Up Time Magazine- February/March 2008

Reactive Maintenance, Preventative Maintenance and Condition Monitoring, with a strong Enterprise Asset Management System as a support. We strive to promote a proactive culture that finds and prevents issues rather that waits and fixes problems. A key component of our PdM program is the daily inspection route. We try to include everyone in our program and assign technicians to short but consistent PdM routes. We use a variety of tools. Examples are Visual Inspection, Ultrasound, Vibration, and Infrared. We stress the importance of visual inspection and find it to be an under appreciated, inexpensive and valuable tool. In addition to our PdM routes, we also use automatic lubrication and oil analysis. Most equipment provides some indications of functional deterioration before failure, and condition monitoring routes look for those early indicators. Condition monitoring at Dell includes, but is not limited to, technologies such as: • Visual Aids • Ultrasonics • Vibration Measurement and Analysis • Temperature Analysis • Lubrication • Oil Analysis equipment failure or partial failure. The success of the program is extremely dependent on dedicated technicians, dedicated not only to running the PdM routes, but also to learning and understanding how and when to use the various predictive tools. Technicians that know, embrace and create change play a vital and indispensable role in the roll out and implementation of CbM programs. Technicians who just follow the process because they are instructed to will not notice the subtle changes in equipment performance that we need for our PdM technicians to notice. Defined Daily / Weekly Routes After equipment and personnel are identified, the department must have the courage and discipline to allow the All PdM routes are technician to complete rolled into standardized the PdM route, above work packages, which all other requirements. are short duration, Consistency in completdedicated assignments. ing the daily route is This standard work necessary to capture any approach facilitates sudden or increasing scheduling, deploying, change during normal training and sustaining. operating conditions. Providing a one hour, PdM Routes undisturbed, window to look for problems, Our PdM routes are will pay tremendous primarily geared toward dividends by detecting CbM, and are used as Figure 2 - Conveyor systems play a large role in Dell’s manufacturing process. failures that a frequency a proactive, systematic PM would otherwise approach to ensure key miss. The daily inspection of equipment and production equipment performs reliably A Sound Implementation Process subsequent repair orders will reduce the and efficiently. This systematic approach is is Required number of events and significantly reduce the a proven method that helps determine the Mean Time To Repair and cost to maintain a stability or deterioration of critical equipThe first step in the process is to identify piece of equipment. ment components. When applied to the all critical equipment. Not all equipment distribution process it is taken to mean this; is covered by Condition monitoring – if the Visual Inspection Routes the use of advanced detection methods and consequences of their breakdown will minitools to determine equipment condition, and mally affect factory flow or reliability, it may Human senses (look, listen, feel, smell) play to potentially predict failures. be justifiable to run to failure and repair it as an important part in the condition monitorquickly as possible when the failure mode is ing process. Using the human senses to CbM measures equipment health and usually easily identified. Well defined failure modes check for and detect potential equipment is not an indicator of the present state of are essential to the success of the process. failure is a low cost and effective method the equipment versus the as-designed state. The technician must be trained to know used to monitor the health of the equipment. Condition monitoring is used to compare the what signals to look for when completing The chances of detecting equipment probcurrent state of equipment to its initial CbM either a daily, or other frequency, scheduled lems are greatly improved by having somebaseline measurements. There are seldom route. They also require training on how to one constantly monitoring equipment, sudden catastrophic equipment failures. use their PdM tool set to detect the onset of www.uptimemagazine.com 37 http://www.uptimemagazine.com

Table of Contents Feed for the Digital Edition of Up Time Magazine- February/March 2008

Up Time Magazine- February/March 2008 Contents Upfront Upclose: Lessons Learned from the Walter Reed Story Information Technology: Parenting and Asset Performance Infrared: It's Alive! Lubrication: A Sense of Change Maintenance Management: PdM, Standardized Motor Testing: Being Well Connected Precision Maintenance: How to be Marketable Reliability: The Voyage of Wells Dairy Ultrasound: Two is Better Than One Vibration: Diagnosing a Cracked Shaft Upgrade: A Different Kind of Journey

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