Professional Documents
Culture Documents
Performance of Maintenance
Maintenance Cost
Equipment Performance
Maintenance Organization with defined key positions
High level of experience, competences and skills
Clear defined limits for operation – Standard operating procedures
Correct design and quality of equipment to assure reliability
Equipment replacement strategy – when to maintain, when to replace
Maintain equipment condition fit for operation – maintain reliability
Proactive, structured management system – Continuous Improvement
Learn about key success factors of Inspections, so you can optimize Equipment Downtime
and therefore increase OEE – have a positive effect on maintenance cost
Major breakdowns
Major breakdowns – Can we avoid them?
Design
Manufacturing
Quality Control of Equipment
We look for…
without defects
small defects
medium defects
large defects
rejected parts
Operation
Maintenance (Equipment Monitoring Solution)
Walk-by inspections
Off-line inspections
On-line Monitoring
Level of Inspections / Monitoring
(Equipment Monitoring Solution)
Parallel
Parallel adjusted rollers show an equally distributed contact stress
Horizontally cut
Rollers which are cut in the horizontal plane show a stress concentration in the middle of
the contact width
Rollers which are cut in the horizontal and vertical plane show a stress concentration at one
end of the contact width
Lead Wire Method. Results evaluation
Roller parallel to the tire, pressure equal throughout the width
Roller slightly cut, pressure in the middle, check wear or inclination
Roller cutting pronounced pressure in one end
Roller surface is not straight and requires machining
The result on the 3 positions A,B, C should be identical.
Difference are indication of a kiln crank or a wobbling tire
Shell test
Kiln downtime causes
The following is a typical breakdown of the downtime causes for a kiln
-Tire stiffness
-Roller adjustment (in some cases)
can be obtained
Shelltest device
Measurement principle
How to measure
Ovality has to be measured as close as possible to the tire, on both sides of it
(feed and discharge side).
-Watch out with the heat shields, in case they obstruct the passage of the device!
As in the lead wire test, on each side of the tire, three measurements have to
be made (120° displacement).
-Each set of points (A, B and C) must be collinear and marked in a permanent way.
-A single diagram disk can be used for the three measurements (adjusting screw position
has to be modified, to avoid overwriting curves).
-After each measurement, identify the resulting curve (A, B or C) . If the curve is not easily
readable, remark it with a pencil).
Calculating ovality
It can be done graphically, or using the formula
The graphic method is much easier
As the relative ovality limit values are given as a range, it is not crucial to
obtain a result with two decimal places.
Low ovality
low clearance (no flattening of the shell at the top)
no deformation at supporting areas
Result: Ideal situation – no actions rather than periodic monitoring needed
Case #2:
High ovality
excessive clearance (flattening of the shell at the top)
deformation at supporting areas (soft tire)
Result: Roller adjustment required, as well as clearance decrease (tire shimming)
What is the issue and what will we do?