SEARCHING TO MAXIMIZE EQUIPMENT RELIABILITY?

Tips to Maximize Production, Minimize Emergency Downtime, and Make Your Maintenance and Production Run a Little More Smoothly

While we all know there is no magic wand that can make breakdowns disappear, there are steps we can take to minimize their impact on our work lives and our business.

Below are a few of the most cost-effective steps I have come across in the past twenty–five years in this business:

1. Identify the most critical equipment and have a plan—not all breakdowns are equal.

After all, we don’t proactively change light bulbs unless they are in a critical area, do we? The easiest way to focus on the most critical pieces of equipment (based on an analysis of our production operation) is to eliminate the ones we do not need to worry about.

2. When developing a plan for the most critical equipment, let’s look at all the options.

I once worked with a customer who had rush orders every couple of weeks on different small motors necessary for their operation. Of the five key locations, all five could be served by two relatively inexpensive motors. We developed a plan to provide inventory for the spares (they stocked two, I stocked one), and the “emergencies” were now reduced to an inventory management issue, a much easier task to manage.

By the way, you should know that in studies we have conducted, rush orders are approximately 35–50% more costly than the same repair done on a non-expedited basis. Shifting some of that expense from expediting costs to spares in inventory can significantly enhance production efficiency.

3. For high-cost equipment where keeping complete spares isn’t practical, maintaining specific component parts is a more feasible option.

Many of our clients will keep a spare shaft, impellor, and gear set on the shelf. When unexpected repairs pop up, the issue is rarely with the bearings, lip seals, gaskets, or O-rings. It is almost always the gears, shafts, mechanical seals, etc.

4. Monitor the most critical equipment.

Infrared Thermography — In my opinion, this is one of the best “bang for the buck” technologies you can invest in from a reliability perspective for electrical distribution systems. Two to four times per year, check on the health of your key electrical apparatus. We just recently discovered a heat signature in an overhead bus duct that, if left unattended, would most certainly have caused a failure. Murphy’s Law tells us that would most likely happen at a very inopportune moment.

Vibration and Temperature of Rotating Equipment — The future is here! For years, we have been talking about the ability to permanently monitor the most critical indicators of equipment failure. In the past, that required a certified analyst with data collection equipment. Now, for a relatively modest fee, you can have much of your equipment monitored in real time. The best practice we recommend is to pair these units with a certified analyst to monitor the most critical equipment or areas with recurring issues. This allows you to maximize the spread of your coverage and monitor the most equipment for the least expense.

5. Lastly, the most important piece: Reliability is an action; it does not happen by accident.

The most successful companies review the data as supplied and take action quickly on the repairable conditions discovered! Whether that is scheduling a repair, adjusting an operation, shifting electrical load on an overloaded phase, or listening to the data provided—all are key steps toward driving reliability. At A&W, we are uniquely positioned to assist you with everything from plan design and operations analysis to data collection, reporting, and repair.

Please give me a call at 704-363-3144 or email me at [email protected] to set an appointment for a free analysis of how we can help “Keep Your Business Running”!

Tim Hebert , Owner