JULY/AUG 2009 BUYERS GUIDE LEAN MAINTENANCE CONDITION MONITORING ISSUE 12
THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS
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So what are the best performers doing differently than others?
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What are the best performers
DOING DIFFERENTLY? So what are the best performers doing differently than others? The short answer is that they do what we all know we need to do; they just do it better and better over a long period of time. They do not change the name of well known basic reliability and maintenance concepts, for example RBM, TPM, VDM and so on. There is nothing wrong in any of these labels and methods, but if your organization frequently starts a new initiative even before you finished the initiative you just started two three years ago, then you will never reach the results that are achievable. Your organization will be tired of new initiatives and as a leader you will not get the followers and true support you need from your organization. If you study any of these three letter acronyms you will soon learn that all of them include about 280 elements that have to be done well in order to achieve best in class reliability and maintenance performance. (Inspections, alignment, balancing, lubrication, planning, scheduling etcetera.) We call these elements best practices and they are used by many organizations worldwide to benchmark, develop improvement plans and to measure success or the lack thereof. Please contact firstname.lastname@example.org if you like an example. Whatever path you chose to improve your reliability and maintenance performance I recommend you stay on track with that initiative for a very long time. FOR THE FULL STORY PLEASE TURN TO PAGE 3
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Here a best performer is defined as an industrial plant that has achieved a high reliability and fast throughput of manufactured products and as a consequence, manufacturing costs, including maintenance costs, are low.
WHAT ARE THE BEST PERFORMERS DOING DIFFERENTLY? â€“ Part I So what are the best performers doing differently than others? The short answer is that they do what we all know we need to do; they just do it better and better over a long period of time. They do not change the name of well known basic reliability and maintenance concepts, for example RBM, TPM, VDM and so on. There is nothing wrong in any of these labels and methods, but if your organization frequently starts a new initiative even before you finished the initiative you just
started two three years ago, then you will never reach the results that are achievable. Your organization will be tired of new initiatives and as a leader you will not get the followers and true support you need from your organization. If you study any of these three letter acronyms you will soon learn that all of them include about 280 elements that have to be done well in order to achieve best in class reliability and maintenance performance. (Inspections, alignment, balancing,
SLIDE 1: One option is to do nothing. If the valid work load remains the same and attrition is at the rate shown in the graph, then there will be a gradually bigger gap between valid work that needs to be done and available internal recourses. During the first six to twelve months some of this gap will be handled by fewer people forced to do more work, but soon this is not enough. After that backlog of valid work will increase, unscheduled overtime will increase, contractor hours will increase, reliability and throughput will decrease and costs will go up. I promise you!
lubrication, planning, scheduling etcetera.) We call these elements best practices and they are used by many organizations worldwide to benchmark, develop improvement plans and to measure success or the lack thereof. Please contact firstname.lastname@example.org if you like an example. Whatever path you chose to improve your reliability and maintenance performance I recommend you stay on track with that initiative for a very long time. The best organizations understand why they need to improve. They do not only know why they need to improve, they understand why they must improve to stay competitive. Besides the obvious reasons that improved reliability will speed up throughput and reduce costs there are more reasons why you always need to continuously improve. Safety is one of them. The less you need to work with equipment the safer you are. Reliable equipment requires less hands-on interference thus reducing risks for safety incidents. If you have to adjust or repair, the task is much safer to perform if it has been professionally planned and then scheduled. One company reported to me that reactive maintenance was 29% more likely to cause an injury than if the task had been planned and scheduled before execution of task. Energy is another. Just with such simple things as cleaning of electric motors and not painting them will extend electric motor life and reduce energy consumption because the motors will run with a lower temperature. Fixing insulation and leaking
3 EMS July/Aug 2009 www.engineeringmaintenance.info
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WHAT ARE THE BEST PERFORMERS DOING DIFFERENTLY? – PART I
steam traps can save much energy. Condition your pumps to run at Best Efficiency Point (BEP) can save a lot of energy and pump repairs. Of course you know this and like to do it, but if your maintenance/operations organization is too reactive, you will not find the time to do it. Future attrition of crafts people. Best organizations know how many crafts people are expected to retire and leave in the next five to seven years. They also have a plan to fill this gap between future work load and resources. In all of the countries I work at present. (Australia, Belgium, Canada, New Zealand, Sweden, UK USA). There is a shortage of skilled crafts people and the future predicts an increased shortage. At the same time not many companies have good training programs or agreements with vocational schools to train for this need. Some plants have their own apprentice programs and in this economic downturn they have been forced to reduce number of employees. In a unionized organization this means that you have to lay off your future work force first. At present many organizations can find skilled people in some trades because of plant shut downs and downsizing, but skilled crafts people are often in their fifties and will soon retire. So what do best performers do? They know the rate of attrition and they have a plan to manage for the future. (Slide 1) The right thing to do is to look into how well you Execute Maintenance Prevention. (Operating practices, Alignment, Lubrication, Balancing, Filtration, Cleaning etc.)(Slide 2). Better planning and scheduling will allow people to work in a system that will enable them to become more efficient and do better quality work. (Slide 3). www.idcon.com Reader Reply Number: 300
SLIDE 2: Maintenance Prevention will trim down work load. If this is done well it can realistically reduce work load by 5 – 10%. Teaching operators why a steam system can not be started up too fast, what happens to an electric motor if it is started repeatedly and so on will reduce work load. Aligning a drive train to precision will reduce need for maintenance work. Lubricating right will do the same etc. You all know these things need to be done; again make sure they are executed right. These measures are not expensive to implement and they are met with high acceptance by crafts people and operators. The reason many of these basic tasks are not done with precision is not the lack of skills or knowledge, it is often that work is too reactive and not planned which calls for fast response and “I go back and fix it right later”. This leads to the next step you need to do to free up time and close the gap between work load and available recourses.
SLIDE 3: Planning refers to all activities you do to prepare a task with parts, tools, material, lock out, tag out, required craft skills and time estimate to do the task etc. Scheduling is to decide when task is to be done and who is going to do it. To become proficient in planning and scheduling and management of people can take time and has to be done on-the-job. It is a common mistake to spend time and money on training of only planners. You also need to train and implement procedures for requestors of work, front line organization leaders and crafts people. Operations also must be involved; they have a key role in defining work and setting the right priorities. In a survey of “Why Planners Do Not Plan” 1160 respondents gave “Too many emotional priorities” as the top reason as to why planning is not done.(Ref www.idcon.com / surveys July 2009) Requestors, often representing operations set higher priorities than necessary to get the job done. This is a very common obstacle to overcome and it has to be done as part of on-the-job training and implementation.
Christer Idhammar, president IDCON INC Christer Idhammar is a world renowned expert in Reliability and Maintenance Management best practices. He started the Idhammar group of companies in Sweden in 1972 and IDCON, INC in USA 1985. In 2002 he received the Euromaintenance Incentive Award for outstanding
international contributions to improve Reliability and Maintenance in industries world wide. In May 2008 he received the Salvetti Foundation reward for best speaker among 154 speakers at Euromaintenance 2008 in Brussels. He can be reached at email@example.com
5 EMS July/Aug 2009 www.engineeringmaintenance.info
GPRS Data Logger - log and upload data to Central via SMS or GPRS 3GTrack, offers a complete line of remote data loggers, fully featured to meet the needs of data capturing and transmission in remote areas. GS828 series GPRS Data Logger can be utilized in monitoring sensors, transducers or measuring devices through I/O or RS485 port. Its huge internal memory keeps >35000 records. Data Logging and Upload Interval is user programmable from 1 min to 24 hours. Its numerous I/O supports wide application – environmental control, building management system, water or gas pipeline and distribution
substations, and power network monitoring etc. 12 analog input 16 digital input 6 pulse input 4 relay output power level alert Server/Client Software supporting MySQL/SQL/Oracle database is available. GS828H is powered by AC or 12VDC, and backup by internal rechargeable battery. GS828L is featured with sleep mode allowing non-stop operation for >2 years with battery. GS828-H2 and GS828-L2 are integrated with additional 2 x temperature sensors and 1 x humidity sensor. E: firstname.lastname@example.org www.3gtrack.com Reader Reply Number: 306
ELITEpro™ Recording Poly-Phase Power Meter – Measure, log and analyze electrical loads The ELITEpro™ is a complete solution for pinpointing electric usage and quantifying energy consumption. It is a portable interval recording power meter that can measure up to four channels of current (0-6,000 amps) on voltage services up to 600V AC. Parameters that can be by measured, stored, and analyzed include Volts, Amps, Watts, Volt-Amps (VA), Volt-Amps reactive (VAR), Kilowatts (kW), Kilowatt Hours (kWh), kVAh, kVARh, and Power Factor. The ELITEpro™ also offers some power quality features such as the ability to view voltage, current, and power waveforms and calculate harmonics
to the 63rd order in real-time. Measurements are stored in onboard memory at recording intervals defined by the user. The ELITEpro™ can be powered from the phases of the service being measured with onboard battery back-up. The Windows-based ELOG™ software package is used to program the meter, display metered values, and retrieve and analyze the collected data. The ELITEpro™ can be mounted anywhere with its magnetic back and is available in an optional weather-tight enclosure. DENT INSTRUMENTS
64 NW Franklin Avenue Bend, Oregon 97701 541.388.4774 (p) 800.388.0770 (toll free) www.DENTinstruments.com Reader Reply Number: 303
NEW 8-Channel Data Recorders The new SRD-99 series record and display process or temperature signals in numeric, tabular or graphical format. Ideal for industrial, building services and process control applications. Choice of 1, 4 or 8channel versions; with Pt100/500/1000 or 0/4 to 20mA inputs. Each input can be simply named, ranged and captioned by the user – using the front key operated menu. Data recording is automatic, or by an externally controlled input, with sample intervals from one second up to one hour. The internal memory – up to 8MB – can store 2 million data points. All versions feature a built-in RS-485 (Modbus RTU) serial port for configuration and data transfer to analysis/archiving software. Data can also be transferred by a memory stick, with the USB port option. All models are in compact 96x96mm panel mounting housings. A lockable clear plastic hinged front door accessory provides IP 42 protection. Full information here www.metrixelectronics.com/HTML/P2L_compact_data_recorders.html Metrix Electronics Ltd T: +44 (0)1256 864150 email@example.com www.metrix-electronics.com Reader Reply Number: 304
6 EMS July/Aug 2009 www.engineeringmaintenance.info
FTR FAULTRACKER The model FTR Faultracker is a new concept designed specifically for fault finding and monitoring and data logging tasks on electrical systems. Modern electrical control systems are complex. Sooner or later, they go wrong. Faultfinding is a tedious, time-consuming task. If the fault is intermittent, it can become a nightmare. The FTR has the ability to monitor many inputs simultaneously and to be able to ‘unravel’ fast sequences. It will monitor, display and record 16 points within an electrical system such that: the state of the system can be seen at a glance. monitoring can be achieved at a safe distance. ‘fast’ events can be replayed
one step at a time. intermittent faults can be ‘captured’. it can be left for days or weeks until triggered by a fault condition. Using the FTR has been proven to reduce frustration and down time simply by being able to replay the true state of the system step by step at the moment the fault occurs. Laplace Instruments Ltd
3B, Middlebrook Way CROMER Norfolk NR27 9JR T: 01263 51 51 60 F: 01263 51 25 32 E: firstname.lastname@example.org www.faultracker.com
Reader Reply Number: 305
GRANT INSTRUMENTS launches Wi-Fi enabled Squirrel portable data logger The Squirrel Wi-Fi data loggers feature built-in Standard 802.11 wireless Ethernet (Wi-Fi) capability which allows easy integration with existing wireless networks in scientific laboratories, offices and factories. Users can now connect their computer remotely to the logger to retrieve data and reprogram the device without the need for communications cabling or expensive converter boxes. With multiple 24-bit analogueto-digital converters and up to 16 true differential or 32 single ended analogue inputs, the Wi-Fi Squirrel data loggers are an out-of-the-box solution for a wide range of data logging applications. These include industrial testing and research, vehicle testing or engine monitoring, scientific and environmental research, and quality assurance. Nathan Neal, commercial manager for data acquisition products at Grant Instruments, said: “The Squirrel Wi-Fi enabled handheld data loggers’ combine high performance and universal inputs with the simplicity of wireless networking in a compact and easy-to-use instrument. As a result, it will be particularly useful for data collection applications where the user is remote from the data logger, for example on moving equipment or machinery, or from
distant office or facility.” The high precision Squirrel WiFi data loggers can store up to 10 million readings in the onboard memory - additional storage is available via a removable Multimedia (MMC) or SD card. The unit also features up to 16 calculated/derived channels, 4 alarm outputs for triggering external devices, USB and RS232 serial ports and is powered from internal cells, an external power supply or via a USB connection. SquirrelView set-up and download software for a PC is provided as part of the system to enable users to export stored data to a chosen PC-based application. Customers that are registered for Grant’s SquirrelView.net web server application can also upload the data automatically to a dedicated web page and thereby allow authorised personnel to access the latest data via their web browser. The Grant data acquisition product range extends from high specification, portable data logging systems (Squirrel family) through to fully integrated custom-configurable acquisition and control systems (dataTaker family), while Eltek, the Cambridge-based Grant affiliate, produces Squirrel variants primarily for remote logging. All products come with a 3 year warranty. OEM versions of most products are available on request. T: +44 (0) 1763 260811 E: email@example.com www.grant.co.uk Reader Reply Number: 308
Race Technology Race Technology initially developed the DL1 data logger for motorsport use. It did however soon become clear that it was also suitable for different applications. The DL1 has a built in 3 axis 2g accelerometer (6g optional) and uses a high precision 5Hz GPS (optional 20Hz) to measure position and speed. The DL1 is also a highly configurable unit with easy automation available. The DL1 can for example record a continuous loop of a specified time and only write the information to the compact flash card if a specified event has occurred. Armed with these built in features and the ability to log
up to 8 analogue inputs and 4 frequency inputs at 100Hz, the DL1 has become a very attractive solution for industrial data logging, including railway, marine and production line monitoring. Not only is the DL1 packed with features, it is also one of the best value for money data loggers on the market, from £499.00+VAT. Also available from Race Technology are the DL2 and VIDEO4 data/video recorder. Race-Technology After12 King Street, Eastwood Nottingham NG16 3DA
firstname.lastname@example.org www.race-technology.com Reader Reply Number: 307
Wireless Sensors interface
to Conventional BMS BluBug has recently launched a completely new and innovative way to benefit from wireless sensors without having to change your existing infrastructure. Our wireless sensors boast a 5 year battery life measuring temperature with the option of humidity too. Sensors use the latest meshing digital radio technology to create a robust wireless sensor network. Measurements are transmitted across the network to a DIN Rail Gateway which supports eight 0-10V outputs. These can be scaled to your requirements and tied to the output of any of the sensors. The industry standard signals can be linked directly to your standard BMS or PLC
control system. The DIN Rail Gateway also features an Ethernet port for remote monitoring of the system or logging of measurements. To benefit from the low cost of installation and to eliminate running cables, call James Wilson on our free phone number 0800 756 5396 or email email@example.com BluBug Ltd
27 The Crescent Emsworth PO10 8JS, UK T: 0800 7565396 E: firstname.lastname@example.org www.blubug.biz Reader Reply Number: 309
7 EMS July/Aug 2009 www.engineeringmaintenance.info
TopMessage and ProfiSignal
â€“ industrial data acquisition The modular TopMessage Data Loggers from Delphin are capable of independent acquisition and monitoring of any required measurement value (e.g. temperature, pressure, flow, vibration). Simple integration of the compact Message devices within an existing company network allows any department to access measurement data via a desktop PC. The data is saved directly scaled and lineated (e.g. bar, Litre/sec, m/min, Â°C). Thermocouple and RTD sensor scaling is preconfigured. Every input is true differential with galvanic insulation.
has also free configurable parameter screens to store and load recipe files for various tests. ProfiSignal enables access to historical data at speeds not previously achieved and provides a smooth transition between online and offline evaluation. For evaluation purposes, Yt, Yx, orbit, FFT and logic analysis diagrams are provided. The Logger is supplied with the software ProfiSignal. This is a SCADA system for industrial applications, monitoring, quality assurance, test bench automation, lifecycle testing, vibration monitoring and analysis. The
software enables users to create their own automated test stand applications. The development environment â€œProgramming by Selectionâ€? allows the user to pick commands from a list box of pre defined code blocks. The software
DAQ Solutions Ltd Scada & Data acquisition
T/F: +44 (0) 1226 341440 M: +44(0) 7595 024 353 www.modmux.com Reader Reply Number: 302
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