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TRANSCRIPT
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Presentation for KYCSA Annual Safety and Education Seminar February 21-22, 2018
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Why do most PdM Programs Fail?
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Safety Issues!
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Predictive Maintenance - PdM
➢ Predictive Maintenance – “Process of monitoring the condition of an asset and taking the appropriate action to avoid the consequences of a failure”.
John Moubray, “Reliability Centered Maintenance II”
Fact: The question is not IF the motor will fail, the question is:
WHEN?
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Do We Have Enough Acronyms?
➢ PM - Preventive Maintenance ➢ PdM - Predictive Maintenance ➢ AM - Asset Management ➢ CM - Condition Monitoring ➢ AEO - Asset Efficiency Optimization ➢ RCM - Reliability Centered Maintenance ➢ PRM - Proactive Reliability Maintenance ➢ RCA - Root Cause Analysis ➢ ODR - Operator Driven Reliability ➢ ROI - Return on Investment ➢ Etc.
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CTA
HFD
MCD
MDM
MCM
FFT
Fmax
gEMHz
kHz
SEE
IPS
DSP
RMS
STA
Ex
ODS
RUCD
LMU
Do We Have Enough Acronyms?
SQL
OLE
GSM
WiFi
ODBC GPS
USB
RISC
AISC
DLL
CE
WWAN
802.11 b
802.11 a
OPC
ARM
IrDA
EHD
L-10
TFO
NDM
SRB
DGBB
TRB
NRB
LSB
D/D
C/P
CRB
a23
BSC
BDC
LCC
PM
KPI
PdM
IMS
TPM
PRM
ODR
AEO
MTBFERP
PAM
RCM
KPI
TPM3
DSS
OBM
RCM2
OEERCA
SRCM
PM
TVA
ROCE
NPV
BOI
ROI
EVA
TCO
EVC
TSV IRR
TBO
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Why is a PdM strategy important?
➢ BE IN CONTROL!
➢ Reduce Unscheduled Downtime by Predicting Imminent Motor Failures and Identifying Problem Areas
➢ Determine Root-Cause of Problem
➢ Ultimate Goal: Save Time & Money
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➢ Perform “condition monitoring” ➢ Determine health status ➢ Predict failure mode ➢ Act accordingly
Advantages: ✓ No surprise downtime ✓ No unexpected failures ✓ No secondary damage ✓ All maintenance is planned
“Predictive” Maintenance
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Motor Problems
25% - 35% 65% - 75%
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Why do most PdM Programs fail?
1) Incomplete Program
➢Vibration Analysis – Mechanical ➢Static Electrical Testing – Electrical ➢Dynamic Monitoring – Electrical ➢Others:
➢Thermography - Annually ➢Ultrasonic - Annually ➢Partial Discharge – Once or twice per year
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Why do most PdM Programs fail?
2) Maintenance is considered a cost center rather than a cost-saving mechanism. Corporate View: Money not spent on maintenance is money saved. However: Studies show that a well executed PdM program actually saves money by preventing unplanned down-time and costly emergency repairs.
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Why do most PdM Programs fail?
3) Maintenance takes a back seat to production.
Far too often maintenance activities are delayed and even outages are cut short or cancelled driven by production demands. )
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Why do most PdM Programs fail?
4) Maintenance personnel are spread too thin.
Every facility has numerous minor issues and tasks that take up the technicians day so Preventative and Predictive activities are left undone. Replacing filters and light bulbs, filling out paperwork and responding to warning lights consume the techs day. Chasing down the root cause of those flashing warning lights and routine testing and data collection are delayed or not done at all. )
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Why do most PdM Programs fail?
5) Maintenance personnel lack experience. 1) Maintenance personnel are often expected to be both electrical and mechanical engineers! 2) Lateral and upward moves within the company cause some issues since those who have been trained at specific tasks are now in another role. New techs have to start over. )
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Why do most PdM Programs fail?
6) Lack of support: Maintenance activities must be a team effort and it is nearly impossible to get everyone to agree on a plan, and even harder to get them to stick with a plan. Maintenance personnel, production managers, facility managers, finance, etc.
)
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What are your options?
1) Hire the right people 1) Mechanical and Electrical
2) Train and develop those technicians 3) Purchase the equipment
1) Vibration Analysis 2) Static and Dynamic Electrical 3) ????
4) Develop a routine/strategy 5) Allow your staff to learn and grow
1) It takes a team! )
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What are your options?
or: Outsource ! 1) Partner with a company that has highly skilled, experienced subject matter experts with the finest test equipment and up-to-date training. 2) Share the activities or let that partner provide the answers and solutions.
)
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Summary
✓ All motors will fail; knowing when a failure is eminent puts the technician in control.
✓ Preventing one unplanned failure will justify money spent on a PdM program.
✓ Plants and facilities are designed to make computers, electricity, cars etc. and PdM issues are better left to the subject matter experts.
)
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Thank You!Timothy M. Thomas
Senior Electrical Engineer Hibbs ElectroMechanical Inc.
Madisonville, KY