Efficient Plant May 2019 - 25
feature | lubrication strategies
+ Sample upstream of filters and downstream of lubricated bearings.
+ Before taking actual samples, use the
10X flush rule, i.e., flush a volume that
is 10 times larger than what you'll collect before taking the sample volume.
+ Always pre-flush sampling equipment
(pump and hose).
+ Only use virgin clean sample bottles.
+ Always sample at the same spot, using
the same procedure and equipment.
+ Forward sample and completed sample
details to lab within 24 hr.
S Infrared thermography (I/R), another important PdM tool, has advanced significantly
and now offers sophisticated diagnostic capability in handheld units at a fraction of the
cost of earlier generation systems. I/R cameras are able to depict potential problems in
image form by displaying object temperatures
in various colors, which, based on appropriate
training, can lead to quick interpretation and
problem diagnosis. I/R can quickly determine
whether a bearing is receiving too much or
too little lubricant or indicate reservoir-fluid
levels where no level indicators are in use. I/R
is also used by laboratories in a FTIR (Fourier
Transform Infrared) spectroscopy test to
determine the lubricant contamination and
In all of the PdM methods and tools
described here, the recurring theme is
discipline and consistency. This must be
factored in when choosing and purchasing
a PdM tool by acquiring assistance in set up,
operation, and training for the tool's use.
3. Act on your findings. A true travesty
occurs when all efforts and resources invested
to accurately predict an impending failure
are wasted because no up-front commitment had been made in the planning and
scheduling process to combat the failure and
its associated, accelerated downtime costs.
When an impending failure is evident,
create a work order to perform a planned
repair as soon as possible, linking the PdM
work order as the requestor. This will result
in a report that depicts the success of the
PdM program. To ensure the work order
is generated, issued, and followed up on,
develop a standard operating procedure that
clearly directs the maintenance department
to take action on it.
Once the pilot is deemed successful, the
program can be rolled out into other areas
using the same PdM method or tool. Then,
if needed, the next PdM tool or method can
then be piloted in the same manner.
Remember, though, that tools solve problems when implemented and used correctly.
Going from reactive to proactive is a big
change but, with a little common sense and
knowledge, it's not impossible. EP
OF PRODUCTION UNITS ACTIVITY EFFICIENCY
DSR company has been working lately on the project
which resulted in the creation and implementation of a monitoring and supervision tool IOT 4FACTORY, enabling the optimization of manufacturing processes in the manufacturing sector.
Comparative analysis was performed for the efficiency of
activity of 11 machines in 2 manufacturing companies. The
aspects analyzed included the availability, cost-consumption
of work as well as machine failure rate and the analysis was
performed for two equal periods.
Within the first period the companies were conducting their
manufacturing activities without the use of IOT 4FACTORY.
After this period, they obtained the access to a prototype
under the form of visualization of the work of machines, results
of identification of factors influencing manufacturing efficiency as well as the value of OEE and other KPIs. Basing on analysis, modifications were introduced and as a result the accessibility of machines increased while failure rate decreased
among each machine type. In the first enterprise, in total for
6 machines analyzed, average increase in accessibility
amounted to 2.18% what translates on average into
31 additional minutes of the machine being in operation
during one day. Similar results were observed in the second
Such result gives annually 182 hours of additional operational time for each machine. Assuming that in a given enterprise, annual revenues amounting to $ 50 million are generated
by the work of 50 machines, increasing their accessibility at
the specified level will translate into over $ 1 million of additional revenue per year.
The biggest advantages observed after IOT 4FACTORY implementation were increased efficiency, easier identification of
bottlenecks, better planning of manufacturing tasks and
future investments as well as increased staff awareness.
Currently IOT 4FACTORY is forming part of the offer of the DSR
company, as one of the components of advanced
DSR 4FACTORY solutions for manufacturing companies.
If you would like to know more about DSR 4FACTORY please
visit us during fairs in Santa Clara, California:
Efficient Plant May 2019
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