Don’t be left behind the training curve.

The Maintenance Reliability team needs to keep on top of their game with effective maintenance and reliability training.

Find training program details, dates and locations

RCM analyses are best conducted at off site locations that allow the RCM team to focus on completing the task at hand. Interruptions for day to day plant issues slow the progress of the RCM analysis and often disrupt the entire team.

If the expense of off site rooms is an issue with your plant you need to learn to be creative. I have conducted RCM analyses in Fire Halls, Legion Halls, Town Halls and Elk Lodges. We have even arranged to have other local companies share conference rooms at no expense.

One of the great values of having a Reliability Centered Maintenance culture is the learning that there is a solution to every problem.

Tip provided by Doug Plucknette
RCM Discipline Leader
Allied Reliability, Inc.
Tel: 888-414-5760

Find out more about RCM Blitz - Fast Reliability Centered Maintenance

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Follow up maintenance from a PM observation or procedure is the return on our PM investment.

Any extra corrective activity that is not part of the preventive maintenance strategy or procedure, but a result of it must be captured on a separate work order and coded as such. Additionally, it is a proactive activity and the work order should be deemed as such. In a lean maintenance environment, follow up corrective work from PM’s should amount to 12% to 20% of the PM total. This is your payback for performing the PM’s.

This is essential for an efficient Work Management system. The work management system is the backbone of any Reliability and Lean Maintenance Program. All work activity must get recorded and properly coded into different categories for performance, financial and root cause analysis. There should be only five to ten major work codes falling into the categories of Proactive, Reactive and Other. This should not be confused with problem codes. Work data that gets recorded, measured and analyzed gets continuously improved.

In conclusion from the data analysis, If data shows large amounts of corrective work resulting from PM’s or emergency work activity on PM’d equipment then the PM frequency may need to be shortened. Hone your program until you reach the 12% to 20% Sweet Spot.

Reader tip provided by Leon Reed
Sr. Reliability Engineer, CMRP
Eli Lilly
Indianapolis IN

Thanks for continuing this discussion Leon - your stainless steel diamond plate coffee mug is on the way!

What is Corrective Maintenance (CM)?

Whenever you think of further developing your predictive maintenance program, you are confronted to various options the market offers, not only in different companies but technologies.

The selection process of testing and tools should first face the technologies you utilize, and once you’ve decided this you should follow with the selection of the company that offers the best price/quality relation.

For this selection process of which test to execute it is useful to ask yourself “Which are the tests that the electric motor manufacturers utilized prior to selling me this motor?” and the answer to this question is relatively simple: Resistance to milliohms, HiPot and Surge. This can be verified by contacting WEG, SIEMENS, A.O. Smith, G.E., Emerson or any other manufacturers.

After determining the diverse testing these manufacturers, with years of experience, have developed. We are now able to know what we need to keep control of the quality of our windings.

Remember: HiPot and Surge

Tip provided by Baker Instrument Company
An SKF Company
Phone: (800) 752-8272 or (970) 282-1200

Find our more about Baker Instrument Company

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As the Boy Scouts say: “Be Prepared” – Did you pack extra cutting tools?

Plant shutdowns are notoriously difficult to arrange, and every effort has to be made to maximize the amount of work that is achieved during this time, this is especially true when installing infrared windows.

Cutting tools, drill bits, files, even drills and hole saws may break or become dull during the installation. Ensure that you have an adequate supply of primary and replacement tools and supplies on hand—you won’t have time to run to a hardware store to purchase replacements.

Tip provided Martin Robinson
IRISS
Tel: +1 (941) 907-9128
Email:

Why Use IR Windows?

The most common traps of Motor Current Signature Analysis can be categorized as inadequate personnel training, inconsistent Motor testing program documentation and deficiencies in the testing process.

All of these areas can contribute to the improper collection and/or interpretation of the data which results in incorrect maintenance. Not only will this waste time and money, but will tarnish the benefits and value of the technology.

Regardless of how the program will be resourced it is vital that internal written practices are developed outlining personnel qualifications and testing procedures. These will be framework for establishing how testing will be conducted and who will conduct the testing.

By following these guidelines, your program will avoid many of the common traps that can result in a false start of your motor testing implementation.

Better said: If you do MCA right, document the findings and are consistent, not only will you achieve a greater buy-in from the Maintenance Teams and Management, but you’ll show a Return On Investment that will go a long way to solidifying your PdM Program in the eyes of the folks watching the bottom line.

Tip provided by Allied Reliability
Tel: 843-414-5760

Find out more about PM/PdM Best Practices Workshops