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Dean Wolever – Airborne Ultrasound Level 1,
Infrared Thermograpy Level 1
Loyd Hopper – Airborne Ultrasound Level 1,
Infrared Thermograpy Level 1
Ross Vanderjagt - Infrared Thermograpy Level 1
Introduction & History
Procedures
Examples,
Suggestions
Savings $$
Age 37, born and live Twin Lake, MI. I am currently employed by Herman Miller Inc. One on the worlds largest Office Furniture manufacture in the world(ranking 3rd). I have been employed there for 14 years. I started in the Powder coat application dept. as a powder applicator then advanced to Powder Technician(10 years), Mid 2004, I transferred to the maintenance dept. in tool repair and preventative maint. My current job duties are Energy savings and Reliability based maintenance. I am certified in level 1 Airborne Ultrasound & level 1 Infrared Thermography.
Spare time: Kids, Racecars, Snowmobiles, Motorcycle, Fab Shop, Vinyl graphics, DJ, & Cage Combat.
Herman Miller began in 1923 as a manufacturer of traditional residential furniture.
Became a leader in “modern” furniture in the 30’s, 40’s & 50’s
1960’s- Transformed to the Office industry with the first Panel System.
Invented and refined ergonomic work seating in the 70’s, 80’s & 90’s
2000’s Reinvented the geometry of systems furniture, and now is the 3rd largest office furniture company in the world.
World Headquarters located in Zeeland, MI
Manufacturing and Distribution: Georgia, Wisconsin, Michigan, China, Italy, and the United Kingdom.
Herman Miller is represented through subsidiaries and corporate offices, Independent dealers, and Licensees in over 40 countries in North America, Asia/Pacific, Europe, Middle East and Latin America.
Had to Convince Management that the predictive science would have pay back-Energy Conservation/Less downtime.
We realized that we had a lot of low hanging fruit with compressed gas leaks.
I (Loyd Hopper) was so convinced that we would show a potential savings in less than 3 months, He would step down from Herman Miller.
Found a Argon leak the first day with a savings over $13,000, Several days later the operator called in a work order stating that he was using less gas and something must be wrong.
In the first year we save a combined savings of $242,000 (In all 3 locations)
In the first 5 months we found 4 Argon Gas leaks totaling over $60,000.00
50% of air leaks are coupling/quick disconnects
In 2008 $164,000 (in all 3 locations)
Average about 20dB on a valve leak
Usually an easy fix by taking off and cleaning rubber seal
Tape fixes everything !! Why ??
Paste thread sealant gets hard and tends to crack easily
Complete valve cost about $ 100
3 O-rings cost less than $1 and takes about 2 min. to repair.
Orifice Leak Rate Reference only
Based on 8760 Hours/
Year AirDiameter
of Leak 150 PSI 125 PSI 100 PSI 75 PSI 50 PSI 25 PSI
1/64" 0.58$ 76.47
0.49$ 64.91
0.41$ 53.35
0.32$ 41.79
0.23$ 30.09
0.14$ 18.40
1/32" 2.37$ 311.42
1.98$ 260.17
1.62$ 212.87
1.27$ 166.88
0.92$ 120.36
0.56$ 73.58
1/16" 9.45$ 1,241.73
7.9$ 1,038.06
6.49$ 852.79
5.08$ 667.51
3.66$ 480.92
2.25$ 295.65
1/8" 37.5$ 4,927.50
31.6$ 4,152.24
26$ 3,416.40
20.3$ 2,667.42
14.7$ 1,931.58
8.98$ 1,179.97
1/4" 150$ 19,710.00
126$ 16,556.40
104$ 13,665.60
81.3$ 10,682.82
58.6$ 7,700.04
35.9$ 4,717.26
3/8" 338$ 44,413.20
284$ 37,317.60
234$ 30,747.60
184$ 24,177.60
132$ 17,344.80
80.9$ 10,630.26
1/2" 600$ 78,840.00
506$ 66,488.40
415$ 54,531.00
324$ 42,573.60
235$ 30,879.00
144$ 18,921.60
5/8" 910$119,574.00
790$103,806.00
649$ 85,278.60
508$ 66,751.20
366$ 48,092.40
225$ 29,565.00
3/4" 1315$172,791.00
1138$149,533.20
934$ 122,727.60
729$ 95,790.60
528$ 69,379.20
323$ 42,442.20
7/8" 1789$235,074.60
1549$203,538.60
1272$ 167,140.80
994$ 130,611.60
718$ 94,345.20
440$ 57,816.00
1" 2338$307,213.20
2023$265,822.20
1661$ 218,255.40
1299$ 170,688.60
938$123,253.20
575$ 75,555.00
20h.p. to 40h.p. wash pump motors
LOVEJOY coupling insert.
Increase of about 20d.B.
Found the dB levels were getting too high( about 25dB)
Outside of booth Inside of booth
3371
ULTRASONIC LEAK DETECTION (ASSEMBLY AREAS)
Job Task
NumberJob Task Description Job Task Long Description
1RECORD ALL LEAKS WITH A PHOTO AND
A REPAIR TAGTHIS WILL MAKE FINDING THE LEAKS EASY
2RECORD THE DB LEVEL AND TYPE OF
GAS OF ALL LEAKS FOUND
3USE THE FOLLOWING FREQUENCY (KHZ)
SETTINGS FOR
COMPRESSED AIR OR INERT GAS LEAKS AND ELECTRICAL ARC = 40KHZ
BEARING WEAR = 30 KHZ
FLOW IN A PIPE OR STEAM TRAPS = 25KHZ
10CHECK ALL JOINTS AND FITTINGS ON
THE MAIN MANIFOLD FOR LEAKS
20
CHECK ALL FITTINGS FROM THE AIR
DRIVEN SCREW GUNS BACK TO THE
MAIN MANIFOLD
30CHECK ALL OF THE FITTINGS ON THE
LIFTSTHIS INCLUDES THE FITTINGS ON THE MANIPULATOR AND THE OVERHEAD TRACK
JOB PLAN REVIEW
5498
RELIABILITY QUANITATIVE/QUALITATIVE ANALYSIS
Job Task
NumberJob Task Description Job Task Long Description Job Task Duration
10 INFRARED SCAN
1. CHECK ALL ELECTRICAL CABINETS FOR ANY TEMPERATURE ANOMALIES
2. CHECK ALL ROTATING BELTS FOR WEAR AND MISALIGNMENT
3. CHECK ALL DRIVE MOTORS FOR TEMPERATURE ANOMALIES
4. CHECK ALL HYDRAULIC SYSTEMS FOR:
A. ELECTRIC MOTOR TEMPERATURE ANOMALIES
B. CHECK HYDRAULIC PUMPS FOR TEMPERATURE ANOMALIES
C. CHECK ALIGNMENT COUPLINGS FOR WEAR OR BREAKAGE BETWEEN MOTOR AND PUMP
D. CHECK TEMPERATURE OF HYDRAULIC OIL AND REPORT ON ANY OVER 190F
5. CHECK SHUNT CABLES FOR TEMPERATURE DIFFERENCES
0.00
20 ULTRASONIC SCAN
1. CHECK ALL ELECTRICAL CABINETS FOR ELECTRIC NOISE INCLUDING
A. CORONA
B. ARCHING
C. MOTOR STARTER CHATTER
2. CHECK HYDRAULIC SYSTEMS FOR:
A. HYDRAULIC PUMP FOR SOUNDS OF CAVITATION, GRINDING OF COMPONENTS, AND BEARING FAILURE.
B. ELECTRIC MOTOR FOR BEARING FAILURE OR INSULATION FAILURE
C. ALIGNMENT ISSUES BETWEEN MOTOR AND PUMP
3. CHECK GEAR BOXES FOR LUBRICATION ISSUES
4. CHECK DRIVE BELT ALIGNMENT
0.00
30FD3055 BRAKE PRESS,
CINCINNATI
PLEASE CHECK
INFRARED
1. ELECTRICAL PANEL
2. VALVES AND HYDRAULIC LINES
3. HYDRAULIC MOTOR
ULTRASONIC'S
1. ELECTRICAL PANEL
2. MOTOR BEARINGS
0.10
40FD3086 BRAKE PRESS,
CINCINNATI
INFRARED
1. ELECTRICAL PANEL
2. VALVES AND HYDRAULIC LINES
3. HYDRAULIC MOTOR
ULTRASONIC'S
1. ELECTRICAL PANEL
2. MOTOR BEARINGS
0.10
50FD3056 BRAKE PRESS,
CINCINNATI
INFRARED
1. ELECTRICAL PANEL
2. VALVES AND HYDRAULIC LINES
3. HYDRAULIC MOTOR
ULTRASONIC'S
1. ELECTRICAL PANEL
2. MOTOR BEARINGS
0.10
60
2938 DECOILER FOR
COVER NOTCHING
SYSTEM
INFRARED
1. ELECTRICAL PANEL
2. ELECTRIC MOTOR
ULTRASONIC'S
1. ELECTRICAL PANEL
2. GEARBOX
0.10
70
2937 DECOILER FOR
LOWER CHANNEL
NOTCHING SYSTEM
INFRARED
1. ELECTRICAL PANEL
2. ELECTRIC MOTOR
ULTRASONIC'S
1. ELECTRICAL PANEL
2. GEARBOX
0.10
80
29953 HYD POWER UNIT
FOR CHANNEL DATA WIRE
MANAGEMENT FIXTURE
INFRARED
1. HYD MOTOR
2. HYD PUMP
3. ELECTRICAL PANEL
ULTRASONIC'S
1. HYD MOTOR
2. HYD PUMP
3. ELECTRICAL PANEL
0.10
902862 NOTCHER, BIG,
LOWER CHANNEL PRESS
INFRARED
1. HYD MOTOR
2. HYD PUMP
3. ELECTRICAL PANEL
ULTRASONIC'S1. HYD MOTOR
2. HYD PUMP
3. ELECTRICAL PANEL
0.10
1002415 NOTCHER, LITTLE,
WIRE COVER PRESS
INFRARED
1. HYD MOTOR
2. HYD PUMP
3. ELECTRICAL PANEL
ULTRASONIC'S
1. HYD MOTOR
2. HYD PUMP
3. ELECTRICAL PANEL
0.10
1102935 STRAIGHTENER,
COVER NOTCHER SYSTEM
INFRARED
1. ELECTRICAL PANEL
2. ELECTRIC MOTOR
3. GEARBOX
ULTRASONIC'S
1. ELECTRICAL PANEL
2. ELECTRIC MOTOR
3. GEARBOX
0.10
120
2936 STRAIGHTENER,
LOWER CHANNEL
NOTCHING SYSTEM
INFRARED
1. ELECTRICAL PANEL
2. ELECTRIC MOTOR
3. GEARBOX
ULTRASONIC'S
1. ELECTRICAL PANEL
2. ELECTRIC MOTOR
3. GEARBOX
0.10
130 WELDER, EIGHT GUN
INFRARED
1. ELECTRICAL PANELS (2)
2. SHUNT CABLES
ULTRASONICS
1. ELECTRICAL PANELS (2)
2. ALIGNMENT ON DRIVE BELT FOR BACK GUAGE
3. BEARINGS ON BALL SCREW
0.10
140
WELDER, CHANNEL, DATA
WIRE MANAGEMENT
FIXTURE
INFRARED
1. ELECTRICAL PANELS (2)
2. SHUNT CABLES
ULTRASONICS
1. ELECTRICAL PANELS (2)
0.05
$350,000 in Compressed gas savings.
$150,000 in cost avoidance for an additional air compressor.
Now able to service an existing compressor while production is running.
Avoided catastrophic pump failures leading to Thousands of dollars.
Approximately 148 hours of production downtime at $600/hr. ($88,800)
WE HAVE CONVINCED
MANAGEMENT THAT PREDICTIVE
SCIENCES WORK !!!!
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