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