Available only at IMC-2006

“What is the actual added value of maintenance?”

That is a frequently heard question in boardrooms the world over. Even though maintenance is often critically important, few maintenance managers are able to answer the question convincingly. Especially when they are asked to express the benefits in terms of economic value added or shareholder value - the language being spoken in boardrooms.

For this reason Mainnovation developed the Value Driven Maintenance (VDM) methodology, which is implemented in leading maintenance organizations like DSM, Smurfit Kappa, Sara Lee, GlaxoSmithKline, Akzo Nobel and Volvo Cars.

VDM builds a bridge between traditional maintenance philosophies and managing by shareholder value. Not only does VDM simplify the boardroom discussion, it also shows that far from being a cost center, maintenance is actually a major economic value within the overall business performance.

Sign up now for the only US Value Driven Maintenance® Business Simulation at IMC-2006 by calling toll free (888) 575 1245 or…

Learn more about the Value Driven Maintenance® Business Simulation online

Checking Contacts and Connections with a Voltmeter

Some of our common tools can be used in such a way to detect problems, or as condition-based testing, if more advanced tools are not available. Of course, newer technologies are faster, safer and provide a greater accuracy. So, as we discuss this tip, the user must consider all company, regulatory and instrument applicable safety requirements.

Infrared imaging is an outstanding tool for detecting loose electrical connections. However, if the technology is not available, a voltage drop test can be used to identify power connections and contact problems. The test is performed by placing the leads of the voltmeter across the input and output of the component being considered (starting with the highest setting and working down), in the same phase. For instance, if testing a three phase contactor for bad contacts, one lead of the voltmeter would be placed on the line side of phase A and the other lead on the load side of phase A of the contactor. The value is noted and the test is repeated for phases B and C. If the value is greater than 1 Volt, then the contact or contactor must be repaired.

Note: It is good practice to always verify the operation of a voltmeter before and after each test. This is done by testing a known source, such as a working outlet, performing the test, then testing against the known source.

Tip provided by Howard W Penrose, Ph.D., CMRP
President, SUCCESS by DESIGN Reliability Services
http://www.motordoc.net

Learn about the Institute of Electrical Motor Diagnostics (IEMD)

OIL MONITORING ANALYST 2006 Training Dates and Locations
* OMA I, II CLS & CMFS, English

Montreal, QC-Canada (in French)
Nov. 8-9
Nov. 10: Exams

Miami, FL
Dec. 5-6
Dec. 7: Exams

Red Deer, AB-Canada
Dec. 12-13
Dec. 14: Exams

To learn more please call CMI at (678) 942-3582 or…

Learn more about OIL MONITORING ANALYST Training

Rust a form of corrosion develops when iron, water and oxygen are present. When water comes in contact with iron, the water combines with carbon dioxide to form an acid. The acid dissolves the iron. During the dissolving process, a portion of the water breaks down into hydrogen and oxygen. The oxygen and dissolved iron bond into iron oxide, better know as rust. This bonding of oxygen and dissolved iron frees electrons from the iron (acting as an anode) which travel to the cathode. This movement of electrons corrodes the iron material.

Assembly fasteners and components on stationary and mobile equipment which are continually exposed to nature’s elements (water, dirt, and temperature variation) can be difficult to disassemble due to corrosive affects of these elements.

Heavily rusted fasteners can break-off or be damaged beyond use during disassembly. Additional maintenance time and costs are required to extract fractured fasteners and repair damaged components.

When planning to disassemble equipment, the equipment should be inspected prior to disassembly to determine the condition of the fasteners and components.

If the fasteners and components are heavily rusted, then it is suggested that a quality penetrating oil be applied to these items. The penetrating oil should be applied 12 to 24 hours prior to disassembly and may require more than one application.

This will allow the penetrating oil to work at loosing the joined parts and greatly reduce the chances of damaging or destroying these items while reducing unplanned work.

Tip provided by Andy FitzGerald
Allied Reliability, Inc.

Request “PdM Secrets Revealed” from Allied Reliability

Pretend You Are on the Team (2 of 12)

Pretending to be a supporter of good maintenance practices is an excellent way to wreck your maintenance organization. If you can master the art of appearing to be an honest team member while tearing down the program behind the scenes, you can stealthily avoid confrontation.

Some handy examples to get you started:
• A maintenance manager says he supports planned and scheduled work, but fails to defend the process. Instead, he happily supports breaking the schedule and doing unplanned work so he can gain points with the operations managers, who do not understand proactive methods.
• A maintenance technician is fully trained to use modern laser alignment equipment, but when no one is looking, he aligns a coupling by eye to save time.
• A maintenance supervisor supports proactive strategies in the Maintenance Improvement meetings, but afterwards criticizes the program to his crew, telling them that it will go away if they just ignore it.

Seek out the other Pretenders in your organization, as you will find strength in numbers. If you can assemble a strong core group of Pretenders, it is possible to engineer the dazzling derailment of all efforts to increase reliability.

Tune in next week as we continue to expose the secret lives of seriously disturbed maintenance “professionals” with The Dirty Dozen Tip #3: Keep Maintenance Successes a Secret.

Tip provided by NoBreakDowns.com
Tel: (218) 327-3114

Receive a complimentary Dirty Dozen: 12 Ways to Wreck Your Maintenance Program electronic poster

The lubricating oil in gas turbines and hydraulic systems is increasingly subject to the ravages of varnish.

The debilitating effects of varnish are well documented. The complexities associated with detecting varnish potential render routine oil analysis ineffective in reporting varnish. However, there are a number of technologies, although seldom used, which have been successful in reporting incipient varnish potential. Insight Services has developed a Varnishing Potential Analysis that incorporates these technologies into one simple report to offer an integrated varnish potential solution.

Find your way back to a healthy lube oil system with a Varnishing Potential Analysis from Insight Services.

How well do you understand varnish?

Take a quiz and find out, maybe even WIN a GPS Navigator

Proper Application of an Adhesive Mounting Pad

The accuracy of an accelerometer’s frequency response will be directly affected by the quality of the installation of the sensor on the targeted machinery. Any hardware which is used between the sensor and the targeted machinery can add mass to the sensor, affect surface area contact with the machinery and add looseness between the sensor and the machinery. All of these factors can adversely affect the frequency response of the sensor and can affect the data which analysts will base some very important decisions on. For this reason it is imperative that proper installation techniques are used for common mounting hardware such as Adhesive Mounting Pads (commonly referred to as Epoxy Pads.)

When applying Epoxy Pads to monitor vibration, remember to:

– Follow all safety rules and wear personal safety protection as required.

– Select a spot which is closest to the site of the vibration you are seeking to monitor.

– For best results, use a right angle drill with an end-mill bit (“spot facing tool”) to mill a flat surface the same diameter as the pad you will be affixing to the machinery surface.

– Using both hands, apply steady, even pressure to the back of the drill behind the milling bit.

– Unlike with the stud mounting preparation, the pilot drill bit in the center of the end-mill should only be set slightly below the mill – just enough to catch the surface and prevent the mill from “skating” sideways.

– After you have milled your flat surface, put on rubber (surgical) gloves. This will keep any grease from your hands from effecting the mounting surface of the machinery or the pad. Using a grease-cutting, residue-free cleaner, clean the surfaces of both the machinery and mounting pad. Windex works well for this since it is also compatible with many shop-floor material restrictions (this may vary depending on your location.)

– Use a thin film adhesive such as Loctite 330. Make sure that the adhesive is compatible with environmental factors (chemicals, moisture, heat).

– Hold in place for 30 seconds, and tape in place for 15 minutes while adhesive cures.

– Touch up with paint to prevent corrosion.

– Mount sensor on pad with 2 to 5 foot pounds (refer to sensor data sheet).

For additional information on mounting techniques and why some mounting methods are preferred over others in certain applications, refer to the iPresentation tutorial link below …

Tip provided by CTC
Tel: 585-924-5900 x 809
http://www.ctconline.com

iPresentation Tutorial invitation: Basics of Accelerometer Mounting & Installation

I just taught a course on Inventory and stock room management in beautiful Louisiana (if you are not familiar with the US- New Orleans is in Louisiana as well as a good portion of our alligator population) and they reminded me about the importance of having the right parts available at the right time.

There were a couple lessons that could be learned by any storeroom starting with the importance of accurate records. Everyone agrees with the importance of accurate records but disagree with how to achieve the goal. Here’s my take on achieving the goal:

• Be sure everyone knows why it is important.

• Encourage people to take responsibility for their part.

• Be sure everyone knows who is accountable for
different aspects.

• Provide physical security.

• Provide training in procedures for storeroom
personnel and your customers

• Conduct motivational talks from different parties

• Provide the tools to make doing the right thing the easiest thing to do.

• Establish goals and measures and report on progress IN PUBLIC

• Management must have the will power to make it so!

Did you ever think of all the areas where mistakes can happen to mess up your inventory numbers?

• Parts removed without paperwork

• Missing shipping, receiving documents

• Wrong part sent in and missed in receiving

• Rebuildables handles differently each time

• Confusion in unit of measure

• Marking wrong SKU (part number) on incoming part

• Errors in transcription

• Returns improperly accounted for

• One part blocking sight of another

• Pilferage, theft

• Toolbox and rat hole inventory

Another thing that struck me was the complexity of the process to change items on the stock list. If you want to see something interesting get a sheet of quad paper (if they still sell it- or use Visio) and take a business process like Return surplus items to stock or the process to agree to standardize on one item (such as a particular bearing). Draw all the steps, authorizations, conversations, files created or changed, forms to be filled out to accomplish the objective. In our class adding an item to stock required 20 steps and a plant manager’s signature!

Thanks for reading- Joel Levitt - Author - Lean Maintenance in a Nutshell

Lean Maintenance in a Nutshell