Presented by Reliabilityweb · PDF fileTools to Execute Your Reliability Strategy Derek Burley CMRP, CRL [email protected] (800) 857-2968

Presented by Reliabilityweb.com

2017 Copyright Reliabilityweb.com

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Reliability Data Management:

The Key to a Sustainable Asset

Management Strategy

Keynote

by Buddy Lee, Reliability SME, Facilex


Rules and Gut Feel, IT, Forensics…


The BASICS of RDM

Why Reliability Data Management? Two basic goals:

1) Eliminate unexpected equipment failure (Eliminate high repair

costs of production interruption);

2) Lower total lifecycle costs (Extend equipment MTBF)

How: Implement & manage condition monitoring, lifecycle and

cost tracking, and failure analysis activities


Leadership: If It Is to Be, It Is up to Me…

“85% of your financial success is due to

your personality and ability to

communicate, negotiate and lead.

Shockingly, only 15% is due to technical

knowledge.”

- Carnegie Institute of Technology


The BASICS of RDM


Barriers: Over, Under or Through


Strategic Data Management

1. Standardization of equipment name, fault description, and

severity scale

2. Integration of condition information for assets

3. Communicate results to personnel (Web SAAS, not email or pdf)

4. Enforce performance accountability of condition tasks and

maintenance

5. Performance metrics: progress toward reliability goals


Condition Assessments (Goal #1 – Eliminate Failure)

1. Equipment name, fault

description, and severity scale

standardization

2. Integration of condition

information for assets


Integrated Condition Status Monitoring

(Goal #1 – Eliminate Failure)

2. Integration of

condition information

for assets

3. Communicate results

to personnel (Web

SAAS, not email)

4. Enforce performance

accountability of

condition tasks and

maintenance


Why Lifecycle Tracking? (Goal #2 – Extend MTBF)

Basic reliability information:

1. MTBF, Root Cause of Failure

and Cost of Failure

2. Critical Spares Management

3. Inventory of Equipment

4. Equipment Documents

5. Warranty

6. History - Location and

Equipment

7. Vendor Evaluation

8. Program Metrics


Why Lifecycle Tracking?

Location History Report



and Cost of Failure




5. Warranty


Equipment


8. Program Metrics


Why Lifecycle Tracking?

Equipment History Report



and Cost of Failure




5. Warranty


Equipment


8. Program Metrics


General Reliability Metrics

World Class Average

Average life of electric motors > 15 yrs < 10 yrs

Mean time between repairs for pumps > 6 yrs < 3 yrs

Average vibration levels < 0.1 in/sec > 0.3

Overtime, percent of total hours worked < 3 % > 10 %

Emergency work < 5% > 15 %

Total maintenance cost as percent of RAV < 2% > 3%

“Reliability impacts safety, environmental, quality, service, cost, and CTO” Source: Bob Taylor SMRP 2003


Reliability Condition Monitoring Metrics


Reliability/CM Task Accountability


Failure Analysis & Metrics (Goal #2 – Extend MTBF)

Performance metrics: progress toward reliability goals


Corporate RDM Strategy

Corporate procedures for asset management and reliability

information flow

Monitoring - frequency & completion

Standardized reliability reporting & metrics (across sites)

Communicate accountability for reliability improvement (Web SAAS)


Asset Health Report


Cost – Benefit Tracking


Cost – Benefit Tracking


3 Keys to RDM

1. Standardization of reliability nomenclature

2. Asset location history vs. individual equipment history

3. Broad communication and accountability


Contact

[email protected]

Tools to Execute Your Reliability Strategy

Derek Bur ley CMRP, CRL

dbur ley@blueskyre l iab i l i t y .com

(800) 857-2968

mailto:[email protected]


3 basic tactical tools

• Reliability Centered Maintenance (RCM)

• Includes FMEA as part of the process

• Preventive Maintenance Optimization (PMO)

• Quick, less rigorous than RCM

• Root Cause Analysis (RCA)

• For when the unexpected happens

©









©

Top 10-15% of most critical systems

The next 70 - 75% of your systems (the bottom 10-15% probably don’t matter)









©

Top 10-15% of most critical systems

The next 70 - 75% of your systems (the bottom 10-15% probably don’t matter)


3 basic tactical tools with one

thing in common

©

RCM RCA

PMO

FMs

Tools to Execute Your Reliability Strategy

Derek Bur ley CMRP, CRL

dbur ley@blueskyre l iab i l i t y .com

(800) 857-2968

mailto:[email protected]


What’s Next for Asset Condition

Management (ACM)?

Educational Session

by Dave Reiber, Senior Reliability

Leader, Reliabilityweb.com


Dave Reiber – CRL / CMRP

Currently – Senior Reliability Leader at Reliabilityweb.comRecently - Predictive Maintenance Lead for General Motors & Global Training for Maximo

• Held several leadership positions at General Motors• Skilled Trades Supervisor and General Supervisor at 2 GM Sites• Maximo Site Project Manager• North American Maximo Business Lead• Global Maximo Business Lead• Member of IBM Maximo Advisory Board for many years• Co-Lead for IBM Manufacturers User Group for Maximo• Speaker at many maintenance and Maximo conferences

• Led Maintenance Webcasts for UE and Plant Engineering Magazine• Hosted many Maximo & Predictive Webinars for General Motors• Certified CMRP from Society of Maintenance and Reliability Professionals• Certified CPMM from Association for Facilities Engineering• Certified – Infrared / Ultrasound


• Did you ever imagine that the information age would open so many doors, so quickly?

• Do you use some of the new tools that handle large amounts of data fast and efficiently?

• Are you on the fast track to improvement, or are you waiting to see what happens?

If you wait to see what happens, it will be too late. When you do decide to take action, your competition is already moving.

Things Are changing fast


• New data from many sources – real time

• Asset health monitors – real time

• Quick access to manuals and data gathered

• Aggregation of the data from all sources – fast

• Auto-generated diagnostics and problem solving solutions

• Trending and patterning of the data with intelligent software

• Permanent learnings from past failures.

• Auto-generated work orders, texts, voice messaging, etc..

What Is Required?



• Vibration Analysis

• Electric Motor Diagnostics

• Airborne Ultrasound / Shaft Ultrasound

• Laser Alignment• Fiber Optics / Optivibe

• Hi-Speed Video

• Infrared thermography

• Oil Analysis

Predictive Maintenance Technologies:


Predictive Maintenance

• Maintenance based on machine condition

• Scheduled downtime held to a minimum

• Downtime, spare parts usage, & overtime can be minimized

Condition Based Maintenance


System DepictionWireless sensors:

Some will come right from the supplier, others

you will purchase and install


Optivibe – Measuring Movement

1. The technician takes a

measurement without making

contact.

2. Vibrations are measured at every

pixel in the image.

3. Data is shown as a color-coded

image based on the intensity of the

vibration.


Electrical Motor Diagnostics

As more and more

studies are done

around motor Circuit

Analysis, we find

that sometimes the

most sensitive

sensor in the

process is the

electrical motor.

(sewing machine

needles)


Electric Motor Diagnostics


Ultrasound


Generic Divisions of Ultrasound

ULTRASOUND

Pulse/Echo

Power

Airborne/

Structure BorneMedical Imaging

Flaw Detectors

Flow Measurement/Control

Ultrasonic Cleaners

Medical

Mechanical Inspection

Leak Detection

Electrical Inspection


Airborne Ultrasonics Is…

• The study and application of high frequency sound

waves inaudible to human ears

• Sound waves above 20,000 Hz

(20,000 cycles/second)


Sound Penetration

•Low Frequency Sound Waves

• Range in size from ¾” to 56’

• Vibrate solid surfaces

• Large objects appear transparent

•High Frequency Sound Waves

• Range in size from 1/8” to 5/8”

• Cannot penetrate solid objects• Short

• Weak


Typical Applications

• Leak Detection

• Compressed Gas

• Heat Exchangers

• Vacuum

• Electrical Inspection

• Corona

• Tracking

• Arcing

• Mechanical Inspection

• Leaking Valves

• Efficiency of Steam Traps

• Bearing Health

• Gear Mesh

• Lubrication Excellence


Electrical Inspection

Arcing:An arc occurs when electricity is

conducted to “ground”

Corona:Voltage on an electrical conductor

exceeds the threshold value

Tracking:Often referred to as “baby arcing,”

it follows the path of damaged

insulation



Condition Based Lubrication

• When a bearing exceeds 8dB over a

baseline, it is scheduled for lubrication.

• A technician can use the dB readout

as a guide to determine when to stop

applying grease and prevent over

lubrication.

http://images.google.com/imgres?imgurl=http://www.newequipment.com/company/Images/UE Systems/grease-caddy-up201.jpg&imgrefurl=http://www.newequipment.com/company/UESystems_2010.aspx&usg=__ZTPNW8T_2vpIFwzrQaHN7-MYDag=&h=174&w=150&sz=6&hl=EN&start=7&itbs=1&tbnid=cdLEYau7SVRWXM:&tbnh=100&tbnw=86&prev=/images?q=Ultrasound+grease+lubricator&hl=EN&sa=N&gbv=2&ndsp=18&tbs=isch:1



Laser Alignment


Laser Alignment – 3 Disciplines

Shaft to Shaft Spindle

Belt & Sheave


Laser Alignment Methods

8/10/98

Measuring Precision

.002" to .001".010" to .005" .0008" to .0002"

Pa

rtQ

ua

lity

To

olL

ife

Straight Edge

Indicator

Laser

0

50

4060

3070

2080

1090


Remote Sensing/High Speed Video


Remote Sensing/High Speed Video

Fiber Optics

• Glass fibers are used to transmit light

• Glass fibers are used to send an image back

Borescopes

• Rigid instruments for inspection of difficult areas

Flexible Video Probes

• Flexible instruments for access to difficult areas

• Can be used in conjunction with high speed video

High Speed Video

• Record fast events

• Review at slow speeds to understand


Fiber Optics

Fiber optics uses glass

fibers to transmit light

to the point of inspection

and then transmits the image

back to the eyepiece.


High Speed Video vs. Standard Video

• High speed video events

• Sequences normally captured at hundreds or thousands frames per second

• Standard camcorders/cameras can only capture 25 or 30 frames per second

• i-SPEED 33,000fps (1,000fps at full resolution)

• Information and detail will be missed

• Understanding high-speed motion is critical in many of today's industries

• New Go-Pro technologies offer some options for speeding up or slowing down video for better diagnostics.


INFRARED THERMOGRAHPY


Infrared Thermography – What Is It?Visible light

Infrared light

• Takes the invisible and makes it visible

• Makes infrared visible

• Able to observe the effects of heat

• All objects emit heat

• A form of energy

• Travels from hot to cold

• Measure temperature

• Temperature is crucial

• The intensity of heat

• Measured by non-contact


Benefits of IR Inspections

• It is non-destructive

• Reduces repair costs

• Extends equipment life

• Averts catastrophic failures

• Increases efficiency saving energy $


Camera Handling

F – FocusYou must focus carefully before storing an image

because you can’t refocus later

R – RangeThe temperatures you plan to measure must be

within the Range you choose for your image

D- DistanceThe Distance to the target cannot be changed

in post processing software


Infrared Image

•Test



Why Bearings Fail…

Improper Lubrication

Contamination

Installation Errors

Overload

Storage & Handling

Other

In a study conducted by the bearing manufacturer SKF, over 50% of

bearing failures were the result of poor lubrication practices.

Lubrication

Related


Six Basic Purposes of Lubricants

• Reduce Friction

• Reduce Wear

• Dampen Shock

• Dissipate Heat

• Prevent Corrosion

• Seal Out Dirt and Other

Contaminants



Cost Savings / Cost Avoidance


Definitions

•Cost Savings• Dollars that are currently spent but will not

be spent in the future

•Cost Avoidance• An estimated dollar amount that would be

expected to be paid in the future if proactiveevents did not keep the machine, tooling,

or system producing units


Questions / Comments

Dave Reiber CRL / CMRP

Senior Reliability Leader at Reliabilityweb.com

Email - [email protected]


Questions & Answers


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The Journey from Calendar-Based

Maintenance to Prescriptive

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WIRAM Series

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Senior Consultant Engineer, Eli Lilly


Building the Business Case for

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