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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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Questions?Comments!

Visit our Website or Download our APP

www.hibbsinc.com tthomas@hibbsinc.com

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Thank You!Timothy M. Thomas

Senior Electrical Engineer Hibbs ElectroMechanical Inc.

Madisonville, KY