Approved DCN# 43-7823-21

ACCELERATING TO THE NAVY & MARINE CORPS AFTER NEXT

Health Management
Technology for Manufacturing
Equipment to Enable CBM

Jeffrey Banks, Systems & Operations

Automation Division Head at ARL/PSU
(814) 863-3859
jcb242@arl.psu.edu
NSRP All Panel Meeting
DISTRIBUTION STATEMENT A: Approved for public
release, distribution is unlimited. 22 March 2021
Distribution/Dissemination Control: Statement A
POC: Andre Ewing 703-588-2266
DISTRIBUTION A. Approved for public release. Distribution is Unlimited. Approved 1 March 2017
 Statement A: Approved for public release; distribution unlimited.

Project Objective
Condition Based Maintenance/
Predictive Maintenance

Preventative
Maintenance Optimum
Physical Asset
Management

Reactive Maintenance/
Run to Failure

• The focus is to implementing machinery health management

technology to enable a condition based maintenance (CBM) capability
at General Dynamics Electric Boat (GDEB) manufacturing facilities to
provide an optimum combination of maintenance methodologies. 

Approved DCN# 43-7823-21

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 Statement A: Approved for public release; distribution unlimited.

Issue Description
• Currently the maintenance planning and production planning (RED) cannot deal
with unscheduled maintenance well.
• Implement predictive maintenance (GREEN) to replace some reactive
maintenance.
• Provide machinery health predictions for maintenance and production planning.
Maintena Maintena
Maintena
Preventative nce nce
nce
(Scheduled) Planning Schedulin
Execution
Maintenance Process g Process

Predictive Reactive
Maintenance Maintenance
(Scheduled) (Unscheduled)

Production Production Manufactur

Planning Scheduling ing
Process Process Execution

Approved DCN# 43-7823-21

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Design of Predictive Maintenance

Program

Implement
Technology Actionable
Integration Information
Reliability with Displays
Select Health
Centered Management Maintenance
Maintenance Technologies Organization
+ for +
Business Applications Conduct
Case Analysis Personnel
Technology
Training Data
Management

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Approved DCN# 43-7823-21
 Statement A: Approved for public release; distribution unlimited.

Failure Modes and Effects Analysis

Approved DCN# 43-7823-21

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Cost Analysis: ROI

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Approved DCN# 43-7823-21
 Statement A: Approved for public release; distribution unlimited.

Predictive Maintenance Technology

• The recommended health monitoring technologies for the implementation of the
pilot program at the manufacturing facilities based on the business case.

• The technologies include:

– Vibration Analysis: Emerson CSI system consists of the portable vibration data
collection device (CSI 2140 Machinery Health Analyzer) and the AMS Machinery
Manager software.
– Thermography: FLIR E85 camera
– Fluid Analysis: On-Site Laboratory Services - Oils Analysis and Cleanroom Lab

Approved DCN# 43-7823-21

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 Statement A: Approved for public release; distribution unlimited.

Predictive Failure
Indication: Vibration
• Vibration Analysis was able to detect a
severe bearing fault in a compressor motor.
Fluting
• Investigation of the bearing indicated fluting
caused by Variable Frequency Drive (VFD)
energy leakage through the bearing.

• Detected the fault and replaced the bearing

before catastrophic failure of the motor
occurred.
– Another similar motor failed before the project
started.

• Corrective Action: Implement Inductive

Absorbers that reduce the high frequency
components and eliminate bearing damage.

• Cost Savings: $48K

– Difference between replacement $60K
and repair $12K

Approved DCN# 43-7823-21

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Predictive Failure Indication:

Vibration Technology
• Critical pump system has experienced frequent performance
issues and failures.
• A vibration analysis survey indicated a combination of issues.
– Resonance frequency is being excited during operation effects
– Excessive bearing wear and premature failure.
• Corrective Action: System design and operation will be adjusted
to alleviate these issues.
• Cost Savings: $65K for repair and lost production

Approved DCN# 43-7823-21

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 Statement A: Approved for public release; distribution unlimited.

Predictive Failure
Indication: Fluid Analysis
• The fluid analysis of a critical motor lubrication oil using the GDEB laboratory has detected
lubrication oil that is out of specification.
• Corrective Action: Replace lubrication oil immediately
• Cost Savings: $50K for motor replacement

Total Acid
Equipment Moisture Viscosity Number

Standards < 0.05 % 41 – 50 @ 40 C <1

Dewatering Pump Motor 1 Top < 0.01 % 54.2 2.2
Dewatering Pump Motor 1 Bottom < 0.01 % 40.5 2.2

Standards < 0.05 % 16.3 - 21.9 @ 100 C <1

Dewatering Pump Motor 2 Top < 0.01 % 25.9 13.3
Dewatering Pump Motor 2 Bottom < 0.01 % 25.3 12.4

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Approved DCN# 43-7823-21
 Statement A: Approved for public release; distribution unlimited.

Project Summary
Condition Based Maintenance/
Predictive Maintenance

Preventative Optimum
Maintenance Physical
Asset
Management
Reactive Maintenance/
Run to Failure

• The benefit of CBM is to convert costly catastrophic failure events into time and cost
saving scheduled maintenance events:
– Reduce unnecessary part replacement costs.
– Reduce misdiagnosis – lessens restrictions on maintenance staffing because more
experienced maintainers are needed for systems with high rates of misdiagnosis.
– Reduce downtime to ensure continued production for the fleet.

Approved DCN# 43-7823-21

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