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Maintenance and reliability training, innovation and education
Frederic Baudart, CMRP
ONE VISION -MULTIPLE TECHNOLOGIES
for your CBM strategy
2© 2018 | Fluke Corporation.Company Confidential.
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3© 2018 | Fluke Corporation.Company Confidential.
Evolution of wireless tool (PM & Wireless)
May ‘14 Jun ‘15 May ‘16Feb ‘15 Aug ‘17 Aug ‘18
(2014-present)
Dec ‘17
4© 2018 | Fluke Corporation.Company Confidential.
Data + Connectivity + Action
Asset Health MonitoringTemperature, power, electrical,
vibration, thermal imaging, SCADA, PLC, BMA
DATA CONNECTORS
ENTERPRISE CONNECTORS
PEOPLE CONNECTORS
Connected Reliability™
Managing of AssetsWork Management
Resource OptimizationMRO Management Historian
ProwessAnalytics & Reports
True MobilityVirtual Expertise
Asset Intelligence
5© 2018 | Fluke Corporation.Company Confidential.
Setting up the stage
New challenges: What are some new challenges that maintenance teams face today and what choices do teams have?
Top questions: What are the top questions that maintenance teams ask regarding Condition Based Maintenance (CBM)?
CBM solution: How can vibration, thermal and electrical wireless monitoring provide a complete CBM solution?
6© 2018 | Fluke Corporation.Company Confidential.
Challenges maintenance team faces todayWhat are some new challenges that teams face today as you try to be more proactive in
maintenance?
7© 2018 | Fluke Corporation.Company Confidential.
Top questions maintenance team ask:
Top questions maintenance teams ask about CBM1. How to monitor all critical assets in the plant with fewer resources?
2. How to bridge the skills gap?
3. Which tools should I begin with?
4. How to get the benefits of Proactive Maintenance without a big program?
5. How to justify the cost of the tools and resources that are needed?
6. How to start up a program when we're already 100% busy with PMs and corrective repairs?
7. How to start or restart a Proactive Maintenance Program?
And some solutions that teams have found to be successful to overcome the challenges that they face . . .
8© 2018 | Fluke Corporation.Company Confidential.
How to monitor assets with fewer resources
New Tiered Maintenance approach
All patients are important → overloads the staff
Benefits of Tiered Maintenance
•Don’t spend time analyzing healthy machines
•Reduce the number of work orders
•Don’t deploy your experts on simple faults
Patients screened & evaluated at each level:
• Nurse uses quick tests to determine if healthy• Doctor diagnoses most common problems• Specialist with advanced tools used only if needed
How the medical industry solves this problem
All assets are important → overloads the maintenance team
9© 2018 | Fluke Corporation.Company Confidential.
How maintenance team can bridge the skills gap
Tiered Maintenance Levels
• Top Tier Machines• Just a few• Main Turbine • Paper Machine• Machining Tools
• Middle Tier Machines• Hundreds/thousands• Vital motors, pumps,
fans, blowers, compressors, etc.
• Bottom Tier Machines• Hundreds/thousands• Non-vital motors,
pumps, fans, blowers, compressors, etc.
Classify rotating machines into three major categories →
Healthy – no action (80%)
Bad - find problem (20%)
DIAGNOSE critical assets for common faults and root cause
The problem is too complex (10%)Easy repair
(90%)
Refer the few complex faults and variable machines to consultant or SPECIALIST to analyze with advanced analytical toolValidate all
repairs (100%)
SCREEN all assets for potential problems during each work flow looking for early warning signs and immediate problems
10© 2018 | Fluke Corporation.Company Confidential.
Which tools/technology should I start with?
SCREEN machines to find out which ones are
good or bad
DIAGNOSE machine faults and determine repair
recommendation
CORRECT the problem CHECK machine to ensure repair is good and return to
service
1 2 3 4
Read & Trend
Step Step Step Step
Recommendation
Asset Health Report
Diagnosis
As Left
As Found
Total condition maintenance in 4 simple steps
11© 2018 | Fluke Corporation.Company Confidential.
Technologies Selection – Which one(s) and types
Ultrasound testing
Fluid/Oil Analysis
Vibration Analysis
Electrical Motor Testing
Infrared Imaging
12© 2018 | Fluke Corporation.Company Confidential.
Technologies Selection – Location & efficiency
$
$
$$
$$$
$$$$
Electric Utility, IT/Computers
HVAC, Motors & Drives
Lighting, Compressed Air, Steam Systems
Building Envelope
Combined technology identify equipment inefficiency and behavioral process waste.
13© 2018 | Fluke Corporation.Company Confidential.
How to get the benefits of Proactive Maintenance without a big program
Setup—Ensures the tool is set up correctly
Measure—Simple readings or complex data
Vibration Meter (screening tool)
Get answers from the reports1
234
Diagnose—Data might need some analysis to get useful answers
Action—Recommended next steps
Look at the report for these critical answers
Vibration Tester (diagnostic tool)
Laser alignment(corrective tool)
14© 2018 | Fluke Corporation.Company Confidential.
How to get the benefits of Proactive Maintenance without a big program
Get answers from the reports1
234
Diagnose—Data might need some analysis to get useful answers
Action—Recommended next steps
Look at the report for these critical answers
Setup—Ensures the tool is set up correctly
Measure—Simple readings or complex data
Thermal Electrical
15© 2018 | Fluke Corporation.Company Confidential.
How to justify the cost of the tools and resources needed?
1ProductionDowntime
Cost
2Energy Waste
(overworked asset)
4Maintenance & labor cost
5Outsourcing
(3rd party)Main area of savings
3Machinery
replacement cost
16© 2018 | Fluke Corporation.Company Confidential.
How to start a program?
✓ Start small and grow – Perform an asset criticality and purchase a few unit to prove success
✓ Start with a pilot program – show success on machines in one small area and then expand to the entire plant
✓ Reduce some PMs & repairs: Trend 25-30 machines => now your team has more time to add more machines in to program.
✓ Re-evaluate program: Over the months, review which machines should be trended for fault condition and which should have PMs.
Trend a few machines => reduce PMs & repairs => now have more time to add more machines to condition monitoring
17© 2018 | Fluke Corporation.Company Confidential.
How to start/restart a proactive program?
2. Technology Selection#1 problem: use one tool to measure everything
Solution: match right tools to likely failure modes
1. New PM Program set-up#1 problem: start too big → no success → canceled
Solution: Start small & simple → grow → funding
3. Data management #1 problem: data overload - What to do with data?
Solution: Need answers from the data!
1
2
3
1
2
3
18© 2018 | Fluke Corporation.Company Confidential.
How can vibration, thermal and electrical monitoring provide a complete CBM solution ?
Combine predictive technology, tools, answers, solutions, & people
19© 2018 | Fluke Corporation.Company Confidential.
How combined technology selection & data collection affect overall CBM
Comprehensive data collection/Creating a complete picture of asset data
• Teams must be able to use a technology mix to capture and aggregate actionable data for decisions about asset reliability and maintenance strategies.
• Barriers exist that frustrate comprehensive data collection. Some of these are similar to the factors that affect IIoT adoption including:
➢ Maintenance team’s position in reliability journey➢ Cost of condition monitoring technology➢ Disparate data sources causing siloed and disconnected views with multiple points of interaction➢ Missing or isolated equipment data➢ Culture change
• Handheld, wireless sensors and other technology and software that can automatically aggregate data for analysis are foundational to Connected reliability framework
• Asset management (EAM) or computerized maintenance management software (CMMS) system should also be included for insights. EAM/CMMS must be fully implemented with asset library, hierarchy and ability to integrate data from many different sources.
All data sources (Mech, Elect, Thermal, Pressure, BMS/SCADA) and types (portable, wireless and software) should be combined to monitor assets.
