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Articles: Predictive Maintenance and Condition Monitoring Management

A Business-Based Approach to Developing an Effective Program

by Krzysztof (Kris) Goly

Over the last decade, there has been a general consensus throughout the industry that modern maintenance and plant asset management require the implementation of predictive maintenance techniques. In most instances, predictive technologies are implemented in the form of a Predictive Maintenance (PdM) Program.  PdM programs are designed and implemented through various approaches.  This article presents a business-based approach that has been utilized successfully by Siemens throughout the world and across various industries.

A Day In the Life of a Proactive PdM Technician

By: Ricky Smith and Carey Repasz

Beginning of the Maintenance Shift and Unplanned Work:

The day begins with the PdM technician reviewing any equipment that has been repaired or replaced in the past 24 hours. If any equipment has been changed or repaired, the PdM technician will identify specific failure modes for the work completed and conduct follow-up inspections of repairs for the purposes of QA/QC, confirming that the defect has indeed been removed and that no new defects have been introduced as a result of maintenance activity.

A Shortcut to Higher Efficiency

Adding Short Repairs to PM’s

by Joel Levitt

Have you ever thought about building in short repairs to your PM schedule?

Air Liquide Breaks Down Condition Monitoring Information Silos

Originally presented at Reliability 2.0

In an industry where it is not uncommon for companies to allow individual mills or plants to maintain their own autonomous condition monitoring operations, Air Liquide chose to go down a different path when it announced that it would partner with Azima DLI to manage all of its plants across the United States. The contract was one of the largest in the condition monitoring industry and indicates a growing trend for leading companies to instill consistency within their operations as opposed to allowing their own mills or plants to compete against each other.

An Overview of Remote Machine Condition Assessment

by John Bernet

Fifty years ago, when labor costs were relatively low compared to operating expenses, managers found that they could simply use more staff to cover the increasing demands of maintaining plant machinery.

Audit Forms for Predictive Maintenance Program Assessment

Audit Forms for PdM Program Assessment

Benchmarking a Better Understanding

Benchmarks Shed Light on Maintenance & Reliability Perceptions

by Klaus M. Blache, PhD

This interesting study compares data collected in 2008 to data collected in 1991 to chart the trends in reliability and maintenance over the last 17 years.

CBM 2011 Video Proceedings

Watch the CBM2011 Video Proceedings online!

Choose Your PdM Partners Wisely

Or Discover Another Reason Why PdM Programs Can Fail

by Alan Friedman

Whether you are considering starting a new program, revamping a dead one, outsourcing or looking for someone to become a long term partner to step in when needed and step back when not needed, make sure you pick the correct partner.

Combining In-House and Outside Laboratory Oil Analysis

By Garry Sands

Most companies rely on outside laboratories to analyze there time-based oil samples. Every six months, or perhaps once per year, oil samples are gathered and sent out for routine time-based analysis. So, for instance, we will be able to say a certain hydraulic reservoir has been sampled every six months, or once yearly, and then we at least know the condition of the oil at that point in time.

Commtest Podcast: Predictive Maintenance and Condition Based Monitoring, Yesterday, Today, Tomorrow

Commtest Podcast: Predictive Maintenance and Condition Based Monitoring, Yesterday, Today and Tomorrow with Terrence O'Hanlon, CMRP, Publisher of Reliabilityweb.com and Uptime Magazine and Mike Howard, Manager, Director of Customer Success for Commtest Inc.

You can listen to this 15 minute audio podcast via streaming by clicking the arrow (requires speakers or headphones) below or you can download the MP3 audio file for your iPod, Blackberry, Smartphone or other portable audio player.

Condition Monitoring Case Study

#15 Air Compressor (a Joy TA-85 centrifugal) is a large, very expensive, but highly efficient unit that has proven to be very reliable over the years. A centrifugal compressor typically has a much lower cost of compressed air relative to screw and reciprocating compressors, but centrifugals are unforgiving and operation and maintenance must be performed in a very professional manor as seemingly small mistakes can have huge or catastrophic consequences.

Condition Monitoring Performance Objectives: Key to Improvement

Certification of vibration analysts has been one of Canadian Machinery Vibration Association's (CMVA) functions for many years. Questions remain, however:

• how can a person prepare properly for a certification exam?

• how can a course provider design and teach a course in preparation for an exam without having access to the exams that will be offered?

• how does a prospective student even know what he needs to know or what kind of course to seek out?

• how does an employer decide who to hire for a particular set of condition monitoring tasks?

Performance objectives are the answer. This paper will define them, show how they apply to the condition monitoring business, relate them to the ISO 18436-2 standard on which we base our certification, and show how they can be useful in related situations. It will also describe the procedures used to develop the ones CMVA uses.

Diagnosing Rotor Bar Issues with Torque and Current Signature Analysis

by Drew Norman

Over the years rotor bar problems have been a diagnostic challenge for motor maintenance professionals.  Now with current signature, spectral torque analysis and automated computer diagnostic software, defining rotor health problems has been made fairly simple.  However, problems arise when professionals do not understand the underlying principles of the what’s, whys and how’s of dynamic rotor testing.

Estimating Failure Avoidance Costs

By Michael Cook and Michael Muiter

Predictive Maintenance (PdM) programs bring value to an organization by detecting potential failures and determining how to correct them before the failure can occur.

Many PdM programs are under-resourced or abandoned because the return on investment (ROI) generated by PdM groups is not obvious to management. If PdM programs are measured by their ability to avoid failures and the resulting failure avoidance costs (FAC) are quickly and accurately calculated and reported to management, the ROI will quickly become evident. Additionally, using the results of these savings from each predictive technology, i.e., vibration analysis, oil analysis, thermography, ultrasonic leak detection, etc., a determination can be made to decide if the technology is properly applied and if the frequency of inspections is appropriate to produce the highest possible ROI.

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