The overwhelming majority of industrial accidents result from human error. Engineers who sleep less than eight hours per night are less productive and almost 10 percent more likely to cause an accident, and many don’t get enough sleep. The solution: take a short nap.
Having a reliable predictive maintenance program at your facility is crucial to the health of your machinery. One cannot stress enough the cost saving benefits of detecting an issue early and being able to repair it versus the cost of fixing it after a catastrophic failure has taken place. For electrical components, infrared thermography is a great technology to incorporate into any predictive maintenance program.
Continuous condition monitoring (CM) is advised for those assets that run continuously, perform functions that are crucial to the production process, have grave failure consequences, are expensive to maintain, or pose a risk to personnel safety and the environment.
Before launching a CM program, though, plant operators have to identify the goals, such as increasing machine uptime, preventing failures of critical machines, protecting workers from the consequences of machine damages, or enhancing product quality.
Imagine a large, global industry that competes on hair thin margins for the opportunity to deliver products continuously, requiring just-in-time (JIT) to process and other nonstop production operations. Combine the urgency of delivery with the fact that many production sites are unmanned and downtime disrupts the customer’s production operations and triggers heavy contractual penalties. Put it all together and you have all the ingredients for the perfect unplanned downtime storm.
This is the competitive environment in which major industrial gases companies operate. Many of their production operations are colocated with the manufacturing sites of customers because they’re supplying ingredients that are critical to customers’ production processes. Uninterrupted on-site delivery is a key industry success factor.
Today’s market is crowded with hundreds of software systems, each trying to position itself as the perfect maintenance and asset management solution. But, they’re not all created equal. Understanding the difference between an enterprise asset management (EAM) system and a computerized maintenance management system (CMMS) and knowing how to tell them apart under all the marketing hype are key to sorting through the herd and finding the asset information system that’s right for your business.
You are probably familiar with life’s golden rule: Do unto others as you would have them do unto you. But have you ever wondered how any given machine, if it could express itself, would feel about this rule? What would it say? This article offers some speculative thoughts from the machine’s point of view, presented as the golden rules for machinery reliability.
For a successful condition monitoring program, you have to have an overall Industrial Internet of Things (IIoT) plan. Sure, you can put monitoring devices on your equipment and extract significant value, but without an overarching plan, over time you will spend unnecessary capital funds, run into scalability issues, and underestimate the impact IIoT will have on your organization.
A major challenge currently confronting plant staff and management is how to deliver cost-effective and sustainable business practices based on plant performance requirements over the lifecycle of the assets. This can be especially challenging when it comes to recruiting and retaining skilled technicians who can operate and maintain an industrial complex. While it is recognized that a primary cause for this challenge is a shrinking pool of newly qualified technicians to replace the retiring workforce, a second and substantial cause is the inefficient allocation of resources that are here TODAY. What can be done to address this inefficiency? This article suggests a ready solution exists when you stop to recognize that not everything in your plants is of equal importance to achieving your objectives. Think return on investment (ROI). How can you identify those systems and equipment that are most responsible (think critical) for the loss of ROI? In the operations and maintenance (O&M) world, the selective application of reliability-centered maintenance (RCM) to your plants can optimize the use of available resources. This article describes a real-world application of RCM to focus the optimal use of your available resources.
Maintenance Connection recently released its 2017 State of CMMS report, an analysis based on survey data from roughly 1,000 organizations. The report analyzes how maintenance teams use computerized maintenance management systems (CMMS), along with the resulting impact on operations and performance. A variety of organizations participated, from industries such as manufacturing, healthcare, and government, as well as maintenance departments with as few as 1 to 5 employees up to 50 or more. Their survey responses revealed the following findings.
In some organizations, reliability is not just a word, but a culture that has been built over a period of time. Developing a reliability culture is not solely a top-down approach or dependent on the company’s vision. Sometimes, it is taken as a normal, routine job, while other times, it may get a fast-track status.