Up Time Magazine- February/March 2008

looking and listening for potential problems. Visual aids provide a quick reference that anyone can look at and instantly tell if equipment is operating within its predetermined specification, or if a piece of equipment is operating out of spec. During visual routes the technician looks at: Gauge Masks - These are translucent plastic masks placed over the gauge leaving only the gauge operating range exposed. Masks provide the standard operating range as well as a visual indication when, for some reason, the pressure has changed. Temperature Labels - Non-reversing temperature labels placed on heat sensitive motors and other equipment. Temperature labels are a very inexpensive way to monitor component temperature continuously. Training everyone in the area on how to detect and report a change in the temperature label is an excellent way to involve everyone working in the area. Torque Seal -- Breaks in torque seal on critical nuts or bolts is a good indication that components are changed or are loosening. Torque seal is another method that can be used by everyone working in the area and does not require technical expertise. Open Guarding -- Lexan covered opening in drive guards that provide safe visibility to the machine’s drive and other critical components. Open guarding is also a method that employs not only the technician completing the daily route, but anyone that works in or passes through the area can notice a partially broken belt or wobbly drive component. Floor Indicators -- Signs of belt or metal shavings underneath the conveyors, rust, oils spills and parts on the floor. Physical Condition -- Condition of the equipment such as missing parts, old repair tags, guards properly installed, electrical wiring neatly secured and good product flow. Although it requires a trained technician or engineer to determine the root cause and repair of most problems, the use of visual indicators involves everyone in the area and and/or eliminating small air leaks throughout the plant. Infrared Thermography New cameras are less expensive, smaller and easier to use, and, therefore, are more useful in the day to day monitoring of equipment. A trained 1st level Thermography technician can frequently scan electrical panels, motors, gearboxes and other critical heat sensitive equipment. This is another tool that, when combined with the other PdM technologies, provides an umbrella of coverage that improves overall equipment reliability and can, when properly used, significantly reduce unwanted events. Today’s cameras are a better investment because they are intuitive, require little training and provide information that is closely related to the real time functioning of the equipment. Problems detected through digital imaging can now be immediately addressed rather than waiting for reports that arrive weeks or sometimes months later – too late to prevent the failure. Figure 3 - A Vacuum lift in use on a production line at Dell. Vibration The principles of monitoring the health of plant machinery by monitoring equipment vibrations are well proven and straightforward. All operating machines vibrate to a certain extent, but, since an increase in vibration almost always precedes deterioration in operating conditions, it is possible to gain valuable information concerning a machine’s condition by monitoring its vibration levels. Vibration analysis is used more for long term detection and equipment or parts failure analysis than in the day to day operation. The results of an ultrasound or an infrared reading that identifies a hot bearing finding on a daily route may result in the use of vibration analysis to determine the source of the sound or heat. Vibration technology falls more in the deterministic rather than the predictive category, because it’s possible through wave form analysis with today’s software packages to accurately pinpoint the source and the problem. is not dependent solely on the technician. Training personnel on what visual signs to look for is an excellent first step in TPM. You’ll probably find that most operations personnel are eager to help implement this plan. Ultrasound Using ultrasound techniques as a component of the daily monitoring route provides the technician with an invaluable tool for detecting equipment problems that are impossible to identify during operating hours. Ultrasound is a great problem locating and troubleshooting tool that helps in troubleshooting most pneumatic, hydraulic and vacuum problems. Technicians can easily learn and effectively use this technology in the completion of daily routes and in troubleshooting equipment issues. Ultrasound tools are also used in identifying issues that produce sound emitted with conditions of interference, rubbing and knocking. Dramatic reduction in the overall use of facility air compressors can also be accomplished by routine use of ultrasound to lead programs aimed at reducing Lubrication Most bearing experts will tell you a major cause of premature bearing failure is poor or nonexistent lubrication. Auto-lubrication de- 38 february/march 2008

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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