Maintenance Technology August 2017 - 14

PLANT PROFILE

you can look at the production
goals for our different systems,"
Durko said. "We must break down
the different processes, look at the
availability requirements for that
equipment, and understand what we
are doing to ensure the equipment
can meet those production goals.
What we did well for many years is
that when it breaks, we are going to
fix it. With an aging facility and with
this aging work force, the challenge
now becomes how to do it cheaper.
How are we effectively managing our
assets? What appropriate programs
do we have in place to ensure that
that equipment will operate when it
is supposed to operate? This is how
we integrate the idea of reliability
across the site."
With a distinct plan and road
map to get there, all the pieces begin
to come together.
"We understand that each milestone is just a piece and not overall
reliability," Durko said. "We now
consider all of the tools in our tool
belt-RCM analysis, PdM technologies, SAP integration, procedural
requirements, etc. Bringing all the
tools together to make the systems
cost effective and also ensure the
safety of our people and equipment
are the ultimate ingredients that will
get us to overall reliability."

Proactive maintenance
The focus in the first year was
building a robust proactive maintenance program, Durko said. "Our
past strategies and mission focus
have caused us to become superb
at finding ways to keep our failing
systems running. We have begun
shifting our mindset."
The Y-12 site averages 2,750
completed maintenance orders each
month, with an average of 99% utility
availability, and has set a goal of 40%
reduction in planning time.
"We are now averaging 64% reduction
in planning time," Durko said. "We are
also proud that we recently reached
50,000 safe work hours with the PMO
program. A bonus result is a 20% reduc-

14 |

MAINTENANCE TECHNOLOGY

Top. A worker wearing protective gear walks down
a hallway in Building 9212. The building's aging
infrastructure and equipment make obtaining
replacement parts for electrical, ventilation, fireprotection, and other systems a challenge.
Middle. Operations at Y-12 are varied and
complex, presenting a wide range of maintenance
challenges.
Above. When Y-12 researchers aren't analyzing
uranium, they are finding new ways to detect
it. This photo is from a project designed to grow
lithium semiconductor crystals suitable for radiation detection, which is the first step in solving a
global shortage of Helium-3, the most common
element used in current detectors.

tion in execution time. That is easy to sell
to customers. Any time you say optimization, you automatically think of cutbacks
and loss of jobs." He added that because
the plant had been in a reactive mode,
they have been able to talk about the
amount of reactive versus proactive work
and actually improve the PM program.
The proactive maintenance strategy
includes condition-based maintenance

using ultrasound and vibration
analysis tools, Durko said. "Also,
document control is a key tool.
We are dependent on what all that
data is telling us to be able to make
our decisions."
With the proactive strategy
taking shape, the next step is
standardization, Durko said.
"Having a repeatable process is
key. We have standardized the
format in a way that the crafts can
better use-they actually helped
us develop the format, so now it's
about execution. Next, we want
to find a way to better rely on our
predictive methodologies and
leverage our technology. Hopefully, the data will tell us what is
the next step. Meanwhile, we are
refining our lubrication program
with ultrasound and honing our
precision-maintenance skills."
None of the improvements made
thus far would be possible without
the interface and support of the
technician work force.

What's next?
The next goal is to increase
condition-based maintenance
work by 15% in the next fiscal year.
"I don't think our road ever
ends," Boudreaux said. "You can
always find a way to be even more
reliable. But if we have that foundation, and we build off of that, then
every time we bring something
in, we can evaluate it against what
we are trying to achieve with
the program and see whether or
not it has value. Having a firm
foundation allows us to do that.
The exciting part is to have some
programs in place and begin to see
the data that tell us it's working." MT

Michelle Segrest is president of Navigate
Content Inc., and has been a professional
journalist for 28 years. She specializes
in creating content for the industrial
processing industries. If your facility
has an interesting maintenance and/
or reliability story to tell, contact her at
michelle@navigatecontent.com
AUGUST 2017



Table of Contents for the Digital Edition of Maintenance Technology August 2017

Editorial
Uptime
On The Floor
Reliable Security, Reliable Operations
Highly Charged Reliability
Drowning in Data? Look to the 'Stars'
Reliable Pumping Supplement
SAP: Tips and Tricks
Steam-Trap Inspections
Saving Tribal Knowledge
Seats for Butterfly Valves
IIoT
ISO 55000
Understand Lube ID Systems
Tomato Processor Boosts Steam Output, Cuts Emissions
Products
Ad Index
Showcase
Final Thought
Maintenance Technology August 2017 - 1
Maintenance Technology August 2017 - Cover1
Maintenance Technology August 2017 - Cover2
Maintenance Technology August 2017 - 1
Maintenance Technology August 2017 - 2
Maintenance Technology August 2017 - 3
Maintenance Technology August 2017 - Editorial
Maintenance Technology August 2017 - 5
Maintenance Technology August 2017 - Uptime
Maintenance Technology August 2017 - 7
Maintenance Technology August 2017 - On The Floor
Maintenance Technology August 2017 - 9
Maintenance Technology August 2017 - Reliable Security, Reliable Operations
Maintenance Technology August 2017 - 11
Maintenance Technology August 2017 - 12
Maintenance Technology August 2017 - 13
Maintenance Technology August 2017 - 14
Maintenance Technology August 2017 - 15
Maintenance Technology August 2017 - Highly Charged Reliability
Maintenance Technology August 2017 - 17
Maintenance Technology August 2017 - 18
Maintenance Technology August 2017 - Drowning in Data? Look to the 'Stars'
Maintenance Technology August 2017 - 20
Maintenance Technology August 2017 - 21
Maintenance Technology August 2017 - 22
Maintenance Technology August 2017 - Reliable Pumping Supplement
Maintenance Technology August 2017 - 24
Maintenance Technology August 2017 - 25
Maintenance Technology August 2017 - 26
Maintenance Technology August 2017 - 27
Maintenance Technology August 2017 - 28
Maintenance Technology August 2017 - 29
Maintenance Technology August 2017 - 30
Maintenance Technology August 2017 - SAP: Tips and Tricks
Maintenance Technology August 2017 - Steam-Trap Inspections
Maintenance Technology August 2017 - Saving Tribal Knowledge
Maintenance Technology August 2017 - Seats for Butterfly Valves
Maintenance Technology August 2017 - IIoT
Maintenance Technology August 2017 - ISO 55000
Maintenance Technology August 2017 - Understand Lube ID Systems
Maintenance Technology August 2017 - 38
Maintenance Technology August 2017 - 39
Maintenance Technology August 2017 - Tomato Processor Boosts Steam Output, Cuts Emissions
Maintenance Technology August 2017 - 41
Maintenance Technology August 2017 - 42
Maintenance Technology August 2017 - Products
Maintenance Technology August 2017 - 44
Maintenance Technology August 2017 - 45
Maintenance Technology August 2017 - Ad Index
Maintenance Technology August 2017 - Showcase
Maintenance Technology August 2017 - Final Thought
Maintenance Technology August 2017 - Cover3
Maintenance Technology August 2017 - Cover4
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