Maintenance Technology May 2016 - (Page 8)
ON THE FLOOR
An outlet for the views of
& reliability professionals
Triggers: Part 2 of 2
s noted in the April issue's introduction to
this, two-part "On The Floor," when it rains,
it pours. The overwhelming and detailed
number of responses we received from our
Reader Panelists regarding maintenance triggers
simply wouldn't fit in two pages. Alas, even with
this second installment, we regret that we haven't
been able to capture all comments. To recap, we had
asked these questions:
1. What triggers our Panelists' maintenance
scheduling, or if they are consultants or industry
suppliers, that of their client(s) or customer(s)?
Sensors? OEM recommendations? Daily walks/
PdM tool data? Word of mouth? A combination?
2. Which approaches work best for them, and why,
and vice versa?
3. Would Panelists (or their clients or customers)
want to change their current maintenancescheduling process(es), and could they? If so,
what would they do?
Edited for brevity and clarity, here are several
College Electrical Laboratory
In our organization, we have different levels of
maintenance staff. The maintenance crew ranges
from technicians who have been at the job for 22
years to the college grads with two to three years
on the job. Their diagnostic methods are very
different. The operation uses a CMMS program
to track the health of all process equipment. The
seasoned technician walks around and touches all
of the equipment at least once a day, checking for
temperature, vibrations, loose parts, and strange
smells. The newer technician uses some stateof-the-art test equipment: infrared heat sensors,
vibration monitor, and sound-level indicators. All
data go into the system so any potential problems
can be handled.
The process that works best varies because
experience comes into play. Some pieces of equipment are very old and have their own personalities.
Test equipment does not always catch some of the
problems, but the experienced maintenance staff
seems to be able to diagnose a pending problem
through their touchy-feely methods. Keeping track
of this history has reduced downtime on most of
the equipment. Education on all processes and
updated technologies has added to our success.
We've been able to add preventive-maintenance
hours to the schedule when we have tooling changes
and other production breaks. Each experienced
technician has a newer technician assigned to him
for in-depth training. Every shift has a 15-min.
maintenance-planning discussion before starting
the daily operations.
Sr. Maintenance Engineer,
Process Industries, Midwest...
[At our plant] it's a combination. Before last year,
it was mostly set frequencies based on historical
failure data, daily walks, or OEM requirements.
Now, we have tied our real-time data-collection
system to our EAM software and are doing more
and more condition-based scheduling using online
temps, vibes, run-hours, levels, etc. We still do "all
of the above," but have become more well-rounded.
I'm not sure there is a best approach. Any of
them work. It's dependent on the situation. In some
cases, walk arounds are the best because the equipment is new, or not in a harsh service, or has no
failure history. In other cases, we have to monitor
key operating metrics very closely to detect slight
changes that signal the start of the failure curve. The
best approach is often learned from past results.
It would be great to have everything monitored
online and condition-based, but it's not feasible,
so, we continue to be flexible and adjust where
necessary, using all forms of monitoring to gather
the needed data.
Our maintenance is scheduled through a combination of methods. Sometimes maintenance, such
as filter replacement, lubrication, and some oil
changes, is performed after the equipment has operMAY 2016
Table of Contents for the Digital Edition of Maintenance Technology May 2016
On The Floor
A 40% Production Boost From Reliability
Beck Helps Women Excel In Engineering
Unleash Your Plant's Hidden Potential
Right-Size Your Maintenance Organization
Respect The Cornerstones of Manual Grease Lubrication
Motor Connection Advice
Maximize Millennial Workers
Compressed Air Filtration
Pneumatic Tubing & Hose Specs
Maintenance Technology May 2016