SlideShare una empresa de Scribd logo
1 de 29
The AWAKENING




                Copyright 2008 Allied Reliability, Inc.
The AWAKENING




      The AWAKENING



Ricky Smith, CMRP




                                    Copyright 2008 Allied Reliability, Inc.
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.
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.
The AWAKENING

              Market Survivor Model



 Market
  Price
Unit Cost =
  Cost
 Capacity




                                  Market Share

                 Source: The RM Group, Inc., Knoxville, TN          060417 ©2006 Allied Reliability
                                                             Copyright 2008 Allied Reliability, Inc.
The AWAKENING




                Copyright 2008 Allied Reliability, Inc.
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.
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.
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.
The AWAKENING

How many know and understand the PF Curve?




                                Copyright 2008 Allied Reliability, Inc.
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.
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.
The AWAKENING

Random Failure Patterns
 Number of Failures




                      Page M - 13      Source: SKF   Copyright 2008 Allied Reliability, Inc.
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.
The AWAKENING

       Extending Equipment Life –
Is it part of your Maintenance Strategy?




                                 Copyright 2008 Allied Reliability, Inc.
The AWAKENING

              What do you think?
• It is time to be;

                 AWAKENED




                                      Copyright 2008 Allied Reliability, Inc.
The AWAKENING

What is Maintenance?
• To Maintain an Asset ---
  – Keep in existing condition
  – Keep, preserve, protect




                                    Copyright 2008 Allied Reliability, Inc.
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.
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.
The AWAKENING

There are no Silver Bullets – We are sold out!




                                       Copyright 2008 Allied Reliability, Inc.
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.
The AWAKENING

Defect Severity – Let’s look at what we know




                                     Copyright 2008 Allied Reliability, Inc.
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.
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.
The AWAKENING

Lesson 4: Build an Effective Maintenance Program
     which provides “Optimal Reliability at Optimal Cost”




                                                    Copyright 2008 Allied Reliability, Inc.
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.
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.
The AWAKENING

Save Jobs NOW – Make Something Happen




                              Copyright 2008 Allied Reliability, Inc.
The AWAKENING




      Questions?

       Ricky Smith
smithr@alliedreliability.com
    Cell: 843-725-8378




                          Copyright 2008 Allied Reliability, Inc.

Más contenido relacionado

Más de Ricky Smith CMRP, CMRT

Skills of a Proactive Maintenance Technician
Skills of a Proactive Maintenance TechnicianSkills of a Proactive Maintenance Technician
Skills of a Proactive Maintenance TechnicianRicky Smith CMRP, CMRT
 
Day in the Life (DILO) of a Proactive Maintenance Manager
Day in the Life (DILO) of a Proactive Maintenance ManagerDay in the Life (DILO) of a Proactive Maintenance Manager
Day in the Life (DILO) of a Proactive Maintenance ManagerRicky Smith CMRP, CMRT
 
Day in the Life of a Proactive Maintenance Planner
Day in the Life of a Proactive Maintenance PlannerDay in the Life of a Proactive Maintenance Planner
Day in the Life of a Proactive Maintenance PlannerRicky Smith CMRP, CMRT
 
Day in the life of a Proactive Maintenance Supervisor
Day in the life of a Proactive Maintenance SupervisorDay in the life of a Proactive Maintenance Supervisor
Day in the life of a Proactive Maintenance SupervisorRicky Smith CMRP, CMRT
 
How to know if your maintenance planning and scheduling is not effective
How to know if your maintenance planning and scheduling is not effectiveHow to know if your maintenance planning and scheduling is not effective
How to know if your maintenance planning and scheduling is not effectiveRicky Smith CMRP, CMRT
 
Day in the life of a Proactive Maintenance Supervisor
Day in the life of a Proactive Maintenance SupervisorDay in the life of a Proactive Maintenance Supervisor
Day in the life of a Proactive Maintenance SupervisorRicky Smith CMRP, CMRT
 
Day in the Life of a Proactive Maintenance Technician Article
Day in the Life of a Proactive Maintenance Technician  ArticleDay in the Life of a Proactive Maintenance Technician  Article
Day in the Life of a Proactive Maintenance Technician ArticleRicky Smith CMRP, CMRT
 
Best Maintenance Repair Practices Article
Best Maintenance Repair Practices ArticleBest Maintenance Repair Practices Article
Best Maintenance Repair Practices ArticleRicky Smith CMRP, CMRT
 
Tool Box Talk - Maintenance Parts Checkout
Tool Box Talk - Maintenance Parts CheckoutTool Box Talk - Maintenance Parts Checkout
Tool Box Talk - Maintenance Parts CheckoutRicky Smith CMRP, CMRT
 
Tool Box Talk - Lubrication of Bearings
Tool Box Talk - Lubrication of BearingsTool Box Talk - Lubrication of Bearings
Tool Box Talk - Lubrication of BearingsRicky Smith CMRP, CMRT
 
Tool Box Talk - Maintenance Planning and Scheduling
Tool Box Talk - Maintenance Planning and SchedulingTool Box Talk - Maintenance Planning and Scheduling
Tool Box Talk - Maintenance Planning and SchedulingRicky Smith CMRP, CMRT
 
Top 7 Reasons why Maintenance Work Orders are Closed Out Accurately
Top 7 Reasons why Maintenance Work Orders are Closed Out AccuratelyTop 7 Reasons why Maintenance Work Orders are Closed Out Accurately
Top 7 Reasons why Maintenance Work Orders are Closed Out AccuratelyRicky Smith CMRP, CMRT
 
Tool Box Talk - How to Stop Hydraulic Leaks and Why
Tool Box Talk - How to Stop Hydraulic Leaks and WhyTool Box Talk - How to Stop Hydraulic Leaks and Why
Tool Box Talk - How to Stop Hydraulic Leaks and WhyRicky Smith CMRP, CMRT
 
PM Tool Box Talk 101 - Fundamentals of Preventive Maintenance
PM Tool Box Talk 101 - Fundamentals of Preventive MaintenancePM Tool Box Talk 101 - Fundamentals of Preventive Maintenance
PM Tool Box Talk 101 - Fundamentals of Preventive MaintenanceRicky Smith CMRP, CMRT
 
How to Develop an Effective Maintenance Skills Training Program
How to Develop an Effective Maintenance Skills Training ProgramHow to Develop an Effective Maintenance Skills Training Program
How to Develop an Effective Maintenance Skills Training ProgramRicky Smith CMRP, CMRT
 
PM Tool Box Talk 101 - Fundamentals of Preventive Maintenance
PM Tool Box Talk 101 -  Fundamentals of Preventive MaintenancePM Tool Box Talk 101 -  Fundamentals of Preventive Maintenance
PM Tool Box Talk 101 - Fundamentals of Preventive MaintenanceRicky Smith CMRP, CMRT
 
Day in the Life of (DILO) of a Proactive Maintenance Technician
Day in the Life of (DILO) of a Proactive Maintenance TechnicianDay in the Life of (DILO) of a Proactive Maintenance Technician
Day in the Life of (DILO) of a Proactive Maintenance TechnicianRicky Smith CMRP, CMRT
 

Más de Ricky Smith CMRP, CMRT (20)

Skills of a Proactive Maintenance Technician
Skills of a Proactive Maintenance TechnicianSkills of a Proactive Maintenance Technician
Skills of a Proactive Maintenance Technician
 
Day in the Life (DILO) of a Proactive Maintenance Manager
Day in the Life (DILO) of a Proactive Maintenance ManagerDay in the Life (DILO) of a Proactive Maintenance Manager
Day in the Life (DILO) of a Proactive Maintenance Manager
 
Day in the Life of a Proactive Maintenance Planner
Day in the Life of a Proactive Maintenance PlannerDay in the Life of a Proactive Maintenance Planner
Day in the Life of a Proactive Maintenance Planner
 
Day in the life of a Proactive Maintenance Supervisor
Day in the life of a Proactive Maintenance SupervisorDay in the life of a Proactive Maintenance Supervisor
Day in the life of a Proactive Maintenance Supervisor
 
How to know if your maintenance planning and scheduling is not effective
How to know if your maintenance planning and scheduling is not effectiveHow to know if your maintenance planning and scheduling is not effective
How to know if your maintenance planning and scheduling is not effective
 
Day in the life of a Proactive Maintenance Supervisor
Day in the life of a Proactive Maintenance SupervisorDay in the life of a Proactive Maintenance Supervisor
Day in the life of a Proactive Maintenance Supervisor
 
Day in the Life of a Proactive Maintenance Technician Article
Day in the Life of a Proactive Maintenance Technician  ArticleDay in the Life of a Proactive Maintenance Technician  Article
Day in the Life of a Proactive Maintenance Technician Article
 
Best Maintenance Repair Practices Article
Best Maintenance Repair Practices ArticleBest Maintenance Repair Practices Article
Best Maintenance Repair Practices Article
 
Tool Box Talk - Maintenance Parts Checkout
Tool Box Talk - Maintenance Parts CheckoutTool Box Talk - Maintenance Parts Checkout
Tool Box Talk - Maintenance Parts Checkout
 
Tool Box Talk - Lubrication of Bearings
Tool Box Talk - Lubrication of BearingsTool Box Talk - Lubrication of Bearings
Tool Box Talk - Lubrication of Bearings
 
Tool Box Talk - Maintenance Planning and Scheduling
Tool Box Talk - Maintenance Planning and SchedulingTool Box Talk - Maintenance Planning and Scheduling
Tool Box Talk - Maintenance Planning and Scheduling
 
Top 7 Reasons why Maintenance Work Orders are Closed Out Accurately
Top 7 Reasons why Maintenance Work Orders are Closed Out AccuratelyTop 7 Reasons why Maintenance Work Orders are Closed Out Accurately
Top 7 Reasons why Maintenance Work Orders are Closed Out Accurately
 
Tool Box Talk - How to Stop Hydraulic Leaks and Why
Tool Box Talk - How to Stop Hydraulic Leaks and WhyTool Box Talk - How to Stop Hydraulic Leaks and Why
Tool Box Talk - How to Stop Hydraulic Leaks and Why
 
Maintenance of Hydraulic Systems
Maintenance of Hydraulic SystemsMaintenance of Hydraulic Systems
Maintenance of Hydraulic Systems
 
PM Tool Box Talk 101 - Fundamentals of Preventive Maintenance
PM Tool Box Talk 101 - Fundamentals of Preventive MaintenancePM Tool Box Talk 101 - Fundamentals of Preventive Maintenance
PM Tool Box Talk 101 - Fundamentals of Preventive Maintenance
 
How to Develop an Effective Maintenance Skills Training Program
How to Develop an Effective Maintenance Skills Training ProgramHow to Develop an Effective Maintenance Skills Training Program
How to Develop an Effective Maintenance Skills Training Program
 
What is Lean Maintenance
What is Lean MaintenanceWhat is Lean Maintenance
What is Lean Maintenance
 
Best Maintenance Repair Practices
Best Maintenance Repair PracticesBest Maintenance Repair Practices
Best Maintenance Repair Practices
 
PM Tool Box Talk 101 - Fundamentals of Preventive Maintenance
PM Tool Box Talk 101 -  Fundamentals of Preventive MaintenancePM Tool Box Talk 101 -  Fundamentals of Preventive Maintenance
PM Tool Box Talk 101 - Fundamentals of Preventive Maintenance
 
Day in the Life of (DILO) of a Proactive Maintenance Technician
Day in the Life of (DILO) of a Proactive Maintenance TechnicianDay in the Life of (DILO) of a Proactive Maintenance Technician
Day in the Life of (DILO) of a Proactive Maintenance Technician
 

Último

UiPath Studio Web workshop series - Day 6
UiPath Studio Web workshop series - Day 6UiPath Studio Web workshop series - Day 6
UiPath Studio Web workshop series - Day 6DianaGray10
 
UiPath Solutions Management Preview - Northern CA Chapter - March 22.pdf
UiPath Solutions Management Preview - Northern CA Chapter - March 22.pdfUiPath Solutions Management Preview - Northern CA Chapter - March 22.pdf
UiPath Solutions Management Preview - Northern CA Chapter - March 22.pdfDianaGray10
 
COMPUTER 10: Lesson 7 - File Storage and Online Collaboration
COMPUTER 10: Lesson 7 - File Storage and Online CollaborationCOMPUTER 10: Lesson 7 - File Storage and Online Collaboration
COMPUTER 10: Lesson 7 - File Storage and Online Collaborationbruanjhuli
 
NIST Cybersecurity Framework (CSF) 2.0 Workshop
NIST Cybersecurity Framework (CSF) 2.0 WorkshopNIST Cybersecurity Framework (CSF) 2.0 Workshop
NIST Cybersecurity Framework (CSF) 2.0 WorkshopBachir Benyammi
 
Igniting Next Level Productivity with AI-Infused Data Integration Workflows
Igniting Next Level Productivity with AI-Infused Data Integration WorkflowsIgniting Next Level Productivity with AI-Infused Data Integration Workflows
Igniting Next Level Productivity with AI-Infused Data Integration WorkflowsSafe Software
 
Empowering Africa's Next Generation: The AI Leadership Blueprint
Empowering Africa's Next Generation: The AI Leadership BlueprintEmpowering Africa's Next Generation: The AI Leadership Blueprint
Empowering Africa's Next Generation: The AI Leadership BlueprintMahmoud Rabie
 
OpenShift Commons Paris - Choose Your Own Observability Adventure
OpenShift Commons Paris - Choose Your Own Observability AdventureOpenShift Commons Paris - Choose Your Own Observability Adventure
OpenShift Commons Paris - Choose Your Own Observability AdventureEric D. Schabell
 
COMPUTER 10 Lesson 8 - Building a Website
COMPUTER 10 Lesson 8 - Building a WebsiteCOMPUTER 10 Lesson 8 - Building a Website
COMPUTER 10 Lesson 8 - Building a Websitedgelyza
 
AI Fame Rush Review – Virtual Influencer Creation In Just Minutes
AI Fame Rush Review – Virtual Influencer Creation In Just MinutesAI Fame Rush Review – Virtual Influencer Creation In Just Minutes
AI Fame Rush Review – Virtual Influencer Creation In Just MinutesMd Hossain Ali
 
Using IESVE for Loads, Sizing and Heat Pump Modeling to Achieve Decarbonization
Using IESVE for Loads, Sizing and Heat Pump Modeling to Achieve DecarbonizationUsing IESVE for Loads, Sizing and Heat Pump Modeling to Achieve Decarbonization
Using IESVE for Loads, Sizing and Heat Pump Modeling to Achieve DecarbonizationIES VE
 
Cybersecurity Workshop #1.pptx
Cybersecurity Workshop #1.pptxCybersecurity Workshop #1.pptx
Cybersecurity Workshop #1.pptxGDSC PJATK
 
Linked Data in Production: Moving Beyond Ontologies
Linked Data in Production: Moving Beyond OntologiesLinked Data in Production: Moving Beyond Ontologies
Linked Data in Production: Moving Beyond OntologiesDavid Newbury
 
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPA
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPAAnypoint Code Builder , Google Pub sub connector and MuleSoft RPA
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPAshyamraj55
 
Connector Corner: Extending LLM automation use cases with UiPath GenAI connec...
Connector Corner: Extending LLM automation use cases with UiPath GenAI connec...Connector Corner: Extending LLM automation use cases with UiPath GenAI connec...
Connector Corner: Extending LLM automation use cases with UiPath GenAI connec...DianaGray10
 
UiPath Platform: The Backend Engine Powering Your Automation - Session 1
UiPath Platform: The Backend Engine Powering Your Automation - Session 1UiPath Platform: The Backend Engine Powering Your Automation - Session 1
UiPath Platform: The Backend Engine Powering Your Automation - Session 1DianaGray10
 
activity_diagram_combine_v4_20190827.pdfactivity_diagram_combine_v4_20190827.pdf
activity_diagram_combine_v4_20190827.pdfactivity_diagram_combine_v4_20190827.pdfactivity_diagram_combine_v4_20190827.pdfactivity_diagram_combine_v4_20190827.pdf
activity_diagram_combine_v4_20190827.pdfactivity_diagram_combine_v4_20190827.pdfJamie (Taka) Wang
 
Videogame localization & technology_ how to enhance the power of translation.pdf
Videogame localization & technology_ how to enhance the power of translation.pdfVideogame localization & technology_ how to enhance the power of translation.pdf
Videogame localization & technology_ how to enhance the power of translation.pdfinfogdgmi
 
Building Your Own AI Instance (TBLC AI )
Building Your Own AI Instance (TBLC AI )Building Your Own AI Instance (TBLC AI )
Building Your Own AI Instance (TBLC AI )Brian Pichman
 

Último (20)

UiPath Studio Web workshop series - Day 6
UiPath Studio Web workshop series - Day 6UiPath Studio Web workshop series - Day 6
UiPath Studio Web workshop series - Day 6
 
UiPath Solutions Management Preview - Northern CA Chapter - March 22.pdf
UiPath Solutions Management Preview - Northern CA Chapter - March 22.pdfUiPath Solutions Management Preview - Northern CA Chapter - March 22.pdf
UiPath Solutions Management Preview - Northern CA Chapter - March 22.pdf
 
COMPUTER 10: Lesson 7 - File Storage and Online Collaboration
COMPUTER 10: Lesson 7 - File Storage and Online CollaborationCOMPUTER 10: Lesson 7 - File Storage and Online Collaboration
COMPUTER 10: Lesson 7 - File Storage and Online Collaboration
 
NIST Cybersecurity Framework (CSF) 2.0 Workshop
NIST Cybersecurity Framework (CSF) 2.0 WorkshopNIST Cybersecurity Framework (CSF) 2.0 Workshop
NIST Cybersecurity Framework (CSF) 2.0 Workshop
 
Igniting Next Level Productivity with AI-Infused Data Integration Workflows
Igniting Next Level Productivity with AI-Infused Data Integration WorkflowsIgniting Next Level Productivity with AI-Infused Data Integration Workflows
Igniting Next Level Productivity with AI-Infused Data Integration Workflows
 
Empowering Africa's Next Generation: The AI Leadership Blueprint
Empowering Africa's Next Generation: The AI Leadership BlueprintEmpowering Africa's Next Generation: The AI Leadership Blueprint
Empowering Africa's Next Generation: The AI Leadership Blueprint
 
OpenShift Commons Paris - Choose Your Own Observability Adventure
OpenShift Commons Paris - Choose Your Own Observability AdventureOpenShift Commons Paris - Choose Your Own Observability Adventure
OpenShift Commons Paris - Choose Your Own Observability Adventure
 
COMPUTER 10 Lesson 8 - Building a Website
COMPUTER 10 Lesson 8 - Building a WebsiteCOMPUTER 10 Lesson 8 - Building a Website
COMPUTER 10 Lesson 8 - Building a Website
 
AI Fame Rush Review – Virtual Influencer Creation In Just Minutes
AI Fame Rush Review – Virtual Influencer Creation In Just MinutesAI Fame Rush Review – Virtual Influencer Creation In Just Minutes
AI Fame Rush Review – Virtual Influencer Creation In Just Minutes
 
Using IESVE for Loads, Sizing and Heat Pump Modeling to Achieve Decarbonization
Using IESVE for Loads, Sizing and Heat Pump Modeling to Achieve DecarbonizationUsing IESVE for Loads, Sizing and Heat Pump Modeling to Achieve Decarbonization
Using IESVE for Loads, Sizing and Heat Pump Modeling to Achieve Decarbonization
 
201610817 - edge part1
201610817 - edge part1201610817 - edge part1
201610817 - edge part1
 
Cybersecurity Workshop #1.pptx
Cybersecurity Workshop #1.pptxCybersecurity Workshop #1.pptx
Cybersecurity Workshop #1.pptx
 
Linked Data in Production: Moving Beyond Ontologies
Linked Data in Production: Moving Beyond OntologiesLinked Data in Production: Moving Beyond Ontologies
Linked Data in Production: Moving Beyond Ontologies
 
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPA
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPAAnypoint Code Builder , Google Pub sub connector and MuleSoft RPA
Anypoint Code Builder , Google Pub sub connector and MuleSoft RPA
 
Connector Corner: Extending LLM automation use cases with UiPath GenAI connec...
Connector Corner: Extending LLM automation use cases with UiPath GenAI connec...Connector Corner: Extending LLM automation use cases with UiPath GenAI connec...
Connector Corner: Extending LLM automation use cases with UiPath GenAI connec...
 
UiPath Platform: The Backend Engine Powering Your Automation - Session 1
UiPath Platform: The Backend Engine Powering Your Automation - Session 1UiPath Platform: The Backend Engine Powering Your Automation - Session 1
UiPath Platform: The Backend Engine Powering Your Automation - Session 1
 
20230104 - machine vision
20230104 - machine vision20230104 - machine vision
20230104 - machine vision
 
activity_diagram_combine_v4_20190827.pdfactivity_diagram_combine_v4_20190827.pdf
activity_diagram_combine_v4_20190827.pdfactivity_diagram_combine_v4_20190827.pdfactivity_diagram_combine_v4_20190827.pdfactivity_diagram_combine_v4_20190827.pdf
activity_diagram_combine_v4_20190827.pdfactivity_diagram_combine_v4_20190827.pdf
 
Videogame localization & technology_ how to enhance the power of translation.pdf
Videogame localization & technology_ how to enhance the power of translation.pdfVideogame localization & technology_ how to enhance the power of translation.pdf
Videogame localization & technology_ how to enhance the power of translation.pdf
 
Building Your Own AI Instance (TBLC AI )
Building Your Own AI Instance (TBLC AI )Building Your Own AI Instance (TBLC AI )
Building Your Own AI Instance (TBLC AI )
 

The Awakening(Rev1)

  • 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.
  • 5. The AWAKENING Market Survivor Model Market Price Unit Cost = Cost Capacity Market Share Source: The RM Group, Inc., Knoxville, TN 060417 ©2006 Allied Reliability 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.
  • 22. The AWAKENING Defect Severity – Let’s look at what we know 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.
  • 28. The AWAKENING Save Jobs NOW – Make Something Happen Copyright 2008 Allied Reliability, Inc.
  • 29. The AWAKENING Questions? Ricky Smith smithr@alliedreliability.com Cell: 843-725-8378 Copyright 2008 Allied Reliability, Inc.