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315 views5160 Guide Asset Efficiency Optimization
5160 Guide Asset Efficiency Optimization
Uploaded by
karthimeenaCopyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
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/ 60
& K SKF Reliability Systems
The Guide to
Asset Efficiency Optimization
for Improved Profitability
“The most valuable assets of a 20th-century company
were its production equipment. The most valuable
asset of a 21*-century institution, whether business
or non-business, will be its knowledgeable workers
and their productivity.”
Peter Drucker
Management Challenges
for the 21 Cenuury / Information »
Reliability Centered /
Maintenance (nem) /, 4, { Foundation |
a ee / oN Strategy/
aintonange RCM / \ feevere
|
Quick Start 60% Macea))
Reliability (QS) / \ ——
Maintenance
Automation
Total Operator
Productive Sriven |
Maintenance | retabatiy
crew} | “opr” |
A conceptual representation Decision
of an industrial maintenance process. Support
System
| @ssy |
Correct / Improve / Optimize SKF
SKF Reliability Systems .....
Beyond the Bearing ......... ey mae
The Reliability Maintenance Challenge
Reliability Focused Maintenance.
Emerging Strategies ..
Maintenance Maturity
The Financial Impact of Asset Efficiency Optimization (AEO)
Critical Factors for Success ..
Summary of Capabilities
The AEO Process
Assessment
Client Needs Analysis
Maintenance Strategy and Engineering
Proactive Reliability Maintenance (PRM) ..
Operator Driven Reliability (ODR) ...
Managing and Applying Knowledge
Advanced Decision Support
Machine Maintenance
Machine Improvements..
Supply Process si
Training
Integrated Maintenance Solutions 32-83
An Integrated Platform for AEO 34-35,
e-maintenance. 96-97
AEO Technology Solutions
Condition Monitoring for Proactive Reliability Maintenance
Reliability Tools
SKF Technology Inside the Machine
Real Conditions, Real Solutions
Integrated Solutions for Complex Data Management ..
Maintenance Strategy 7 .
Machine Reliability Assessment—A Fan Solution
Operator Driven Reliability (ODR) ..
Integrated Maintenance Solution (IMS)
SKF Reliability Systems—Global Locations SKF Reliability Systems
Transforming asset management into a competitive edge
Achieving asset efficiency is a significant challenge
Optimizing the efficiency of equipment has a significant
impact on profits—and shareholder value. It affects
productivity and qualty. In some cases, it may even
Getermine a company's abilty to compete, or survive.
Corporations that focus on overall equipment efficiency
find that they can add capacity without large capital
investments.
Very often, management is aware of the significant benefits
that can be achieved from a well run asset management
program. However, in some organizations, actually
achieving asset efficiency can present a major challenge,
Few companies have the resources or expertise to
implement the rapidly developing new technotogies,
processes, and cultural changes that are so important to
achieving timely, long-term success. Many begin the
process but are hindered by an incomplete strategy
or insufficient planning or benchmarking, The result is
inefficient utilization of capital and maintenance resources,
and uitimately, faliure to achieve atticiency objectives.
‘SKF can help you optimize asset efficiency
to increase profitability
‘Typically, machine and component manufacturers stand
at the forefront in developing and implementing new
technologies. SKF for example, has traditionally invested,
significantly in research and development, and is
committed to the application of new technologies
and materials to enhance the design and quality of our
products.
‘Today, reliance on supplier expertise is often recognized as,
‘one of the most practical and cost-effective means to
enhance internal competencies. SKF enables customers to
benefit from nearly a century of experience in developing
‘solutions for optimizing machine and process performance.
‘Through the business area called SKF Reliability Systems,
SKF offers unique and highly effective methods to help
corporations improve asset efficiency and manage
maintenance costs more effectively
‘The Asset Efficiency Optimization concept
SKF's Asset Efficiency Optimization (AEO) concept picks
Up where plant asset management programs typically
stop, AEO enables a plant to increase production while
maintaining or even decreasing costs. It is @ system of
‘organizing and applying assets—from personnel to
machinery —bringing knowledge and technology together
to achieve the greatest return on investment. By applying
‘the power of SKF's technology and service solutions, you
can benefit from a program which assists in achieving your
‘organization's overall business objectives. These include
reduced costs, greater productivity, better utilization of
resources, and as a result, increased bottom line
profitability.
SKF Beyond the Bearing
Improving machine and process performance
‘The bearing is the heart of the machine
From huge roling machines to the smallest motors, if
there's a potential problem with the equipment, the bearing
“knows.” As the key interface between moving parts, the
bearing is literally the diagnostic heart of the machine:
misalignment, unbalance, looseness, and friction are all
‘telegraphed through the bearing. Understanding the
information coming from this diagnostic pulse, and then
applying the latest and best technologies to correct or
avert a problem, is critical to raising machine productivity
and lowering operating cost,
SKF expertise extends far beyond bearings
‘AS a world leader and innovator in bearing technology
since 1907, SKF has developed a unique understanding of
‘not only how a bearing performs in an appiication but an
intimate knowledge of machine components, systems and
related processes —allowing us to create and provide
realistic solutions for optimum machine and process
rellabilty and productivity,
‘The evolution of SKF machine knowledge over nearly a
century has enabled the company to become a leading
supplier of condition monitoring and maintenance
iagnostic systems, hardware and software. These tools,
and the knowledge of how to best use them, enable us
‘to monitor operations and identify problems.
Our experience includes virtually every industry
Close working partnerships with customers worldwide
have provided SKF with an extensive knowledge of
applications in virtually every industry. As a result, we have
learned to apply the most relevant of today's emerging
technologies to industry-specific applications.
SKF
You can benefit from SKF’s advanced
capabilities in manufacturing and research
SKF is taking the underlying competencies that have been
behind our product success, and putting them ‘in front’ of
‘our customers. We view our manufacturing and research
capabilities as ‘portable’ expertise that can be transferred
to other manufacturing operations—enabling you to
benefit from our success.
‘SKF offers comprehensive solutions
'SKF's near-century tradition of excellence in bearings and
machine reliability has evolved in response to industry
need. Through SKF Reliabiity Systems we now provide a
single source for a complete productivity solution. Our goal
is to help reduce total machine related costs, enhance
productivity and strengthen profitability. m The Reliability Maintenance Challenge
Creating shareholder value through enhanced factory efficiency
Increasing productivity means building more
factories. Yet, one of the biggest opportunities today for
creating profits, positive cash flow and, ultimately,
shareholder value is through improved factory efficiency.
In fact, capitalizing on improved efficiency—as measured
bby Overall Equipment Efficiency (OEE)—may reveal the
bottom line equivalent of a new factory “hidden” within
‘many companies today.
Achieving optimum reliability is essential to maximizing
OEE—and maintenance plays a critical role in meeting
reliability targets. Reaching these targets, however,
requires a shift trom tracitional maintenance activity,
which is reactive and functional, to a proactive process.
that is fully integrated into overall plant activity.
SKF Reliability Systems is uniquely qualified to construct,
‘a comprehensive, customized change plan for the
‘maintenance organization that is ready to be transformed
from a cost center to a profit opportunity. Our seasoned
asset management “pragmatists” work in true
partnership with our clients, sharing risks as well as
benefits in the quest to achieve optimum OEE. SKF
works with clients to develop effective maintenance and.
asset management strategies and helps companies
transition to even higher levels of efficiency. From
streamlined analysis services to factory floor automation
tools, SKF Reliability Systems has the breadth and depth
to help its clients make practical, lasting changes with
significant financial benefits.
In today’s economic environment, shareholders are taking
a closer look at how companies manage asset efficiency.
Wherever you stand, whatever your goals, SKF Reliability
‘Systems can help you enhance productivity and value.
The results could have a very positive effect on your
company's financial spreadsheet.
(Our experience in the area of Asset Efficiency
Optimization isnot just limited to the successes we have
helped our customers achieve. As the leading bearing
supplier with 80 factories worldwide, we have learned
how to optimize asset efficiencies to have an impact on
our own bottom line—regardless of market conditions.
‘The bearing industry is an extremely competitive market
driven by the classic commodity supply model where the
cost of production is one of the main determinants of
company profitability. The profitabilty and financial
stability of SKF demonstrates that employing the Asset
Efficiency Optimization process isa viable route to
increased shareholder value.
SKF Reliability Focused Maintenance
Shifting maintenance practices from reactive to proactive
Developing a reliability-focused maintenance program
is an ongoing process that begins with determining
where your reliablity and maintenance practices lie in
‘the range of reactive to proactive maintenance, and
then adjusting them to improve efficiency.
While in theory, this process is complete when you
achieve optimum efficiency, in reality the process is
ever finished. A successful program is dynamic in
nature, incorporating and retaining the most efficient
mix of reactive, preventive, predictive, and proactive
maintenance, as well as measures enabling
operator driven reliability.
‘The goal, of course, is to optimize plant efficiency
by shifting as much as possible from traditional,
corrective activities to a fully integrated, proactive
approach to reliability.
‘There are a wide range of scenarios to be considered,
depending upon where your maintenance program is
in the range, and what your business goals are.
‘The chart below illustrates the range of maintenance
Practices. A business-supported dynamic blend of all
Of these will generate the best results,
Operator Driven Reliability (ODR)
Frontline operators are empowered to ‘own" their
machinery. They identify, describe and communicate
‘machine information to the plantwide team to keop
machinery up and running,
Proactive Reliability Maintenance (PRM)
Predictive maintenance is applied to help identity
the root causes of machine and process problems;
machines operate with virtually no unplanned shutdowns;
‘Mean Time Between Failure (MTBF) on machines and
‘components is significantly increased.
Predictive Maintenance (PdM)
Machine condition is assessed using condition monitoring
technologies; shutdowns are scheduled based upon machine
problems which are identified using sophisticated vibration and
condition monitoring equipment; unplanned shutdowns are
significantly reduced,
Unplanned and planned shutdowns are scheduled to overhaul equipment
at pre-determined intervals; mainienance efforts are not based upon an
assessment of the machine's condition while it operates.
e@— Reactive/Corrective
Fixit when it breaks approach; unplanned shutdowns occur when the machine
breaks.
SKF m Emerging Strategies
Aligning your reliability maintenance strategy with your business goals.
A
JM Preventive Maintenance
Pe ape Lubricate
/
J Repak Ar Fare
/
Maintenance Efficiency
V Historic Development
In the 1960's, it was common practice to wait for
equipment to fall, and then repair it—known today as
“firefighting.” Generally speaking, management regarded
maintenance as a necessary cost of doing business.
Over the decades, this standard way of working—
and thinking—began to change. During the 1970's
‘most plants had some kind of preventive maintenance
program. By the 1980's, the best run facilities were
employing predictive maintenance strategies and, by the
1990's, diagnostic tools and software were providing
maintenance personnel with machine condition
information that would have been unthinkable a
‘generation earlier
~ Reliabiity Engineri
Felanity Gertered Mantenance RCM)
AE Root Cause Diagnostics,
a
_-SE~ Concurrent Engineering
al tite Cycle Costing (LCC)
=
AB Operator Maintenance
Sal Proauebve Maintenance (TPM)
PX rete ebonence
/
ML systematic Planing & Scheduling
>
‘Today, itis clear that maximizing the efficiency of a plant
and its equipment requires a shift from traditional —
or repair focused—maintenance activity, which is both
reactive and functional, into a proactive maintenance (or
reliability and risk focused) process that is fully integrated
into overall plant activity.
The evolution of predictive to proactive and the
integration of industrial decision support systems can
often complete the transformation of maintenance from
cost center to a profit center.
SKF Maintenance Maturity =
Moving through four phases to achieve world class efficiency optimization.
In an ideal world, every plant could make use of all the
best new technologies for enhancing machine reliability.
In reality, this is not possible.
Why? Because many techniques and technologies are
appropriate only for plants that have reached a specific
stage of maintenance maturity, and that have the
necessary culture and processes in place.
Other practices, ideal for facilities in the early stages of,
matulity, offer little additional value to plants that are in
the advanced phases of asset optimization.
oo “The graphic above ilustrates the drivers, rewards
. Tee Seterors expatonedd by n plat as Kris
through the four phases of maintenance maturity
ow firefighting, maintaining, promoting and innovating.
‘The first step toward the goal of improved asset
efficiency optimization is to accurately identify
your plant's current situation and then construct
and implement a program to achieve the
optimum level of maintenance maturity.
SKF 7 m The Financial Impact of AEO
Adding shareholder value through Asset Efficiency Optimization
Improved asset efficiency and reliability can have a direct A more sustainable reduction in cost of goods sold is
impact on a company Statement of Income in three achieved if maintenance processes are designed to take
distinct areas: into account the enti ife cycle costing of the asset.
‘A maintenance process improvement can be targeted to
(a) Cost of Goods Sold reduce the level of unnecessary and preventable work and
(6) Cost of Capital can often mean doing less maintenance just as much as
alan crtaee tieonih kngroved itcould mean doing more. The key isto optimize the
fred ayia ates arti process so the right amount of maintenance is done at
the right time and for the right reason. The result will be
wi os 2 measurable improvement in cost of goods sold.
Increase in Income
Because the expense of maintenance is accounted for a5 _(b) Reduction in Capital
a part of the cost of goods sold, itis often a tempting Effective application of maintenance strategy and
target for reduction. However, if the impact of asset practices has been shown to reduce the need for capital
reliability and risk are not properly recognized, history has by improving the reliability of existing assets and
shown that short term savings will need to be repaid extending asset life. This reduces the amount of capital
‘multiple times in the following years to regain the ability to tied up in assets overall including spare equipment and
produce. Pars inventories and has a significant influence on
Economic Value Added (EVA). It also can have a very
The Wall Street Journal reported that for several huncred significant beneft of alowing the postponement of
companies that engaged in cost cutting through layoffs or investment of new capital due to improved utiization of
downsizing over a period of about five years: existing assets.
+ Only 33% showed profit improvement
+ Only 50% showed productivity improvement
++ 88% experienced a serious decline in morale
(c) Asset reliability improves
every aspect of OEE,
1
(2) O&M costs are calculated in the
cost of goods sold. Improvements impact
> the operating profit component of EVA.
(0) Improved asset reliability
reduces amount of capital needed,
é SKF Overall Equipment Effectiveness (OEE)
‘Excess Capacity,
orton rae | >
f—___Eavipment Fate h ta |
— Setup & Adjustment
_
J
(c) Increase in Sales
Another direct contribution to profitability can come from,
producing more with the same assets or producing at
the same level with fewer assets. The most direct way
to calculate this level of asset reliability is through the
measurement of Overall Equipment Effectiveness (OEE).
Improvements in OEE are an indication of an increase in
asset reliability. A more reliable asset will make more
products available for sale by:
‘* Being available to produce reliably when needed.
'* Producing at a higher run rate or for
longer periods of time
‘+ Producing more products within the required
standards for quality and consistency.
SKF
However, to simply “improve” the efficiency of
an asset is an open-ended target and will at some point
‘bring a diminishing return. The term “Asset Efficiency
Optimization” means what it says: fo achieve an
optimized level of asset efficiency. The decision about
‘which level is correct for your firm should be driven by
the overall business strategy of your company. Linking
this strategy to an appropriate maintenance strategy
land supporting it with a suitable blend of maintenance
processes and practices can create profit opportunities,
that would otherwise be overlooked. M Critical Factors for Success
10
Achieving Asset Efficiency Optimization requires balance
‘The experience gained by SKF Reliability Systems in real
‘world conditions in a wide range of industries shows that
achieving competitive productivity and increased
profitability through machine asset management depends
on a balance of key factors:
* Corporate culture - It is important to have a culture
that is willing to emibrace change. With regard to improving
reliability, the required changes may involve the shifting
Of responsibilities among plant personnel. This means
‘a company must be willing to invest the time and energy
to re-train employees and bring them emotionally and
intellectually into the culture.
‘Technology ~ Successtul
‘companies use
technology as a tool to
facilitate
improvements
in products and
productivity. In
addition, they
commit the
financial,
‘educational, and
personnel resources
necessary to make the best
use of new and emerging
technology initiatives.
‘= Processes — To be most effective and to achieve long-
lasting results, technology must be supported by updated
and enhanced processes. In the case of machine asset
‘management, incorporating new technology into the data
collection, knowledge management, and decision making
processes is critical to achieving success,
Logically, each process connects to or has a relationship to
others, so the health of one area affacts the overall system.
(Our experience has shown that most companies have
‘one or more maintenance programs in place. tis actually
2 rare situation where these are integrated into the overall
plant activity, and thought of as a strategic component of
the enterprise.
Viewing reliability maintenance from the asset management
standpoint means that all improvements are important, and
can be made at any and all levels of the plant. Whatever
your current machine asset management
strategy, SKF Reliability Systems
hhas the knowledge to help you
‘identify the areas that can be
improved to help you
meet your company’s
business objectives,
The chart on the
opposite page
summarizes the
capabilities of SKF
Reliability Systems—
from initial assessment
to full Asset Efficiency
Optimization. Page numbers
accompanying each heading indicate where
‘you will find adaitional information about these subjects
in this brochure.
SKF Summary of Capabilities
The Asset Efficiency
Optimization (AEO)
process
‘See pages 12-13.
* Glent Howes Assessment
+ Machine Reliability Assessment
+ Maintenance Strategy Ravow
+ Operating Unit ASsessment
+ Rlisblty-Centered Maintenance (RCM)
+ Streamlined Relabilty-Cener Maintenance (SRCM")
+ Risk-Based Maintenance (RBM)
+ Cicaty nals
+ Quick Star Reity
+ Planned, predictive and proactive maintenance provedures
+ Process Dacuertation
‘MMS structure and implementation
+ Spare Pats Algnment Rationalization
‘and Optimization (SPARO)
SKF service
capabilities are
available in a variety
of forms to meet the
‘most unique
requirements. All of
the capabilities
shown in this
section are offered
to support the AEO
process described
on the next page.
tig * tn EES” pte ome
“Pregiane mameance | [Prison algonet | | «Tovbe-tee spy | | +Mectie wnrade,
‘ea ‘Precio banca | | ce-swray i a Sign
=a ean “Lanaton ‘econ + Design nginesing
anes anager’. '* Spare Parts Alignment ‘Technology upgrade
‘Condition monttoriag . caine ai ‘Rationalization ano 7 Somponents
ST aniis analyst ptmzaton (SPARO) | | SIS ond
“Uestor Maas | | * Being instalation, “ety
= eon ‘menvnane snd
= Opentng Detection + Postminenanee
pe Analysis ‘+ Maintenance tools testing
Operator Driven
atbiy
+ Main Sagnostes
+ rouge
‘manapetrent
+ Deion Support
Sytem
“Machine Readily
+ Condition mentoring
= Vibration analysis
+ Application spect
tring
+ Libation
‘management
- Beating aplication
+ Bering maintenance
+ Asset management
eter to pepe 3
SKF
u The AEO Process
A process for translating asset knowledge into bottom-line value
‘A key aspect of any world-class asset management
program is a proactive, efficient work management
process, designed to ensure the effective performance
Cf maintenance on critical assets. To achieve maximum
return on investment and maintain the greatest degree of
productivity, it is pivotal that organizations have a process.
that effectively translates asset information to knowledge,
and ultimately gain value from that knowledge.
‘To help organizations achieve these goals,
SKF offers Asset Efficiency Optimization (AEO), a
‘management process designed fo achieve maximum
efficiency and effectiveness from work management
activities focused on business goals for the facility,
‘The AEO process encompasses four key elements:
Strategy, Identification, Control and Execution. Within
each of these elements, the coordination and participation
of three essential factors within the organization—process,
culture, and technology—is paramount to the overall
‘success of the AEO process.
Maintenance Strategy involves the evaluation of work
activities in relationship to a facilty’s business objectives,
‘a procedure that creates the documented basis for the
‘maintenance program,
Work Identification is where “work is identified from the
‘evaluation of a comprehensive flow of data in conjunction
with an integrated decision-making process. Key to the
‘success of Identification is a comprehensive CMMS
(Computerized Maintenance Management System).
Work Control involves establishing procedures for
planning and scheduling the work identified by the CMMS.
‘Tasks are organized based on several parameters,
including time and condition; job plans or procedures;
man-hours required; data feedback; special requirements;
and many other factors,
Work Execution is where identified, planned and
‘scheduled work is performed. Once work is completed,
feedback from the field plays a key role in measuring the
overall effectiveness of the AEO process and making
refinements for even greater efficiency in the future.
‘The AEO process transforms conceptual asset
management to tangible competitive edge. SKF can help
plan a course of action to align your reliability and risk
focused maintenance strategy with your organization's
business objectives. Our team will help correct known
problems, and will then work with you to assess and
identity additional opportunities for improvement in the
areas of production, safety and environment.
SKF Asset Efficiency Optimization—
Work Flow Process
Maintenance
Strategy
Work
‘ja becten hin
Work
Control
Work
Execution
‘Maximum return is achieved when all parts of the process are implemented; however,
customers can focus on first one area then another in progressive stages.
SKF Assessment
4
Identifying the problems—when, where and how they matter
‘The most common reason for the failure of an asset
‘management change initiative is the failure to establish if
there really is a problem—and when, why and how it
‘matters. Planning a shift to an integrated reliability and
risk-based asset management strategy starts with a deep
understanding of where you have been, where you truly
are today and where you really need to go.
‘The purpose of an assessment is to gain this
understanding and then to use it to put together a
detailed, structured improvement plan that includes.
realistic, achievable, and necessary actions. To achieve
and measure success, there must be clear and objective
documentation of what the AEO process is intended to
accomplish.
Work
Execution
Work
Control
Innovating
Promoting
Maintaining
This is the
Identification
Fire Fighting
Every assessment is unique
‘We make sure that we clearly understand a client's needs
before recommending the type, depth and complexity of
the assessment.
‘Assessments vary from a three-hour facilitated Client
Needs Analysis to situations where we deploy multiple
subject matter experts at the client’s site for periods of
four to five days.
‘The Client Needs Analysis can be completed in just a few
hours and asks 10 assessment questions for each of the
four main facets of the AEO process: maintenance
strategy, work identification, work control, and work
execution. These 40 questions are designed to
investigate, quantify, and visualize the situation at your
‘acilty. Results are displayed in a graphical “spider chart*
format which provides a visual footprint of a particular
plant's assessment in accordance with international
standards/models of business excellence.
Maintenance
Strategy
assessment result.
SKF Each assessment is conducted via a standardized and
proven process that uses our detailed AEO model as a
baseline from which to work. At a practical level,
assessments can use purely quantitative
(discrete/numerical approach), purely qualitative
(descriptive/questioning/interview approach) or a
composite approach.
Skilled assessment teams
‘Our assessment teams are made up of specialists selected
for their knowledge and understanding of your specific
industry, type of plant, and the equipment it uses. Their job
is to interview plant personnel to collect information that
will be used to pinpoint problem areas, and serve as a
benchmark for improvements. They will lso provide
recommendations for streamlining processes and
implementing the most cost effective practices.
The Quick Start Reliability Program
‘SKF typically offers the Quick Start Reliability program
to facilties that are organized in a classically reactive
structure or hierarchy, and so often have absent or sub-
optimized maintenance/reliability engineering capabilites,
The program can provide a basic first step in the
evolution towards using the complete AEO process.
The Quick Start Reliability program is:
1= Targeted to those clients that are in the lower maturity
phase (firefighting) in the maturity pyramid.
= Designed to establish a maintenance process where
none exists or is sub-standard,
'= Focused on the first 90 days of the overall change
management plan for maintenance,
SKF
= Geared to quickly put a performance management
culture or process in place.
= An 8-step process that identifies a plant's best “early
wins” and implements @ program to achieve them.
‘= Built around performing the right work at the right time
in the right way—on equipment that is business
critical
= The best course of action when a plant has neither the
time nor the funding to conduct a comprehensive
maintenance strategy review. m Maintenance Strategy and Engineering
Setting a course for success
‘Maximizing the efficiency of a plant and its machine
assets requires a shit from discrete maintenance
activities to a strategic process that is embraced
company-wide.
Properly structured and implemented, a well thought-out
maintenance strategy transforms maintenance from a
cost to a profit center.
‘A comprehensive maintenance strategy is likely to employ
‘a number of techniques working to support each other.
Choosing the right technology tool, or combination of
tools, requires a sound understanding of the plant and
the relative data that may or may not be available.
SKF Reliability Systems has assembled a formidable
body of expertise in the field of maintenance engineering
and employs seasoned asset management pragmatists
who are skilled at developing and executing strategies
based on their knowledge and a real world understanding
of all current maintenance techniques.
In addition to more than 15 years in the business of
reliablity maintenance, SKF Reliability Systems also
has acquired several firms recognized in the field of
‘maintenance engineering to complement our capabilities
with in-depth first-hand knowledge and understanding
of reliability issues.
With this knowledge and experience, we are able to
identify what is truly needed for each client and then
create a maintenance strategy which most effectively
combines the right technologies to meet those needs.
The following is a brief discussion of the most commonly
applied maintenance techniques:
RCM ~ Reliability-Centered Maintenance
This is often recommended for equipment where
criticality is high and confidence in existing maintenance
is low. The role of RCM in most cases is to provide a
defensible base for specific equipment where there is
limited knowledge and history. While RCM can be quite
effective for reliablity improvements in specific areas, in
{general itis inappropriate for the rest of the plant. This
aspect of RCM has led to the development of other
similar maintenance techniques which are more
appropriate on a plant-wide basis.
‘SRCM?-
Streamlined Reliability-Centered Maintenance
‘This enhanced version of RCM focuses on the dominant
failure modes of equipment and the significant effects of
those failures such as production losses, personnel
safety, environmental releases, etc. A key benefit of an
SRCM program is developing the understanding of plant
personnel on the value of a modern-based maintenance
strategy. As such, SRCM Is particularly appropriate where
‘a major change in the maintenance culture within the
enterprise needs to be made, which also makes it a good
‘option for new builds.
RBM - Risk-Based Maintenance
This is @ financially based analysis technique which
focuses on establishing the relative worth of
maintenance. It was originally developed as a means of
reviewing existing maintenance programs, and in this
mode it works well as a continuous improvement tool.
RBM defines opportunities for incremental improvement
through the elimination of tasks of low value and the
introduction of tasks which address high commercial risk
areas. As such, RBM is also valuable in transferring
knowledge from existing installations to provide a
baseline for new builds.
SKF Typical Maintenance Strategy Model
== $f
+, Planned Maintenance:
Continuous Run to Fallure
SKF a M™ Proactive Reliability Maintenance (PRM)
A process to achieve the best possible return on plant assets
‘SKF Proactive Reliability Maintenance addresses failures and
implements the processes necessary to prevent recurrence. At the
foundation of the process is a systematic method to benchmark
asset productivity and implement corrective actions that will
reduce total life cycle costs. In short, it enables an organization to
take complete control over what is happening on the piant floor.
While traditional Predictive Maintenance (PdM) processes form a
sustained maintenance loop, the PRM process forms a continuous
improvement loop.
‘The SKF Proactive Reliability Maintenance process is based on
four key steps:
1. Predictive Maintenance
Predictive Maintenance (PdM) is a process aimed at detecting
‘@ machine condition that will eventually lead to failure and then
estimating the amount of time before failure occurs. To do this,
sophisticated condition monitoring technology is used to gather
data such as machine vibration, thermography, lubricant condition,
motor current analysis, process parameters, etc.
While most PdM programs stop at detecting a problem and
making a residual life prediction, SKF uses this information as the
basis to diagnose the problem with the objective to determine
which proactive tasks are necessary to achieve an extension of
machine life
Prodictive
Maintenance
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SKF 2. Diagnostics and Root Cause
Failure Analysis (RCFA)
‘SKF Reliability Engineers use applied knowledge
and its accumulated experience to diagnose
collected data. This may lead to the
recommendation for actions such as precision
alignment, precision balancing, alterations in
lubrication management, redesign of machine
or critical components, etc.
‘To complement the knowledge derived from the
diagnosis of data, detailed machine and component
diagnostics are conducted on site, or at a centralized
‘SKF Reliability Systems center. Damaged or failed
‘components undergo a thorough Root Cause Fallure
‘Analysis (RCFA). This information is used to prevent a
recurrence of the problem or, if required, to assist our
(OEM partners in a redesign of the machine.
3. Key Performance Indicators
Key Performance Indicators (KPIs) are performance
improvement targets established jointly between plant
‘management and SKF. They can cover a range of factors,
such as unplanned mechanical downtime, quantity of
product manufactured, plant efficiency, maintenance costs,
and bearing performance. KPIs are also used to determine
the number of personnel needed to maintain asset
performance, and what qualifications those individuals
need in terms of specific skils (e.g. lubrication, mounting,
alignment). Where possible, once a KPI is achieved, a new
target is set to facilitate continuous improvernent.
4, Operational Review
‘Achievement of Key Performance Indicators is monitored
through a periodic review of the total PRM program.
Results are documented and presented at performance
review meetings between plant management and SKF
Reliability Systems. These meetings also help to assure
that the process is continually refined to achieve the best
asset performance and PRM process activity cost.
SKF
‘An effective decision support system further enhances the
PRM process, allowing for information and data that is
captured throughout PRM to be fully utilized in decision-
making processes. The decision support system facilitates
efficient organization and presentation of data, interprets
data based on user-defined parameters, and then provides
recommended actions for maintenance and operations.
‘A wel-implemented and managed Proactive Reliabilty
Maintenance process is the most effective method of
managing risk, increasing reiabilty and ensuring the best
possibie return on plant assets. Depending on your needs,
‘SKF can design, implement and manage the process for
your entre plant or specific sectors, and supply all
necessary hardware, software and technical resources.
For those who wish to run the process on their own, we
‘can provide consulting services and the technologies
necessary to initiate and manage the process.
9 ™ Operator Driven Reliability
Making operations part of your reliability maintenance strategy
‘The relationship between operations and maintenance is,
an under-exploited opportunity in most companies today.
‘The reasons for this are usually organizational, cultural or
historic. Even in firms where a healthy relationship exists,
the interaction process between the two departments can
be improved. Trend-setting firms have realized this and are
embracing a strategy called Operator Driven Reliability
(ODR). ODR is built upon the following main concepts:
Operators are critical to asset reliability
Being in close proximity to the machines—24 hours a day,
7 days a week—operators are often the first to notice even
the smallest changes in machine condition. What they do
with this information can mean the difference between
machine failure and failure avoidance. ODR provides a
process to turn early detection of developing problems into
prompt corrective actions.
Shared ownership of assets
Most companies are being asked to produce more
with fewer personnel. ODR creates a culture of shared
ownership that leads to a greater contribution and a
higher level of job satisfaction for operations personnel.
Operations is responsible for process reliability.
Maintenance is responsible for asset reliability. Together
they can generate improvements in process availabilty
Maintenance Operations
Gelvers equipment delivers process
reliability >
Maintenance Technology Tools Bearings SKF e-maintenance 36 Enabling Proactive Maintenance Reliability via the Internet Management of a predictive maintenance program can be a challenging task due to the amount of data acquired and the time required to reduce it into meaningful information. In some facilities, the personnel who collect, machine data are also required to perform the analysis. This leaves litte time to focus on corrective actions and ‘work order follow-up. It then becomes impractical to ‘evolve from PdM into a full Proactive Reliability Maintenance program. ‘SKF has developed a solution for this cilemma called ‘e-maintenance, which uses web-enabled technology and integrates SKF Machine Analyst data management and analysis software; the @piitude” Industrial Decision ‘Support system; and the Microlog" portable vibration ata collector. The entire process is managed by a group cof experienced SKF reliability engineers. The result is a complete analysis process built upon proven techniques that support your existing infrastructure, And your PGM program begins to evolve into a true PRM program, For companies that do not have a PdM program or have trad trouble in maintaining one due to lost expertise or investment limitations, the SKF e-maintenance process ‘can be used to run your PdM program at one facility. rit can also be used to standardize on PdM processes across multiple facilities. SKF can manage the entire ‘e-maintenance program for you or put together the infrastructure as a turnkey system for your company to run itself. Benefits of an Internet-enabled e-maintenance solution from SKF: 1 Remote monitoring 24/7 Data collected via portable or on-line surveillance devices at remate locations can be uploaded to the ‘SKF Diagnostics Center for analysis and reporting. = Centralized data repository Historical data from all locations is easily accessed by all responsible personnel. Reports are generated centrally and distributed to local workstations electronically. = Better informed field technicians Maintenance and operations have access to more complete and timely data, w= Efficiency and consistency Data is managed more efficient, and in a consistent manner throughout an organization. mized investment A centralized location eliminates the need for redundant analysis centers, saving on hardware, software and manpower. 1 Savings through outsourcing Users may choose to use the SKF Diagnostics Center; supported by SKF reliability experts and a dedicated web server. SKF SKF Diagnostics Center ees a ee Maintenance Technician Bees Data Routes il ae. . Reports Plant ‘An example of e-maintenance at work (1) From a central SKF Diagnostics Center, a data Collection route is sent electronically to the laptop computer of a technician in a remote location. (2) The information is downloaded to a Microlog portable data collector. (3) Once collected, ‘machine vibration or process data is (4) uploaded into the remote PC and then (6) sent electronically bback to the SKF Diagnostics Center where its displayed, analyzed and stored in SKF Machine Analyst software. (6) Using the @ptitude system, an SKF analyst generates reports or work order requests which are sent to the customer along with the supportive data. This information is also posted to a web server for future reference by the customer. ‘The SKF Diagnostics Genter provides the data repository. 7 m AEO Technology Products Condition monitoring for Proactive Reliability Maintenance (PRM) Accurately interpreting what data means is more effective when the hardware and software used can also analyze, then seamlessly blend It with other systems. As the world's largest supplier of condition monitoring products, SKF offers ‘everything from simple hand-held devices to plant-wide protection systems. Portable vibration analysis for predictive maintenance programs The Microlog® family of vibration analyzers and data collectors incorporate a ‘comprehensive range of features ideal for walk around condition monitoring. Selected products include on-board smart diagnostic wizards, single or two channel capability color screens and intrinsic safety for industries with hazardous/gaseous environments. All Micrologs are supported by the SKF Machine Analyst Data Management and. Analysis software and seamlessly integrate with the @ptitude” Industrial Decision ‘Support system. Portable systems for Operator Driven Reliability ‘The MARLIN?® system automates the machine inspection process and builds a technology and communications bridge between the operations and maintenance functions. MARLIN collects, stores, analyzes and reports on vibration, process and inspection data, providing information needed to take proactive measures to improve machine and process reliability. The MARLIN family includes a range of rugged PDAS that operate with Microsoft® Pocket PC, is supported by SKF Machine Analyst Suite and integrates with the @ptitude system. ‘Surveillance systems for 24/7 on-line machinery monitoring Continuous monitoring systems alert operations personnel to important changes in machine condition before they result in unexpected downtime, They also enable vibration analysts to spend less time collecting data and more time identifying the root causes of machine problems, SKF's surveillance family includes the Multilog® ‘and MasCon lines—each designed for specific applications and supported by data management and analysis software including SKF Machine Analyst and ProCon. Both integrate with the @ptitude system, Critical machine protection and diagnosis ‘The SKF range of API compliant machinery protection systems can be easily extended to include condition and performance monitoring capabilities. They monitor both mechanical condition and process variables. Versatile and open, the systems operates in standalone modes or as parts of a comprehensive network linked to plant-wide information systems, and can be integrated with the @ptitude system. 38 SKF Accelerometers, Eddy Probe Systems and accessories ‘SKF offers a broad range of high quality industrial sensors, accelerometers, velocity transducers, eddy probes and mounting accessories to suit a range of applications from {general purpose to those in the harshest environments. SKF's experience in every ‘aspect of on-line condition monitoring and machine protection systems means that we have the expertise to identify and apply the appropriate product for the best result. Integrated software platform ‘SKF Machine Analyst software manages, manipulates and analyzes machine condition data, and forms the core platform in SKF's family of reliability software applications called ‘SKF Machine Suite. The software may be customized for maximum efficiency and ease of use. Open architecture enables easy access to data within the Oracle® relational database as well as easy integration with the SKF @ptitude” system and other plant-wide systems. Human machine interface software The SKF Machine Analyst /HMI enables an effective and timely response to changes in machine condition by showing a graphical representation of the machine. Data from the on-line system is displayed “live” enabling an operator or analyst to identify not only the symptoms of an alarm condition but the potential cause. Specialty Applications - Wind turbine monitoring ‘The SKF WindCon system helps to extend maintenance intervals by continually ‘monitoring the operational parameters and the key mechanical components of a wind, turbine. This allows potential maintenance needs to be identified earty and incorporated in scheduled maintenance stops. As a consequence, the time between maintenance intervals increases and costiy emergency stops can be significantly reduced. Together these benefts result in less downtime, which increases the performance and cost efficiency of the turbine. The products shown here are only samples from the range SKF has to offer. For information about other products ‘or more information about the ones shown, contact your local SKF representative or go to www. skf.com/reliabilty. SKF 39 ™@ AEO Technology Products 40 Reliability tools for mechanical machine maintenance Safe and damage-free machine maintenance is oritical when the goal is to optimize running time. The development of SKF tools and lubricants is based on our own experience in field work, and includes the latest technologies for effective bearing maintenance and extended productivity. ‘SKF shaft alignment tools ‘Shaft misalignment in rotating equipment can cause frequent breakdowns. It generates additional loads and vibration which can cause premature damage to bearings, seals and couplings. And, it can significantly increase energy consumption. Shaft alignment tools from SKF use the latest laser technology to provide a more accurate way of detecting and correcting shaft misalignment. The display unit provides ‘lve’ values of the nature and degree of misalignment, allowing easy and quick correction of shaft ‘misalignment. Vibracon” SM element Vibracon is a universal, adjustable steel chock that eliminates the need for rigid stee! cchocks, shims or epoxy resin chocks. For generators, compressors, turbine and pump ‘sets, Vibracon chocks eliminate a number of problems common to traditional methods ‘such as parallel and angular soft foot and it is not necessary to machine the base frame r foundation. and there are no on-site problems related to arranging or installing st ‘When used in combination with laser alignment equipment, alignment time can be reduced by 50 percent, ‘SKF BeltAlign: belt alignment tool Pulley misalignment can result in frequent breakdowns, additional noise and vibration, land higher energy consumption. Therefore, accurate pulley alignment is an essential ‘element in reducing maintenance costs. While traditional methods align the face of the pulley, BeltAlign provides fine-tuning of alignment where it counts most: in the grooves of the pulley. Personal Digital Assistants (PDAs) for vibration monitoring 'SKF's most powerful palm-sized vibration meters are made to fit the expansion slot of a standard PDA. The unit collects acceleration, velocity, displacement, High Frequency Detection (HFD) and enveloped acceleration—then automatically evaluates results. It stores overall vibration signals, FFT spectrum and time waveform data for later recall. The PDA easily fits into a shirt pocket and is the perfect starter for beginners or a spot-check tool for technicians. SKF The produ SKF s shown information about the one: Vibration PenPlus “The Vibration PenPlus is a pocket-sized vibration monitoring tool which measures overall vibration caused by rotational and structural problems like imblance, misalignment, and looseness. It can also take enveloped acceleration measurements Of vibration in higher frequencies, such as those caused by rolling element bearings or {gear mesh problems. The LCD simultaneously displays both overall and enveloped acceleration measurement values, providing useful fault detection data, SYSTEM 24” automatic lubricator The System 24 automatic lubricator delivers greases or oil continuously for up to 12.months. The System Multipoint keeps up to eight lubrication points simultaneously and automatically lubricated. Simply use SKF's Dia\Set re-lubrication calculation program for the correct grease cispense rate. The interactive LubeSelect available on the @ptitudeXchange website helps you to identity the appropriate lubricant for your application. SensorMount* ‘SensorMount is designed to prevent errors when mounting large-size bearings by ‘measuring the bearing inner ring expansion during drive-up on a tapered shaft seating. The system includes a bearing with sensor and a hand-held indicator. The signal from the sensor is picked up by the indicator, which displays a value representing the internal clearance reduction (mm) divided by the bore diameter (mn). Induction heaters Forcing a bearing into place can damage bearings and compromise employee safety. By heating the bearing before mounting, larger bearings can easily be mounted onto a shaft. SKF induction heaters quickly heat bearings to the optimum mounting temperature, enabling a fast, easy and accurate installation. SKF offers induction heaters for a wide variety of bearings and other components including gears, pulleys, shrink rings, couplings, belt wheels, pistons and sleeves, les from the range as to 0 form: shown, contact your local SKF representative or go to 1. For other products, w.skt.com/r a m AEO Technology Products SKF technology inside the machine ‘The world's largest manufacturer of high quality rolling bearings, SKF is also a leading innovator of new bearing technologies. Beyond our line of standard bearing products, SKF has developed new, technologically advanced bearings designed to solve problems related to extreme operating conditions and specialized machine applications. CARB® for non-locating bearing arrangements The CARB” bearing from SKF, is a toroidal roller design exclusively for use as non-locating bearing, In addition to accommodating shaft deflection, CARE bearings allow axial freedom not possible with traditional locating and non-locating bearing arrangements that use self-aligning bearings in both positions. The CARB bearing finds the best position to carry the load, no matter how the shaft moves. ‘SKF Explorer spherical roller bearings provide endurance and performance After years of intensive efforts by an international team of SKF scientists and engineers, Explorer bearings have been reengineered at the micro and molecular levels for superior lite and performance. Field tests confirm that Explorer bearings last longer in real-world conditions than any other brand of bearing, including previous generations of SKF bearings. Explorer designs have been introduced for spherical roller, angular contact ball, cylindrical roller, taper and spherical roller thrust bearing product ines. INSOCOAT® electrically insulated bearings INSOCOAT” bearings are insulated to protect against flashover damage in electric motors and generators. Thay are designed with an outer ring coated with a thin layer Of aluminum oxide of uniform thickness, which is further treated to make it virtually impervious. The SKF plasma spray coating technique used on INSOCOAT bearings provides significantly better adhesion than is possible using other methods. At just +100 microns thick, the INSOCOAT bearing insulation layer can withstand 1000 votts. 2 SKF SKE Sensorized Rotostat Seal SKF has a strong capability in providing customized sealing solutions. A good example of this is the sensorized ROTOSTAT™ seal design which integrates a speed sensor and PTFE seal in a custom designed metal frame to form a single, integrated assembly for Use on the crankshaft of a passenger vehicle. SKF has extensive experience in providing all types of radial shaft seals, as well as @ unique capabilty in bonding elastomerics and metal ‘SKF Hybrid Ceramic bearings surpass extreme conditions The silicon nitride ceramic balls used in hybrid bearings make them an excellent choice ‘or applications that require high speed, high stiffness, high temperature, low noise, and intrinsic electrical insulation. The lower density of ceramic material enables higher speeds and more rapid acceleration. A low coefficient of fiction enhances wear resistance, so bearings run cooler. NoWear® bearings for increased lifetime in difficult conditions NoWear’ bearings are made of steel, but the rolling elements are coated with a new ‘ype of diamond-like-carbon which is only a few microns thick. This coating can be ‘applied to most bearings and other components such as gears and bushings. Steel Coated in this way has all the resilience of steel, plus the hardness and low friction Coefficient of NoWear bearings. Ideal for demanding environments, NoWear helps to increase component lifetime, improve machine performance, and reduce risk of unplanned downtime, ‘SKF Magnetic bearings ‘The SKF line of magnetic bearings is non-contact and lubrication-free, providing cleaner, faster and more efficient performance. They operate at extremely high rotational speeds, Unaffected by harsh environments, corrosive fluids, and even cryogenic temperatures, Recent advancements in electronics, software and motion control systems make them suitable for applications ranging from compressors to machine tools. SKF has developed magnetic bearing solutions for industries as diverse as petroleum, semiconductor fabrication, HVAG, machine tools and pulp and paper. KF representative or go to 4B REAL CONDITIONS. REAL SOLUTION Real Conditions. Real Solutions. =z For machine and plant productivity (On the following pages are examples of how SKF Reliability Systems has combined its knowledge, services and products to provide solutions to real-life application conditions. The applications described are only ‘samples from the multitude of industries in which SKF is, involved. For information about how SKF can help increase profitability in your type of business, talk to your SKF representative or visit wwww.skt.com/reliabiity SKF 43 M Real Conditions. Real Solutions. Integrated solutions for complex data management In modern process plants, growing demands upon the availability and reliability of critical rotating machinery have lead to requirements for more complex machine condition data in automated monitoring systems. The machine's monitoring function must be integrated with the plant's control and safety functions. In addition, vital machinery health data must be available for manual or automated analysis over the plant LAN (Local Area Network) and over a corporate WAN (Wide Area Network) for enterprise-wide analysis. A successful example follows: Station 2 Application: Gas-turbine-driven power generation. Condition: Aseries of remote power stations—some 500 km ‘apart—each relied upon aeroderivative gas turbines as the prime mover for the generation plant. The availabilty of the turbines had been adversely affected by ‘compressor section problems, which manifested themselves as specific sub-synchronous vibrations. ‘The existing vibration monitoring system was unable to react to these vibrations in order to provide adequate early warning for corrective action. A more complex approach was required, yet be reliable, usable and accessible over a WAN. Soluti An integrated system combining machinery protection, condition monitoring and transient analysis was installed at each site. The protection hardware was programmed to track and, through voting logic, automatically trip on the occurrence of the dangerous sub-synchronous vibrations. The condition monitoring system acquired ‘complete FFT data continuously to gather a full scope of, diagnostic information for analysis by dedicated trending, analysis and data management software. A vital factor was bandwidth limitations of the WAN for transfer and/or access of data from a remote location. ‘Additional options were expansion of the data into the plant control system by modern open protocol such as ‘OPG, Object Linking and Embedding (OLE) for Process Control, and interfacing into a decision support system (@ptitude® from SKF), SKF CTO OTTO LT CSO TRELETON Integrated Condition Based Maintenance System Machine Protection System integrated with Condition Monitoring Condition Monitoring and Transient Analysis Surveillance System Ges Turbine Generators 1S 5 Ethernet LAN Bi mee aYou might also like
