Condition Monitoring Services
Do you find....?
- You have critical machine failures at the most inconvenient time or have irritating problems that just won't go away?
- You don't always carry spares and some assets have long lead times?
- Are your uptime and productivity targets always getting compromised?
- Are you under pressure to improve your reliability from the company?
- Do you focus on good practices, yet still fall foul of unplanned outages?
I could go on, but if your don't identify yourself with the questions above then you most probably have a good reliability programme already in place. Unfortunately most companies with an established condition monitoring department can loose focus and the behaviour is to do what you always did and chalk problems up to "you can't get everything"...... well to some extent this is true. Even with online 24/7 condition monitoring, we have seen operators dead head pumps and watched online as 10 minutes later the pump has destroyed itself and by the time you realise that the valve wasn't opened, the damage is done.
What we discovered
Back in the 90's we were introduced to predictive maintenance techniques at DuPont and as part of the engineering leadership team we identified that it was not just technology that was going to help with our uptime issues, but a change in behaviour was also identified, to help improve the running of the plant. We had to change, firstly, the beliefs and principles around our maintenance practices. The strategy before was to carry out preventative maintenance which meant that the planning department gave out a schedule of work and this was the metrics of how well your maintenance practices were measured. We change this around by making the planning follow the PdM routes and so the 'tail didn't wag the dog'. Machines would no longer be taken out for service due to an hours run basis, but on the condition monitoring reports. Therefore we knew the machine didn't have any problems , so why touch it...... The outcome was an increase in uptime. This was key as the plant was downsizing and experienced maintenance staff were disappearing in a wealth of golden handshakes.
Less people + Less Maintenance = improved uptime. from this experience the realization was that condition monitoring was the way forward.
How we can help.
We can help you set up a Condition monitoring programme, whether it utilizes your existing personnel, or by bringing in trained reliability consultants.
- Firstly we look at your critical machines and weight them as to their importance. We ask questions not only of the engineering department, but production and the QSHE people. Most people look at the big machines, but sometimes a small environmental pump can cause massive problems for the company and be looked at differently, because the QSHE people weren't involved
- Next we set up a route based plan of the identified assets measurement points, which are then scheduled on a plan depending on criticality and the technology to be used. (we find Vibration analysis the cornerstone of any CM programme)
- We baseline the machines and set them up with industry standard ISO 10816 alarm levels as the arbitrary levels (these will be adjusted over time if needed)
- We then report on the data using simple to understand traffic light reporting, coupled with detailed reports and recommendations of what to do...... we have a saying " To monitor is to know when to ....
Change (Behaviours, Strategy, Technology)
Inspect (Take a closer look. Problems on the horizon!)
Repair (A fault is identified and needs fixing)
Clean (Parts get out of balance and often need just a good clean)
Upgrade (Sometimes the machine is not fit for purpose)
Lubricate (This is so overlooked)
Adjust (Tweak the speeds or adjust the valves)
Re-align (Misalignment is an asset killer!)