Monitoring to Identify Mechanical Issues

2011-12-14T08:50:54-06:00

Dynamic electric motor testing is often called on-line testing because it requires the motor to be running and generally assumes the motor is in its natural environment. Dynamic testing involves the connection of voltage probes and current transformers. Connecting dynamic test equipment is safe, quick and non-intrusive. Data is acquired and results are displayed in a summary format. The collected data is compared to the user-entered nameplate information and is presented in a pass/fail format with both current test data and trending logs displayed after each successive test.

The Need for Motor Testing

Every reliability technician knows that costs associated with motor failures can be devastating to any business operation. Finding that a motor is operating with conditions that create excessive heat or stress is a guide to the technician to make changes in the motor’s operation and to monitor its insulation. Knowing that a motor is in imminent dang

5 Keys to Maintain Equipment Reliability

2011-12-05T08:55:44-06:00

There is so much similarity in all that we do within the maintenance planning and scheduling world that compares to other separate and distinct functions. Let me explain. Borrowing from root cause analysis process methods, I trust you are familiar with Ishikawa diagrams (also called fishbone diagrams or cause-and-effect diagrams). These diagrams are one method that is used for product design, quality defect avoidance or variation, or to identify factors that lead to some event, hence the use in root cause analysis.

The categories typically include:

Man (people)
Methods: How the process is performed and the specific requirements to perform the tasks, including time estimates
Machines: Any equipment, tools, etc., needed to do the job
Materials: Consumables, parts required
Measurements: Data generated from the process

All of these items combine together to create some output or event. In

How to Implement an Effective Chain-wear Monitoring Program

2011-11-16T09:34:54-06:00

Chain-wear monitoring has been a part of equipment reliability programs since the first link was forged. It is such an integral part of an organization’s reliability program that it has become part of industry slang as in the phrase, “A chain is only as strong as its weakest link.”

Chains are a part of almost every industrial process. They are found in a plant’s material-handling transportation system, key components in the operation of hoists and cranes, or as a part of the connection that controls a safety stop device.

Regardless of its function, the failure of any component that makes up a chain is costly to the owner, if not disastrous. Even though we would all agree that a chain failure is undesirable, modern industry’s chain-wear monitoring has remained varied in its approach and frequency.

Typically, chain reliability inspections are applied through a periodic inspection sampling procedure or replacement schedule. Visual in

6 Techniques to Error-proof Your Plant

2011-11-10T08:59:05-06:00

When faced with the task of improving plant efficiency, the average plant manager breaks the task down by the five or six existing "departmental silos." Each silo leader subdivides responsibility, repeating the mistake, and passes it on to individuals. As a result, we see young, intelligent engineers overwhelmed by the task handed to them of "get out there and improve maintenance." The situation is not so bad for the less intelligent or those who have become automatons; they just keep repeating what has gone on forever and collect another paycheck.

What the plant manager needs is a better way to visualize his situation, a method that will allow him to develop a new strategy. The following insights are based on work done at MIT and by many other professors in "human error" at international centers of learning. The "Error Pyramid" is unique, but the remaining techniques and technologies have been established for 15 years or more.

How to Reap the Benefits of Parts Standardization

2011-11-07T10:49:04-06:00

Nothing leverages your parts and training budgets like standardization. It is one of the key areas of the 5-S process. The more you can standardize, the fewer parts you need to maintain and the further your training goes.

Some plants have dozens of manufacturers represented on their production floor with the subsequent glut of critical spares in the storeroom, shelves full of manuals and lost time while technicians re-familiarize themselves with troubleshooting procedures. It can also mean extra money spent on special tools, calibrators and handheld programmers, as well as maintaining extra vendors on file with the insurance, credit and shipping requirements that go with them. It takes some time and effort up front to establish standards, but the payoff can be continuous. The flavor of the month may be sexy and/or cheaper at the time of purchase, but you will probably pay for it later.

Here are some simple guidelines to get you started. These are just a few places to loo

Unleash the Power of Your CMMS

2011-11-02T09:30:46-05:00

A properly configured and utilized computerized maintenance management system (CMMS) is a foundational element of every successful maintenance and reliability program. However, implementing this technology by itself will not ensure that users will achieve greater efficiencies or maximum value from their investment. Trying to obtain value from technology alone is like trying to stand on a three-legged stool that is missing two legs. The other two critical items (legs to this stool) are well-designed work processes and engaged people.

We as a maintenance and reliability community need to educate our management and co-workers on the benefits and potential value a CMMS brings to the entire organization, not just the maintenance department. Empowering and encouraging the plant staff to learn how to use this critical tool can pay huge dividends in improving plant performance and increasing the efficiency of maintenance and reliability programs. Through better analysis of asset failures,

How to Keep Maintenance in a Proactive Mode

2011-10-31T08:38:36-05:00

I stumbled across some music trivia lately, that the old rock band Chicago finally had its album “Stone of Sisyphus” released a few years ago. One of the more famous “lost” albums, it was originally recorded in the early 1990s but had languished for years, available only in illegal bootleg copies.

That reminded me of when I used to use the story of Sisyphus in maintenance training sessions.

I never encountered a great number of serious Greek mythology students in those sessions, but was always amazed how mythology suddenly grasped attendees’ attention when I started telling about Sisyphus showing up in an episode of the TV series “Xena: Warrior Princess.” A statuesque, obviously very strong gal who always wore a brief, Roman-style leather outfit, Xena

Konecranes Launches Remote Crane Maintenance Services

2011-10-25T10:50:05-05:00

Konecranes recently launched its Truconnect remote services to ensure that cranes used in industrial processes are up and running at all times. The first two products being offered are the Truview data-reporting service and the full-service package Trucare solution.

Based on remote connection between the crane and a Konecranes remote center, Truview provides customers with a realistic view of their crane’s operating conditions through continuous data collection.

“All information from the crane is automatically sent to the remote center to be further processed and finally concretized in sophisticated reports,” says Tuomo Härkönen, head of Global Technical Services. “In the remote center, we have a dedicated organization and enough resources to operate the r

Improve Equipment Effectiveness by Targeting 11 Major Losses

2011-10-24T08:30:38-05:00

Everyone wants a silver bullet to address the competitive environment pressuring profits and, ultimately, jobs in North America. Having transitioned from a controls engineer to a maintenance manager to an operations manager, I can attest to the quest for that silver bullet. The reality is that few levers exist for you to pull that will radically improve the profitability of your organization. With global markets and price supports, commodity costs are generally fixed. The same applies to prices received for your company’s products or services. Labor markets and costs are somewhat fixed as well. With the exception of fuel surcharges, logistics costs are generally set.

As a maintenance or operations manager, your span of control is bound by the four walls of your site. With energy prices, some opportunities exist for cost reduction in pursuing energy audits and savings activities. The largest opportunity is focusing your efforts on improving equipment effectiveness by targeting

Keep Maintenance Simple: Use Senses and Sensibility

2011-10-17T09:05:59-05:00

What good is it to have advanced maintenance techniques if they have no real benefit over simple basic maintenance? Now I am not saying go and throw away all of your fancy toys. What I am saying is that you don’t have to have advanced tools for every maintenance task. I have seen many maintenance groups that have adopted certain maintenance techniques and, in turn, overuse them on everything they can be used on. The point is, why use them if they are not cost effective?

There are many cases in which a failure can be detected with an operator’s or technician’s built-in test equipment that takes no special training to use. This equipment is his or her senses — sight, sound, feel and taste (not recommended). These are all skills that should be taken into account when performing any kind of maintenance analysis. In many cases, a technician or operator can detect a potential failure in adequate time to mitigate the consequences of a functional failure.

How Proper Training Can Increase Reliability

2011-10-12T09:24:45-05:00

I recently had the opportunity to make a first visit to a new client’s site. As you would expect, upon arrival I was required to attend the contractor/vendor safety orientation training before I could be set loose in the site facilities. This client site was in the Deep South, and our instructor for the training was the site safety coordinator, a local gentleman who had been employed in or around the area all his life. With his Southern drawl, he said everything about three times. (I could never quite figure out if he wanted to make sure we “got it,” or if he just liked saying everything at least three times.) I recall that the training was very good and to the point, and everyone in the training session was fully aware of all the safety rules and all the potential hazards of the site.

Why was this safety orientation training required by the client site? First, there is an OSHA requirement that everyone be trained in the real and potential hazards of the sit

How to Set Frequencies for PM Inspections

2011-10-03T09:10:04-05:00

For those of you who want to indulge in the details of setting preventive maintenance (PM) inspections, let’s begin with defining what I mean by inspections. Inspections include all objective inspections (we measure something) using an instrument – for example, a vibration analyzer, an infrared camera, a volt meter, a flow meter or ultrasonic equipment. Inspections also include all subjective inspections (look-listen-feel-smell). In order to set inspection frequencies, we need to understand what a failure-developing period is.

The failure-developing period (FDP), also called the Pf Curve by some, is the time period from when it is possible to detect a failure until we have a breakdown. A failure is when a system or piece of equipment is operating correctly within given parameters, but it shows signs of problems. For example, a centrifugal pump may be cavitating, but it is still providing the required flow for the operation. We have a failure but not a breakdown. The cav

Quick Guide to PM Development and Execution

2011-09-19T09:18:41-05:00

In many organizations, groups are often trying to chase the latest buzzwords of the day and yet have never established the foundation required to support those efforts. PM development and execution are classic examples. For this discussion, when I refer to PMs, I am talking about both preventive maintenance and condition-based maintenance tasks. This is by no means an exhaustive explanation of all of the considerations necessary for a comprehensive PM program. It is intended as a rough guide to foster continued discussion into the topic.

Stop doing non-value added PMs or task steps within the PM. We can never seem to find time to update or correct the PM tasks or frequencies but can always find time to continue doing the wrong work (go figure! ).
Assuming that you already have a PM program in place, start with the equipment where you are bleeding or hemorrhaging the most. This is often not your most critical assets.
Identify the failu

How Kitting Can Enhance Reliability

2011-09-14T08:13:15-05:00

In the world of manufacturing, we are looking for better, more efficient ways to improve our production uptime and quality, reduce the cost per unit, improve human capital utilization and create a higher quality of work life for our personnel. Kitting for maintenance crafts to perform their tasks is one of the easier and more effective ways to allow quality completion of the job with minimal productivity impact, especially when accompanied by a well-planned and functionally scheduled job.

Understanding the value of kitting in relation to the value of the time lost requires asking and honestly answering some questions:

Does the job have to be done now or can it wait to be planned and scheduled at a time that minimizes production loss? Will we be able to schedule it at a time that will reduce the amount of product lost through the equipment downtime for the repair?
What materials should be kitted for the job(s)?
Is there a

Why Reliability Excellence is Imperative for Safety

2011-08-16T08:20:22-05:00

We tend to speak about financial issues more than moral issues in the business world. Safety is an issue that has significant ramifications from both moral and financial perspectives.

Safety is a financial imperative in today’s business world. According to a 2010 Liberty Mutual study, the annual documented direct and indirect industry cost of U.S. workplace accidents totaled $240 billion per year. The average cost to industry for a fatal accident ranges from a low estimate by the National Safety Council of $1.27 million to the enormous average of $8.6 million per fatality paid out by BP after its refinery explosion.

According to an Air Force study, the average cost of a permanent disability is $1.3 million, while a partial disability costs $210,000. Workers’ compensation premiums, which correlate directly to your accident and incident rate, amount to millions of dollars per year in even a modest-sized company. Any way you look at it, accidents are expensive.

The 10-second Measure of Maintenance Effectiveness

2011-08-15T16:09:17-05:00

Two decades ago, I worked in the Florida citrus industry. Near the end of each growing season, the fruit became softer. This promoted increased damage during handling, especially in the bins where the fruit was temporarily stored during testing.

This, of course, wasted money, as juice literally went down the drain.

We built and automated a system that would allow us to bypass these storage bins while still allowing us to meet all of the necessary testing requirements. But this system came with its own costs and risks, so it was only economical to operate late in the season when fruit quality was diminished.

Our company had sophisticated measurements in place, including comparative values across the state. We could use these measures to determine at what point in each season we should convert to this system.

But, we didn’t need those comparisons.

My engineering office was on one side of those elevated fruit bins. The business offices

Let Risk and Your Equipment Determine Your Maintenance Strategy

2011-08-11T14:38:02-05:00

When I attend conferences and workshops and read articles on maintenance and reliability, more and more I hear people touting that preventive maintenance is more costly and not the right approach. When we talk about preventive maintenance, we are primarily talking about time-based inspections, but it can include overhauls/rebuilds as well. But before we take statements like these as the gospel and apply them carte blanche to all of our equipment, we need to understand the basis for that reasoning and when to apply it.

From the Reliability-Centered Maintenance side, we know that we can’t apply the single bathtub curve to all equipment failures. We recognize that six separate failure curves exist, and greater than 80 percent of all failures occur outside the infant mortality or end-of-life wear-out zones, meaning the failures are totally random in nature. No doubt that condition-based monitoring using various tools like vibration or temperature monitoring is better and a less c

What Plants Have Failed to Learn in 25 Years

2011-08-04T16:54:44-05:00

Twenty-five years ago, I left the U.S. Navy nuclear submarine program.

As I gained experience in civilian industry, I began to appreciate the Navy’s aplomb for reliable engineering, exceptional training and consistent operations. Their penchant for comprehensive preventive maintenance programs also impressed me.

What I found in industry 25 years ago was quite different.

There was almost no redundancy in design; the failure of a single small pump could shut down an entire plant. Sanitary systems had been modified over time, introducing unsanitary attributes. Many components were chosen solely on initial cost, not reliability or life cycle cost.
Operator training was limited to “hit the green button in the morning, the red button at night, and call mainte

The Maintenance Supervisor Enigma

2011-08-04T16:32:12-05:00

In my pre-retired life, I managed the development of maintenance procedures, PM programs, methods and service tools for all deployed equipment within the U.S. Postal Service. We also monitored our maintenance procedures manuals which incorporated support policies for the maintenance management information system. Any local changes were to be approved on a trial basis by my shop.

At that time, we were scratching our heads on how to get the supervisors out of their desks and out on the floor for more face time with the craft employees. I received a call from a plant maintenance manager requesting to stop recording the employees’ work order time on the daily work schedule forms. This was accomplished at the end of each shift by the supervisors from completed work orders. Each supervisor spent

Quintessential Asset Management: The Road to Reliability-centered Maintenance

2011-07-13T14:24:10-05:00

Asset-management programs and software are getting a lot of press these days. Every maintenance engineer and his site manager are writing a white paper and/or book about the value of asset management to a company’s bottom line. There are measuring tools and concepts galore, all intended to provide an instantly successful maintenance process. Much of this content makes achieving reliability-centered maintenance (RCM) and condition-based maintenance (CBM) sound relatively easy and commonplace. This fosters a misguided concept that RCM and CBM are commodities that can be purchased and implemented in short order.

In order to explain how to gauge where a company’s maintenance program stands and where its goals need to ultimately lie, we need another catch phrase that is all encompassing of the total maintenance-management-process approach and ultimate goal. How does Quintessential Asset Management (QAM) sound?

In this article, I’ll outline the five levels of

RobotWorx Debunks Used Robot Myths

2011-06-23T12:40:13-05:00

All too often companies are reluctant to consider used industrial robots as a viable automation option, despite their lower cost. Common misconceptions of used robots paint them as slow, finicky and unsupported. However, not every used robot is created equal. Robotics integrator RobotWorx debunks the used robot myths, offering its customers reliable, high-performance and fully warrantied used robots.

“At RobotWorx we’re focused on bringing automation within reach and changing the way used robots are perceived. We take robot reconditioning and customer support very seriously,” RobotWorx President Jarrod Bichon said. “Hopefully more and more companies will give used robots a chance and take advantage of the excellent performance and affordability they offer.”

The secret behind RobotWorx’ top-quality used robots is attention to detail. Prior to reconditioning, the acquisitions team is careful to select only robots with low hours and minim

Lubricant Market Expands to Wind Turbines

2011-05-17T09:08:35-05:00

First Oil Reprocessing Plant in New England Almost Complete

2011-05-16T08:50:44-05:00

YRC Worldwide Launches Initiatives to Reduce Emissions, Cut Costs

2011-05-13T10:30:36-05:00

Valvoline Launches New Line of Recycled Oil

2011-05-13T09:01:53-05:00

Oil analysis provider unveils new services

2011-04-25T15:02:37-05:00

Expanded Lubrication Oil Monitoring for Gas Compressors

2011-04-12T14:13:57-05:00

Worldwide Industrial adds grease, oil and lubricants to its marketplace

2011-04-08T08:49:06-05:00

Mobile lubrication system now available

2011-04-07T08:35:03-05:00

Universal Lubricants set to recycle used oil for Colorado company

2011-04-06T16:59:01-05:00

Ashless extreme pressure additive offered for greases

2011-04-05T14:53:48-05:00

Automotive industry pursuing new technology, techniques

2011-04-05T09:44:06-05:00

Maintenance is not a cost: How to justify an investment in maintenance and reliability

2011-03-04T11:48:30-06:00

As many of us strive to improve the reliability of our plants, several comments bemoan how challenging that is to do in an era of continuous deep cost cutting. They say that in their operation, maintenance is seen as a cost, and is one of the first things to arbitrarily cut.

Some think their operations have cut too far! What they seek is a way to justify a strong maintenance capability.

I submit that one approach is to speak of maintenance as an "investment in capacity." Use the language that plant managers, controllers and senior management understands: capital investment and return on investment (ROI).

“When you substitute your own estimates, the resulting comparison will be different in the details, but it will almost always favor an approach that improves reliability.”

Before I continue, this article is NOT intended for factories with clearly wasteful practices. We do need to cut costs where doing so will

The power of a clear, concise vision to improve M&R results

2011-03-04T11:30:22-06:00

One of the first responsibilities of leadership (of an organization, company, team or country) is to provide a simple, clear view of what the future can and should look like. Visionary leaders throughout history have done this in different ways. Many leaders that were effective used short, simple vision statements to allow people to clearly see what the future state can be. This provides huge momentum and propels the organization, country or team to aggressively pursue the vision.

Several examples are:

"Give me liberty or give me death."
- Patrick Henry, United States Revolutionary War leader, 1776

"We shall never surrender."
- Winston Churchill, England prime minister, 1941

"By the end of the decade, we will put a man on the moon."
- John F. Kennedy, United States president, 1962

"A computer on every desk and in every home."
- Bill G

Educating corporate executives on importance of SMRP

2011-01-20T09:03:08-06:00

This video was made to attract corporate executives to the Society for Maintenance and Reliability Professionals and its Certified Maintenance and Reliability Professionals exam.

Using iPad application for vibration analysis

2011-01-19T13:49:44-06:00

Are you overlooking your plant's maintenance issues?

2011-01-19T07:43:22-06:00

Are you overlooking your plant's maintenance issues? Are you covering them up or Band-Aiding them? This video slide show features photos from one plant that shows the myriad of maintenance issues that remain to be addressed.

Do you know how much it costs to run that equipment?

2011-01-17T16:17:34-06:00

Decisions have to be made – to save energy, to save dollars. Having hard data on which to base those decisions removes the “guess factor” and ultimately has a positive effect on the bottom line. Can recording data, analyzing results and then making intelligent decisions really have that large of a dollar effect, though? The answer is “Absolutely yes!”

Equipment ownership for maintenance technicians

2011-01-17T16:10:05-06:00

As a maintenance technician, do you believe having responsibility for specific equipment is the best way to perform your job? By responsibility, you are the only one that conducts preventive maintenance tasks and major repair work on that specific equipment. Do you believe it’s the right answer for the organization? As a maintenance manager, is this approach to equipment ownership the right answer for you or your stakeholder partners like operations? This facet of maintenance is traditionally a struggle for many organizations.

How Solutia uses the Optalign Smart shaft alignment system

2011-01-17T16:07:56-06:00

A sales engineer at Ludeca Inc. introduces the Optalign Smart shaft alignment system. He then speaks with Nihal Raval, a maintenance reliability engineer from Solutia Inc., about how Optalign Smart helped him.

Animation explaining laser shaft alignment

2011-01-14T08:55:56-06:00

Up to 50 percent of the damage to rotating machinery is directly related to misalignment! So just see the advantages of laser shaft alignment and increase your machine availability, productivity and machine lifetime

How to laser align rotating shafts

2011-01-14T08:50:23-06:00

This video shows how to laser shaft align rotating shafts as quickly as possible with Fixturlaser's "True Position Sensing", available on the Fixturlaser XA and the Fixturlaser GO. Laser shaft alignment with Fixturlaser's dual laser, dual sensor design means the system tracks the shafts' true positions, allowing alignments to often be completed with just one set of measurements and adjustments. The XA and GO laser shaft alignment tools are available in the United States from VibrAlign Inc.

Creating effective and sustainable maintenance work procedures

2011-01-12T08:36:53-06:00

You may not know how work procedures really work and their impact on asset reliability or asset integrity.

‘Pruning’ your inventory: Setting MRO stocking levels

2011-01-10T13:36:44-06:00

Is three widgets enough? Is six gizmos too many? Author Doug Wallace often get asked: “How do we determine the right stocking levels for our parts?” People want to know what the “magic formula” is. Unfortunately, the answer often is: “it depends.” Throughout this article, Doug will address some of the considerations involved in making these difficult decisions and then suggest one method for helping to determine the appropriate stocking levels for your own materials.

Making sense of electrical measurement

2011-01-10T13:13:41-06:00

Clamp meters really are the way to go in a wide range of measurement scenarios, especially if you’re working with higher amperages – or if you need a comprehensive motor test in one device.

Bearing protection rings help cement plant boost uptime

2011-01-10T12:56:21-06:00

It seemed as though nothing could stop the squealing. Not that the Monarch Cement Company’s huge ball mill wasn’t already loud. Powered by a 5,000-horsepower motor, it pulverizes 100 tons of clinker per hour. But the squealing was not what Randy Riebel wanted to hear. As electrical supervisor at Monarch’s plant in Humboldt, Kan., he knew the noise meant the motor’s bearings were going – again. What was the solution? Read this case study to find out.

AC drives: Choosing the correct motor

2011-01-10T11:42:11-06:00

This seminar video was written by AC drive and motor expert James Shumberg. This seminar introduces induction motor theory and offers tips on proper motor selection for motors used on AC drives. AC drive are sometimes called variable frequency drives, or VFDs. Reasons for avoiding high efficiency and NEMA Design A motor are explained. Motors rated for inverter duty are discussed.

Wireless condition monitoring for rotating equipment

2011-01-06T15:59:36-06:00

Ron Kittle, a senior product analyst for the Timken Company, talks about the StatusCheck wireless condition monitoring system.

GE acquires remote monitoring and diagnostics firm SmartSignal

2011-01-06T13:44:45-06:00

GE Intelligent Platforms on January 6 announced that it has completed the acquisition of SmartSignal, a privately held, analytics software company based in Lisle, Ill. SmartSignal specializes in providing remote monitoring and diagnostics solutions to the Power Generation, Oil & Gas and other industrial sectors. SmartSignal is a leading provider of predictive diagnostic software and monitoring services used to anticipate, prevent, and avoid equipment failure. The company has more than 40 product and technology patents, and has won more than 25 awards for product excellence.

Tips on maintaining the maintenance spare parts database

2011-01-05T14:10:50-06:00

Groups really struggle with managing their spare parts data due to years of neglect and lack of ownership. On the initial CMMS implementation, the data may have been properly described with a noun/qualifier/qualifier approach for the short text description. As time passes, people move on and someone else takes over the database. They may not receive training or understand the naming concepts. Soon, the users of the data can’t find the parts housed in the storeroom due to the way items have been named. The storeroom inventory value goes up, too, as parts become duplicated since no one could find the stocked item. How do you straighten this mess out?

Performing maintenance at a high level (literally)

2011-01-05T11:10:51-06:00

Think you have a challenging maintenance job? Try performing maintenance high off the ground. Laing O'Rourke has recently been awarded the next contract for the continued maintenance and inspection of all aspects of the two Severn Bridges in the United Kingdom for the next seven years. Paul Lane, Inspection and Maintenance Manager for Laing O'Rourke, talks about the challenges of maintaining these busy bridges.

A poem about plant maintenance (you need to read this!)

2011-01-05T09:50:45-06:00

"Maintenance evangelist" Joel Leonard forwarded this poem to us at Reliable Plant. We thought it important enough to share it with you. Enjoy!

ARC examines MRO inventory rationalization and optimization

2011-01-04T09:24:36-06:00

Inventory optimization directly affects C-suite metrics by providing a positive impact on the P&L statement (lower inventory carrying costs and reduced spend) and balance sheet (less inventory and increased cash). Making your boss look good is always a good career move.

Guohua wind turbines choose SKF for remote monitoring

2011-01-03T07:32:58-06:00

When the fourth-biggest wind farm operator in China increases its installed capacity by 50 percent within one year, that indicates a company that knows its business. And one of the business aspects that all wind farm operators need to take care of is “turbine reliability” – keeping the turbines turning as much as possible and keeping maintenance activities down to a minimum. Reduced or controlled maintenance is always a valuable contribution to bottom-line profitability, but when you’ve got 2,000 megawatts of installed capacity, the target by end 2010 for Guohua Energy Investment Company, based in Beijing, China, then you are talking about huge amounts of money.

GE notes its favorite monitoring and maintenance apps of 2010

2010-12-29T12:39:32-06:00

GE has been in the app fast lane — from consumer-friendly apps such as healthymagination’s Morsel, which helps people chip away at unhealthy habits, to GE Lighting’s Mood Cam app, which let’s you snap a picture of a room and see how different lighting styles might look to CNBC Real-Time, the only free app that offers real-time stock quotes from the NYSE and NASDAQ before, during, and after market hours. (The professional version gives real-time information and analytics on over 100 international markets.) But three that particularly caught our eye this year are the ones that most people might not at first think of when it comes to apps — as they’re for planes, trains and electric utilities.

8 traits to look for in an assistant manager

2010-12-28T17:06:00-06:00

Great companies are populated by great employees. While a top general manager is necessary, it’s not sufficient for the genuine long-term success of any company or major operating division. Businesses that genuinely succeed and flourish over the long run have general managers who possess the vision, wisdom and courage to identify, attract, hire and mentor great assistant managers.

PdM software innovations lead to improved operating margins

2010-12-28T16:57:45-06:00

The capability of today's predictive software provides immediate answers, not merely data. By proactively using predictive maintenance, one automobile manufacturing plant realized savings of up to $112,000.

What reliability-improvement tools should I invest in?

2010-12-28T16:37:09-06:00

Successful M&R programs start with the choice of one or two core tools and then add on as function and need permit. This allows people time to get to understand the tools and develop habits that are effective in application of the tools. As time goes along, those people are better equipped to be able to adapt to more tools in the toolbox.

Lean shutdowns: 10 ways to cut fat and do the right thing

2010-12-28T16:21:09-06:00

For most companies that run continuously, shutdowns and outages consume a lion’s share of both the maintenance and capital budgets. By its very nature, the shutdown is fat. The reason for this is the skewed balance between the cost of downtime and the costs of shutdown resources. In some cases, the costs of having extra resources (such as extra cranes) are dwarfed by the avoided cost of downtime. In this article, Joel Levitt offers 10 concrete ideas that will lean up the shutdown event without compromising safety or environmental security.

A common asset management context through international collaboration

2010-12-21T09:11:27-06:00

This month, the Global Forum on Maintenance and Asset Management (GFMAM) held its third face-to-face meeting during the Gulf Society of Maintenance Professionals (GSMP) inaugural conference in Manama, Bahrain. Attracting 748 registered delegates from 15 countries, the conference presented a program that included 57 papers and panel discussions.

Maintenance and sustenance at a Tata Steel plant

2010-12-20T09:51:53-06:00

This video provides a brief explanation of maintenance project performance at a Tata Steel plant.

How a printing plant uses infrared thermography to detect issues

2010-12-20T07:47:19-06:00

This video shows how a printing plant utilizes infrared thermography cameras to detect issues on press equipment.

Sappi Fine Paper completes $49M worth of capital projects at Maine mill

2010-12-16T14:15:17-06:00

Sappi Fine Paper North America announced December 16 that it has successfully completed capital projects totaling $49 million at its Somerset Mill in Skowhegan, Maine. The investment was comprised of a major capital project that upgraded recovery cycle equipment at the Somerset pulp mill, as well as 17 other related projects that improved manufacturing processes, all of which were completed on time with no interruptions to the mill's paper production.

When troubleshooting equipment, first impressions are important

2010-12-16T09:17:27-06:00

When troubleshooting a machinery problem, whether for an unusual vibration problem or a component failure such as a bearing or seal, first impressions from the initial machinery inspection are very important. Any troubleshooting exercise should begin with a thorough investigation of machine history - process, design, operation, maintenance, and all available machine details. These first impressions are necessary to make sure the troubleshooting team is fully armed with important data and minimize the chances of a misdiagnosis.

Eaton agrees to acquire Tuthill Coupling

2010-12-16T08:52:40-06:00

Diversified industrial manufacturer Eaton Corporation on December 16 announced it has agreed to acquire the Tuthill Coupling Group, a division of Tuthill Corporation. Terms of the deal were not disclosed.

Vibration analysis at an AkzoNobel plant

2010-12-15T07:45:10-06:00

Structural vibration monitoring of wind turbines

2010-12-15T07:43:03-06:00

This video explores the subject of structural vibration monitoring of wind turbines.

How the Oglethorpe Power Plant uses vibration analysis

2010-12-15T07:40:20-06:00

Progress Energy targets uptime, costs with infrared cameras

2010-12-15T07:38:03-06:00

See how FLIR's P640 infrared camera is used by Progress Energy, a power transmission company, for predictive and preventative maintenance to ensure constant supply.

Orlando to play host to 2011 infrared thermography conference

2010-12-15T07:35:57-06:00

Organized by the Infraspection Institute, IR/INFO is the most important conference of the year for infrared thermographers. This year, the infrared conference will be held at the Disney Boardwalk Conference Center in Orlando, Fla. For infomation, visit www.irinfo.org.

Infrared cameras provide benefits for utility companies

2010-12-15T07:33:29-06:00

This video shows FLIR cameras in the field and why infrared thermal imaging has become a key tool for predictive maintenance programs for utility firms everywhere.

MSC acquires Rutland Tool & Supply

2010-12-14T09:37:17-06:00

MSC Industrial Direct Company, one of the largest direct marketers and premier distributors of metalworking and maintenance, repair and operations (MRO) supplies to industrial customers throughout the United States, announced that it has completed its previously-announced acquisition of Rutland Tool & Supply Company, a subsidiary of Lawson Products Inc. for approximately $11 million in cash plus the assumption of certain liabilities. The company continues to expect the acquisition to become accretive to earnings in late-fiscal 2011 or early-fiscal 2012.

MIT research to set a new standard for life-cycle assessment

2010-12-10T10:53:12-06:00

The Massachusetts Institute of Technology (MIT) on December 10 released preliminary research findings that will help set a new standard in life-cycle assessment (LCA) modeling. The studies, which are part of an ongoing research initiative at the MIT Concrete Sustainability Hub, will quantify the cradle-to-grave environmental costs of paving and building materials, and will ultimately result in the most comprehensive LCA model produced to-date.

Defense maintenance personnel honored during DoD symposium

2010-12-10T10:50:50-06:00

The 2010 Department of Defense Maintenance Symposium and Exhibition, administered by SAE International, attracted a record number of attendees and brought together key leaders and maintainers throughout the Department of Defense and commercial industry to discuss maintenance, technology, sustainment operations, and materiel readiness.

Machinery Health Monitor combines vibration and temperature monitoring

2010-12-08T10:34:27-06:00

Emerson Process Management announces the addition of a unique temperature module for the CSI 6500 Machinery Health Monitor. The new A6630 temperature module complements the vibration monitoring capabilities already available in the CSI 6500 and delivers critical bearing temperature measurements. The A6630 module accepts RTD and thermocouple signals directly, reducing the installation cost and complexity of temperature monitoring.

The 5 biggest risks to effective asset management

2010-12-06T14:36:23-06:00

Asset management is an integrated approach to optimizing the life cycle of your assets, beginning at conceptual design, through to usage, decommissioning and disposal. By acknowledging and paying attention to the five primary risks to effective asset management, you can put in place plans to mitigate the effects these might have on their program.

Research aims to enhance efficiency of wind turbines

2010-12-06T14:02:48-06:00

A new type of air-flow technology may soon increase the efficiency of large wind turbines under many different wind conditions.

NRC inspectors watch maintenance, safety practices at Three Mile Island

2010-12-06T13:08:22-06:00

Resident inspectors with the U.S. Nuclear Regulatory Commission are stationed at Three Mile Island nuclear power plant to protect public safety and to be independent watchdogs over the plant's hundreds of employees and the actions they take every day. This incloudes all maintenance work (including machinery lubrication). There are inspectors stationed at all commercial nuclear facilities in the U.S. View the article at http://articles.lancasteronline.com/local/4/321494.

Food for thought: Avoid tunnel vision in the plant

2010-12-06T11:54:45-06:00

Often times, we become complacent in our surroundings and we simply don’t notice things that are changing all around us. It’s like we are wearing blinders, suffering from tunnel vision. We only look straight ahead or, worse, hang our head when we move through the plant. In doing so, what are we missing? An emerging safety problem? A cleanliness eyesore? Or, a potentially catastrophic reliability issue? Food industry veteran Jeff Shiver provides commentary and a call to action.

Strategies to optimize shutdowns, turnarounds and outages

2010-12-06T10:21:00-06:00

Poorly executed STOs can cost an organization millions of dollars in lost revenue, drive up operating costs and cause permanent damage to the careers of those involved. This has long been true but is now amplified in the current operational environment, in which most organizations are operating with reduced workforces and resources. Simply put: In today’s business environment, STOs represent not only an increasingly significant challenge, but also an increasingly significant opportunity. Read this article and learn how to maximize your next STO.

The history behind the OPTALIGN laser shaft alignment system

2010-12-06T08:41:46-06:00

Learn more about PRUEFTECHNIK, a leader in laser alignment technology, and its OPTALIGN laser shaft alignment system.

Awards program provides evaluation and recognition of asset management capabilities

2010-12-02T08:11:34-06:00

Asset owners, service providers and organizations responsible for physical assets and their revenue, reliability and safety outcomes are encouraged to apply to the Asset Management Council’s 2011 Asset Management Awards.

Quality pros' salaries on the upswing, finds ASQ salary survey

2010-12-01T12:40:48-06:00

Signs of economic turnaround are evident in the quality profession, according to the 24th annual salary survey conducted by Quality Progress (QP), the American Society for Quality’s monthly flagship publication. The overall average salary for U.S. full-time quality professionals is now $85,289, a steady increase from $83,442 in 2009 and $81,064 in 2008. The salary increase is seen this year, just as apparent demand for quality management is surging, as evidenced by ASQ’s online Career Center.

Plain or rolling element bearings? What's the correct choice?

2010-11-30T12:36:58-06:00

Plain bearings are available for an extremely wide variety of applications. Most are used in sliding or oscillating roles: door hinges, ball joints on cars, the fifth wheel on a tractor trailer. But when full rotation is required, plain bearings change shape to a "sleeve" that fits around the shaft. In addition to being called sleeve bearings, other names include plane, journal or babbitt bearings.

Controller, recorder selection tips for food and beverage applications

2010-11-29T14:40:05-06:00

With food and beverage companies producing and dispatching thousands of products each day, the need to pick the best technology to help ensure high levels of product quality and safety is of paramount importance. This article provides advice about key factors in control and recording equipment selection for F&B processes.

Got hoarders? Squirrels? How to overcome hidden stores

2010-11-29T13:57:22-06:00

If you spend much time opening cabinets, drawers and looking behind locked doors in facilities and plant sites, it is almost guaranteed that you will come across someone’s stash of parts and consumable materials. When you begin a maintenance best practices implementation or storeroom improvement effort, one of the first things is to go and collect up all of those parts and materials to put them back into the storeroom. After all, there is a lot of money just laying around out there in those “hidden stores” locations, right?

SKF device enables machine condition diagnosis

2010-11-29T12:58:06-06:00

The new SKF Microlog Advisor Pro gives maintenance, service and quality inspection technicians on-the-spot and easy to understand machine condition diagnosis. This stand-alone device does not rely on prior measurement data, and does not require advanced predictive maintenance software. As a result, users immediately benefit from a proactive maintenance approach without the need for vibration expertise, or prior setup of an advanced PdM route-based system. And with the ability to choose from a range of application modules, the SKF Microlog Advisor Pro delivers the functionality of several maintenance tools in one handheld device.

How Universal Orlando Resort achieves safety and uptime

2010-11-29T08:00:26-06:00

David Winslow, senior vice president for technical services at Universal Orlando Resort, discusses uptime and safety at the Rockwell Automation Process Solutions User Group (PSUG) 2010 event.

How a Nucor mill benefits from condition monitoring

2010-11-23T12:38:26-06:00

This article describes the justification, development, application and benefits of an integrated condition monitoring and diagnostics solution. Specific case studies at a Nucor Steel plant are presented along with discussions of deployment issues and barriers that have been overcome.

Get to know the PAS 55 asset management standard

2010-11-23T11:12:47-06:00

You may have heard the term PAS 55 and wondered how it applies to you. Here’s some background in order to help you understand what this internationally recognized specification for asset management is and where we go from here.

Baldor representative discusses new motor efficiency requirements

2010-11-23T08:17:40-06:00

At the 2010 International Manufacturing Technology Show in Chicago, Baldor Electric product manager George Weihrauch talks about the Energy Independence and Security Act of 2007 and what the new motor efficiency requirements mean to the end-user. EISA, which was signed into law in 2007, becomes effective on December 19, 2010. This law expands the mandated energy efficiency standards from the Energy Policy Act of 1992 (EPAct) for a wider range industrial motors which are manufactured for sale in the United States.

Wireless technology helps boost production, cut costs at Tecpetrol

2010-11-22T10:38:58-06:00

Emerson Process Management’s Smart Wireless technology, based on the IEC 62591 (WirelessHART) standard, is enabling Tecpetrol to boost production while reducing maintenance and operations costs at natural gas compression and delivery facilities in Argentina.

The three principles of TPM and Total Process Reliability

2010-11-22T09:56:02-06:00

Marshall Institute provides this presentation on the key principles for Total Productive Maintenance and Total Process Reliability. You can find additional information from Marshall Institute at www.marshallinstitute.com.

Jet engine too hot? Schedule an MRI

2010-11-22T07:32:57-06:00

Researchers at Stanford University are using MRI to improve jet engine efficiency. The technique could also provide insights into other fluid mixing problems, ranging from combustion to the flow of oil through porous rock in a well.

var images_count = 1; var item_id = 570915; var videos_count = 0;

Hydraulic Institute updates two pump standards

2010-11-19T10:02:31-06:00

The Hydraulic Institute (HI) has updated the 2000 edition of the ANSI/HI standard on sealless centrifugal pumps and published ANSIHI 5.1-5.6—2010 Sealless Rotodynamic Pumps for Nomenclature, Definitions, Application, Operation and Test. The revised standard covers sealless rotodynamic pumps driven by canned motors or through magnetic couplings with conventional motors.

SMRP Certifying Organization extends time for certification exam

2010-11-19T09:49:12-06:00

The Society for Maintenance and Reliability Professionals Certifying Organization (SMRPCO) on November 18 announced that at the October board meeting a decision was made to extend the time allowed for CMRP exam candidates from two hours to two and a half hours. This change will take place starting December 1 of this year.

Using root cause analysis to investigate haul truck incident

2010-11-12T08:42:30-06:00

Follow Ron Hughes of Reliability Center Inc. as he examines a haul truck accident and uses PROACT RCA to facilitate this root cause analysis.

Grainger honors veterans through expanded scholarship program

2010-11-11T13:28:46-06:00

Grainger, North America's leading facilities maintenance supplier, has expanded its Grainger Tools for Tomorrow scholarship program for the fifth consecutive year. In the 2010-2011 academic year, Grainger will offer 75 community colleges across the United States two, $2,000 scholarships to award to community college students enrolled in industrial trades programs such as welding, plumbing, automotive and construction. In addition, upon graduation, scholarship recipients will receive a Westward toolkit outfitted for their industrial trade skill.

Tutorial on failure modes and effects analysis

2010-11-11T13:21:01-06:00

This video provides a tutorial on failure modes and effects analysis, a key tool for reliability engineering.

Rockwell safety team helps customers sleep at night

2010-11-10T12:02:25-06:00

Specialists from the Safety Solutions business at Rockwell Automation share best practices for improving worker safety while maintaining or increasing productivity.

How to safely and efficiently troubleshoot drive applications

2010-11-10T11:59:26-06:00

Reed Buell from Fluke Corporation discusses how to safely and efficiently perform troubleshooting for typical drive applications.

Hydraulic Institute debuts updated standard for rotary pump tests

2010-11-10T10:00:50-06:00

The Hydraulic Institute (HI) has updated the ANSI/HI Standard for Rotary Pump Tests version 2000, and has introduced ANSI/HI 3.6 – 2010, Rotary Pump Tests. This updated Standard applies to industrial/commercial rotary positive displacement pumps and includes detailed procedures on the set up and methods for conducting hydrostatic test and performance tests of such pumps. ANSI/HI 3.6-2010 is immediately available for purchase through the HI online retail store, http://www.eStore.Pumps.org. It is offered at $75.

Industrial distributor MSC acquires Rutland Tool & Supply

2010-11-10T09:18:57-06:00

MSC Industrial Direct Company Inc., one of the largest direct marketers and premier distributors of metalworking and maintenance, repair and operations (MRO) supplies to industrial customers throughout the United States, on November 10 announced that it has signed a definitive agreement to acquire the assets of Rutland Tool & Supply Company, a subsidiary of Lawson Products Inc., for approximately $11 million in cash. The acquisition is expected to close in the fourth quarter of calendar 2010, subject to customary closing conditions. The company will finance the acquisition using available cash, and expects the acquisition will become accretive to earnings in late-fiscal 2011 or early-fiscal 2012.

How to trend chronic failures through root cause analysis

2010-11-08T14:07:01-06:00

Bob Latino from Reliability Center Inc. provides this video on how to trend chronic failures through root cause analysis. Learn why you should trend chronic failures for the bottom-line results.

Primer on root cause analysis and cause-and-effect diagrams

2010-11-08T14:05:10-06:00

Bearing failure investigation and explanation

2010-11-08T14:01:20-06:00

In this video, Lee explains what's wrong with several bearings and why they've failed. He also shows some new bearings for comparison and gives some preventative maintenance tips.

Dry ice blasting of power plant generators and turbines

2010-11-05T07:22:08-05:00

The Cryogenic Institute of New England provides dry ice blast cleaning services to energy companies for the maintenance and refurbishment of their generators and turbines. The company cleans generators to remove carbon and other contaminants.

Maintenance work planning: 5 elements to consider

2010-11-04T15:18:43-05:00

Tim Kister, senior planning and scheduling subject matter expert with Life Cycle Engineering, explains the five elements of work planning that planners frequently give limited attention and detail.

TVA keeps reliability high, prices low during challenging year

2010-11-04T14:30:44-05:00

The Tennessee Valley Authority delivered good performance in 2010, keeping reliability high and prices competitive, despite stress that extreme weather placed on TVA's electric power infrastructure, president and CEO Tom Kilgore told the utility's board of directors on Thursday, November 4.

Using vibration analysis to test for bearing wear

2010-11-04T09:47:51-05:00

This article discusses an example of an outer race-bearing defect on a 1,250-ton air-conditioning chiller. The defect was detected using off-the-shelf portable vibration analysis hardware and software. The article discusses methods used to diagnose and trend the bearing defect using vibration spectra as an indicator of the bearing condition. The diagnostic methods covered are universally applicable to other types of machines (pumps, fans, gears) with rolling contact bearings.

Diagnosing a boiler pump motor with an ultrasound detector

2010-11-04T08:52:54-05:00

In this video, a maintenance technician uses the UL101, an ultrasound detector, to diagnose a thrust and non-thrust bearing in an injector boiler pump motor. He places the UL101 on the grease fitting and adjusts the UL101's gain to the lowest possible setting. Lowering the gain setting will isolate the ultrasound to only the bearing being tested. Maintenance teams use the UL101, ultrasound detector, for quick troubleshooting on mechanical components.

Pop the hood: A maintenance checklist can save your day

2010-11-03T14:58:46-05:00

While most groups will say they have maintenance checklists, requiring their use and accountability are often major factors for success. In your organization, what processes do you have in place to ensure that people use maintenance procedures and checklists? How do you validate their use?

7 tips for selecting asset management software

2010-11-02T10:48:35-05:00

Sophisticated enterprise asset management software is a must for companies with business models that rely on maximizing output of expensive and complex assets. The right EAM software will help you not only ensure asset availability by seeing that necessary maintenance is performed, but allow senior management to manage and protect their overall investment, be it in an offshore drilling platform, power plant or manufacturing facility.

Case study: Diagnosing a low-speed gearbox problem

2010-11-02T10:28:22-05:00

This article explores the diagnosis of a suspected gearbox problem in a large plant connected with the paper industry. The lubricating oil in the gearbox was regularly subjected to analysis, and the last report stated that there were iron particles in the oil. The maintenance supervisor sought to determine the source of the oil contamination, and it was suspected that the metal was coming from one or more of the gears. The problem then became to identify the faulty gear (if any), so as to allow the maintenance effort to proceed without delay.

Best practices for storeroom cycle counting

2010-11-01T15:58:15-05:00

Doug Wallace, materials management subject matter expert at Life Cycle Institute, describes the basics of an effective cycle counting program, and explains how it can benefit your storeroom processes and improve the reliability of your inventory balances.

What root cause analysis tool is best for operators

2010-11-01T15:56:12-05:00

Carl March, reliability subject matter expert with Life Cycle Engineering, presents a novel approach to an age-old root cause analysis tool for operators - "Should-Actual-5 Whys" This installment is a part of a series of informative video lessons called "Reliability Made Simple."

CBM and RCM help to maximize safety, uptime at YICT

2010-11-01T08:34:15-05:00

Being one of the biggest single container terminals in the world brings certain expectations from the operators and customers alike. Professionalism, reliability and efficiency are three of the most important and, coupled with a high regard for safety, are major focus areas for the Yantian International Container Terminal (YICT), in Shenzhen, southern China.

GE awarded 12-year contract by NV Energy to help boost power plant fleet performance

2010-10-28T13:57:39-05:00

GE on October 27 announced it has been awarded a 12-year services contract by Nevada utility NV Energy to help ensure the long-term reliability and availability of four key power plants within the company's generating fleet.

Heat and bearings: Coping with shaft expansion

2010-10-27T16:11:34-05:00

Axial shaft expansion can be an issue in machines that generate or use heat in operation. In industrial hot gas fans, the heat is transmitted through the shaft. In paper machine drying cylinders, hot steam is passed through a hollow shaft directly through the bearing bore. There are a number of ways to allow bearings to handle the linear expansion of a shaft.

Tutorial on Macro Sensors LVDT Signal Conditioner

2010-10-27T09:46:58-05:00

Learn how to connect, install and calibrate the EAZY-CAL MME-1000 Mini-Module LVDT Signal Conditioner from Macro Sensors in this informative video tutorial.

PPE assessment can positively impact bottom line

2010-10-26T13:16:35-05:00

The economic downturn has incited many companies to take a closer look at how they can reduce their day-to-day operating costs. In many instances, a personal protective equipment (PPE) assessment can help maximize a company’s strengths and identify opportunities for improvements that can positively impact the bottom line.

A guide to threadlocking adhesives

2010-10-26T13:15:06-05:00

Failure in threaded fasteners results from one of two causes. Tension relaxation is frequently caused by temperature changes, and involves the expansion and contraction of bolts and substrate materials, which reduce bolt tension and clamping force in the assembly. Self-loosening is caused by lateral sliding motion between fastener contact surfaces. Chemical threadlocking adhesives can inexpensively and permanently prevent threaded fastener failure.

Fluke creates online glossary of vibration terms

2010-10-26T10:29:44-05:00

Fluke Corporation has made available at its Web site a glossary of the key vibration terms that those involved in equipment maintenance and vibration diagnosis may encounter when evaluating machine vibration.

The five key elements of Total Productive Maintenance

2010-10-26T09:54:00-05:00

Marshall Institute president Greg Folts discusses the five key elements of Total Productive Maintenance (TPM). All five elements must be in place for an organization to achieve the full potential of TPM and maintenance excellence.

Maintenance's role in organizational performance is finally being realized. The efficiency of a facilities operation is largely dependant on the effectiveness of its maintenance program. TPM is a proven initiative - driven by both maintenance and operations - that can significantly increase equipment reliability and uptime while reducing unnecessary costs. The end result is a large impact of the company's bottom line.

Testing tip: Armature defects on DC motors

2010-10-26T09:25:40-05:00

Current analysis of DC motors can provide health assessment of the DC armature while the motor is running. Armature-related anomalies can include commutator bar defects, riser defects (very common) and shorted turns or coils in the armature circuit. The fundamental analysis of these anomalies starts with understanding that the bar, riser or winding with a fault passes under and out of the carbon brush face at a rate of the shaft speed times the number of brushes passed in a rotation. This causes a modulation of the DC armature current. A DC motor turning at 2,000 rpm with four brush holders has a brush passing frequency of 8,000 rpm, or 133.33 Hz. Trending of the brush passing frequency amplitude is highly recommended for early identification of developing armature circuit anomalies.

Overview of a condition-based monitoring system

2010-10-26T08:23:42-05:00

This video provides an overview of the Infor Hansen CBM (condition-based monitoring) solution.

In today's global recession, you have to do more with less than ever before. Every dollar counts, every minute matters. Infor Hansen CBM connects your operational technology (automation devices and alarms) with information technology (Infor Hansen Asset Management System).

Infor Hansen CBM includes a "Virtual Employee" with every copy. His responsibility is to monitor your organization's equipment 24/7/365 and listen for any anomalies or early warning of problems, capture run-time hours and cycle counts, manage preventive maintenance intervals and predict equipment failures before they happen.

Vibration analysis and PdM with RFID tags

2010-10-26T08:20:20-05:00

This video outlines how maintenance technicians can perform vibration analysis and predictive maintenance with RFID tags.

Methods to ensure sanitary practices in pet food plants

2010-10-22T09:58:46-05:00

Until recently, contamination in the production of pet food products had not been considered an issue of concern to pet food manufacturers. With recent outbreaks of salmonella in human beings that were traced back to dog food, producers of pet foods have been re-examining their manufacturing processes. Every aspect of such facilities – from product movement through the plant, contamination from outside sources, to equipment design – require rethinking in light of FDA regulation, sanitary practices and Good Manufacturing Processes.

Bad part descriptions can gum up storeroom processes

2010-10-22T09:45:22-05:00

When it comes to storerooms and materials management, one of the struggles that Jeff Shiver repeatedly sees in organizations is the issue of effective part descriptions, especially the short descriptions. This food industry veteran says that it is especially true when you consider the domino effect these descriptions can cause.

Prolonged bearing life through effective grease lubrication

2010-10-21T16:55:55-05:00

Grease lubrication knowledge is vital for a bearing company. SKF is putting its knowledge of this area into creating new products and services that contribute to sustainability, energy efficiency and extended bearing life.

AFE, MentorNet encourage students to enter facilities-related professions

2010-10-21T13:04:09-05:00

The Association for Facilities Engineering (AFE) has signed an agreement with MentorNet to locate members of the AFE community willing to guide and support students interested in pursuing facilities engineering, maintenance and operations careers.

Pump vibration testing in the shop

2010-10-15T07:17:46-05:00

A basic principle of machinery vibration analysis is evaluating whether specific vibration amplitudes are excessive. The use of vibration equipment in preventive maintenance involves keeping a vibration history on individual pieces of equipment in a plant, keeping a record of all PM heat and when the unit was greased and what type of grease was used.

Candy maker finds way to increase safety, save money

2010-10-14T16:29:00-05:00

A comprehensive wiring devices audit contributed to increased efficiency, reduced downtime, code compliance and workplace safety recommendations for Georgia-based Crown Candy Corporation.

Power plant alters way it determines moisture in lube oils

2010-10-14T14:51:56-05:00

For years, Karl Fischer (KF) titrations have been used to measure the degree of water in oil, but this analytical method can have limitations. Three years ago, Ferrybridge C Power Station in England replaced its KF method and now uses Fourier transform infrared (FTIR) analysis to measure and control the level of water contamination in lubricating fluids. It found that the FTIR analyzer provides accurate data in less time and with less complication than the KF titration.

How 'green' is your energy consumption?

2010-10-14T14:19:54-05:00

Environmental responsibility is becoming more than just not discharging pollutants into the nearby stream or emitting toxic materials into the atmosphere. Many companies are making the decision to “go green” to show their customers, shareholders and employees that they care about the environment; and as an equal incentive, they look to lower energy consumption, increase equipment reliability and cause a positive change to the profit and loss statement. As the leadership of an organization begins to look for potential areas to make investments to achieve these goals, they often look at their production processes to find these opportunities. Many times, the areas of the business that provide the greatest return are overlooked and investments are made in areas that don’t generate the energy savings expected.

Spans of control for maintenance planners and others

2010-10-11T11:53:28-05:00

As you may know, I travel frequently. The first part of the week was no different as I found myself on a flight to Atlanta. I was leafing through a maintenance book when the person across the aisle struck up a conversation. Turns out, he worked as a veteran maintenance supervisor in a large mill where he has worked for the last two years. He spoke about how things were bad from a reactive standpoint and had gotten worse after the mill downsized. As part of the downsizing effort, they had slaughtered some key players and replaced them with some not-so-key players. We talked about how their maintenance planning and scheduling activities were progressing, to which he was disappointed in the progress they had achieved.

You know you are in reactive maintenance if ...

2010-10-07T09:11:27-05:00

Have you ever wondered if your company is in reactive maintenance? Ricky Smith gives you some clues to determine whether you are there or not.

Smart Wireless network helps Northstar Bluescope Steel boost production, reduce costs

2010-10-06T09:18:53-05:00

Emerson Process Management’s Smart Wireless technology has helped Northstar Bluescope Steel improve furnace control at its mini-mill in Delta, Ohio. As a result, the mill has been able to boost production by as much as one batch per day, cut maintenance costs by $200,000 annually, and improve worker safety.

Del Monte finds gravy train of savings from DOE assessment

2010-10-01T14:39:33-05:00

The U.S. Department of Energy "Save Energy Now" program completed an Energy Savings Assessment at the Del Monte Foods plant in Hanford, Calif. The objectives of the assessment were to identify compressed air system improvement recommendations, train plant personnel in how to correctly model the current system, and predict potential savings using a DOE software tool. Read this case study and see how Del Monte harvested outstanding savings from this work.

Back to basics: How to measure electricity with a clamp meter

2010-09-29T08:53:23-05:00

A clamp meter is an electrical tester that combines a basic digital multimeter with a current sensor. Clamps measure current. Probes measure voltage. Having a hinged "clamp" jaw integrated into an electrical meter allows users to simply clamp around wire, cables and other conductors at any point in the electrical system and measure its current, without disconnecting it.

Is your MRO storeroom a productivity trap?

2010-09-29T08:30:00-05:00

Forty to 50 percent of all maintenance departments have an "open" storeroom, where the "honor system" is in effect. Is this the right thing to do? The author of this article says "no". Allowing mechanics to focus on equipment maintenance and reliability while having storeroom personnel manage the materials will not only optimize the productivity of the workforce, but it can also have other significant benefits.

Overhaul and maintenance practices at Vector Aerospace facility

2010-09-28T14:03:48-05:00

In this video, we visit the Vector Aerospace maintenance, repair and overhaul (MRO) facility in Andalusia, Ala., where they complete TH-57 overhauls and depot maintenance for L3 and the U.S. Navy. You can learn more about the Vector Aerospace facility at www.vectoraerospace.com.