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Assuring Asset and Process Reliability
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Proactive Techniques Training
The Future Operating State
• Operational excellence is a must.
• Assets must be available and reliable.
• We must operate at the lowest cost.
• We must do the right maintenance on the
right equipment.
The Future of Manufacturing
What is reliability?
What is a Complete Maintenance
Strategy?
A complete maintenance strategy is a combination
of tasks designed to eliminate, predict or prevent
failures in order to maintain the inherent designed
reliability of a process or piece of equipment.
Economic Useful
Life
Time
Preventive Maintenance
• What is Preventive Maintenance?
Lubrication Excellence
1 5 10 15 20 25 30
Bearing Number From: Ball and Roller Theory,
Design, & Application.
Eschmann, et al
John Wiley & Sons, 1985
• 20 to 30 years
PPM 2 3 4 5 6 7 8 9 10
50,000 12,500 6500 4500 3125 2500 2000 1500 1000 782
25,000 6250 3250 2250 1563 1250 1000 750 500 391
10,000 2500 1300 900 625 500 400 300 200 156
500 125 65 45 31 25 20 15 10 8
250 63 33 23 16 13 10 8 5 4
100 25 13 9 6 5 4 3 2 2
Lubrication Excellence
Work to reduce moisture in equipment.
– Better seals
– Wash down controls
– Control temperature of oil
– Use desiccant filters on vent ports
– Filter out the moisture
Lubrication Excellence
• In most applications this film of lubrication
is only 5 microns.
• What is a Micron?
Lubrication Excellence
• Bacteria is 3 microns
• Red Blood cells are 5 microns
• Talcum Powder is 10 microns
• Fine floor dust is 40 microns
Computer search for ISO 4406 will list the complete chart
Lubrication Excellence (Noria
Inc.)
Lubrication Excellence
MOST NEW OIL IS DIRTY!!!!!!!!!
Tips:
– Filter all new oil to a minimum of 10 microns
absolute.
– Purchase oil safe equipment to keep oils clean.
– Train everyone on keeping oil clean
– Filter all large oil reservoirs regularly to at a
minimum 10 microns absolute.
– Minimize greasing thru sirks and improve
methods to keep dirt off sirks.
Lubrication Excellence
Engineering
Design
Fabrication
Installation
Operations
Maintenance
Precision Alignment
In our plants we have equipment
parts that must be precision aligned.
Coupling between motors and
pumps, pulleys on belt drives.
160
140
120
100
90
80
70
60
50
40
30
20
5 10 20
Misalignment (min.)
What are we doing?
The objective is to
align the centers of
the shafts.
Precision Alignment
Angular Misalignment Offset Misalignment
Mils per inch Mils
.001/1” .001”
– Straight Edge?
– Single Dial Indicator?
– Reverse Dial Indicator?
– Laser alignment tool?
Precision Alignment
Straight Edge
Single Dial Indicator
Precision Alignment
Material C (in./in./F)
Aluminum 0.0000126
T X D X Temp Coff.
D = 12”
.076
8 146,000 6800
207,000 .076
10 10,000
tolerances
Alignment Tolerances (Horizontal)
tolerances
Cost of Alignment
RULES FOR OFFSET MISALIGNMENT AND INBOARD BEARING LIFE
1000
Actual L 10 Life = (Design L 10 Life) x ( 1000 + 275 ) 3
= 0.48 Design L 10 Life
Precision Balance
Drawbacks to Precision Balance
You are trying to replace only the weight of the remove metal in the keyway slot
Precision Balance
PP
Lubrication Excellence
Precision Maintenance
Alignment, Balance, etc.
Select Suppliers
Supplier Specifications
Metrics
Equipment Ranking
RCM
TPM
RCA/FMEA
RCD
Training Programs
Written Procedures
Job Planning/Scheduling
CMMS System
Time FF
RCA
Select Suppliers
How can selecting the best suppliers
improve your equipment reliability?
PP
Lubrication Excellence
Precision Maintenance
Alignment, Balance, etc.
Select Suppliers
Supplier Specifications
Metrics
Equipment Ranking
RCM
TPM
RCA/FMEA
RCD
Training Programs
Written Procedures
Job Planning/Scheduling
CMMS System
Time FF
RCA
Metrics
What are metrics at your plant?
Leading metrics-measures process
Lagging metrics measures results
Metrics should be reviewed against
performance
Examples of Metrics:
OEE
Cost of Maintenance/RAV
TEEP
Labor cost/equipment type
Emergency Downtime hours
MTBF
Reliability Measures
Performance =
(Ideal cycle time/total pieces)/Operating time
OEE
Quality:
Quality takes into account “Quality Loss”,
which factors out produced pieces that do
not meet quality standards.
Non conforming parts
Out of spec product
Rework materials/product
Availability = 90%
Performance = 90%
Quality = 90%
.90 X .90 x .90 = .73 or 73%
OEE 52% 73% 86% 91% 97%
Yield 80 90 95 97 99
Quality 80 90 95 97 99
Availability 80 90 95 97 99
• Equipment breakdown
Operational • Lack of materials
Losses • Lack or resources
• Set up time
• Change over time
PP
Lubrication Excellence
Precision Maintenance
Alignment, Balance, etc.
Select Suppliers
Supplier Specifications
Metrics
Equipment Ranking
RCM
TPM
RCA/FMEA
RCD
Training Programs
Written Procedures
Job Planning/Scheduling
CMMS System
Time FF
RCA
RCM
PP
Lubrication Excellence
Precision Maintenance
Alignment, Balance, etc.
Select Suppliers
Supplier Specifications
Metrics
Equipment Ranking
RCM
TPM
RCA/FMEA
RCD
Training Programs
Written Procedures
Job Planning/Scheduling
CMMS System
Time FF
RCA
Equipment Ranking
–“SHIT HAPPENS”
Root Cause Analysis (RCA)
• Does “Shit Happens” on an airliner at
30,000 feet?
Fire
Air, fuel, ignition source
Injury
person present, exposed hazard,
contact
AIR OR VAPOR PRODUCT LEVEL IMPROPER TORQUE OR ERRORS IN SELECTING DISC DESIGN MATERIAL FABRICATION
PRESSURE ABNORMALLY HIGH SEALING OF SURFACES PROPER DISC FOR INCOMPATABLE WITH DEFECTS DEFECTS
ABNORMALLY HIGH ASSURED SERVICE MOUNTING FLANGE
4 HYP 2A 0 HYP 2B 5 HYP 2C 5 HE 2D 5 HYP 2E 0 HYP 2F 0 HYP 2G
What Happened
Loss Event
-$1,000
-$2,000
Reduction in
Failures and
-$3,000 Repair Costs
-$4,000
Failure analysis
-$5,000
complete and
solution
implemented
-$6,000
-$7,000
Failure Root Cause Coding
Categories
Maintenance Engineering
Manage Equipment Life Cycle
strategic asset planning
design and construction
operations
maintenance
disposal
TPM is Based on the Following
Principles
Lubrication Excellence
Precision Maintenance
Alignment, Balance, etc.
Select Suppliers
Supplier Specifications
Equipment Ranking
RCM
TPM
RCA/FMEA
RCD
Training Programs
Procedures
Job Planning
CMMS
FF
Time RCA
Reliability Centered Design
This is a process of defining what we will
buy for equipment and the components that
will be installed on the equipment.
Operating Operating
Not Operating
MTTR
Job Planning
• Job Planning is a move from Reactive to
Proactive work methods.
• You can not plan reactive work effectively!
The most
important
step
When you Don’t Plan!
Scheduling
PP
Lubrication Excellence
Precision Maintenance
Alignment, Balance, etc.
Select Suppliers
Supplier Specifications
Metrics
Equipment Ranking
RCM
TPM
RCA/FMEA
RCD
PM Tasks
Training Programs
Written Procedures
Job Planning/Scheduling
CMMS System
Time FF
RCA
CMMS (Computerized Maintenance Management Systems)
Lubrication Excellence
Precision Maintenance
Alignment, Balance, etc.
Select Suppliers
Supplier Specifications
Equipment Ranking
RCM
TPM
RCA/FMEA
RCD
Training Programs
Procedures
Job Planning
CMMS
FF
Time RCA
Proactive Maintenance
Maximizes precision work techniques
Minimum spare parts, 50% reduction
Maximum Runtime, Minimal downtime
80% of maintenance tasks proactive
Minimal E, H, &S exposure
Very Low quality Issues
Maximum Equipment Life
Lower MRO costs
Reduction of Predictive Maintenance Costs
Elimination of equipment failure modes
Allows you to perform “Lean Maintenance”
Preventive Maintenance
PP
Lubrication Excellence
Precision Maintenance
Alignment, Balance, etc.
Select Suppliers
Supplier Specifications
Metrics
Equipment Ranking
RCM
TPM
RCA/FMEA
RCD
PM Tasks
Training Programs
Written Procedures
Job Planning/Scheduling
CMMS System
Time FF
RCA