Brewery Asset Care Practices

Milwaukee BreweryMilwaukee, WI

MBAA Milwaukee ChapterMay 18, 2015Fred’s Pub

Miller Coors, Milwaukee, Wisconsin

Michael Du Mont:

Brewery Asset Care Practices

Agenda

� Why asset care?

� Principles & approaches of maintenance

� Building an RCM-based asset care program

• Condition Based Monitoring (CBM)

• Electrical Best Practices

• Advanced Troubleshooting Tools

• Lubrication Principles and monitoring

� Maintenance work planning

� Problem solving

� Asset care auditing

� Summary – Reliability Through Maintenance

Why Asset Care?

From book by Howard Penrose - Electrical Motor Diagnostics

(Vice President Engineering and Reliability Services for Dreisilker Electric Motors, Inc., PhD, CMRP, Author)

MIT Tribology Study (U.S.)

� 20% of US GDP (12.5T) was lost due to improper maintenance in 2005.

Why Asset Care/Maintenance?

Why Asset Care/Maintenance ?

The ultimate objective of Asset Care/Maintenance is:

“To maximize the profitability of the

organization by leveraging asset capabilities for competitive advantage.”

There are two ways to Increase profits: To increase revenues and (or) cut costs.

Principles and Approaches of

Maintenance

Asset Care Journey

Don’t Fix It

Fix it when it Breaks

Fix it before itBreaks

Main

ten

an

ce E

ffecti

ven

ess

World Class Asset Care

Maximize cash by running assets into

the ground

Provide rapidresponse to breakdowns

Minimize unscheduled maintenance

downtime – routineplanned

maintenance

Optimize use ofpreventive and

predictive maintenance to

avoid “Over Maintaining”

Preempt failures by removing

causes/defects. Design forReliability

Reactive Maintenance Proactive Maintenance

Maintenance

Condition Based

Maintenance

Eliminate the

Source of defects

FirefightingBreakdown Stabilization

Breakdown Prevention

Maintenance Improvement

MaintenanceReduction

Goal is to Eliminate the Six Major Machine Losses

• Breakdowns – Bearing seized,

snapped shaft, gearbox failure etc.

• Setup & Adjustments -changeover adjustments, labeler setup, lack of procedures etc.

Downtime Losses

(Availability)

• Idling & minor stoppages-Bottle jam on conveyor, crown jam in chute, can & bottle twist jams etc.

• Reduced Speed-slow filler to achieve fills, improper line flow, defective materials etc.

Speed Losses

(Performance Rate)

• Quality defects & rework-low fill rejects, loose crowns, poorly executed maintenance etc.

• Startup/Yield losses- Beer

loss, Can & bottle loss, label, glue carton losses etc.

Quality Losses

(Quality Rate)

Key Principle - Achieving Inherent Reliability

of Equipment

• Inherent Reliability Definition: Ability of the

equipment to sustainably perform it’s intended

function as designed.

• Scheduled Maintenance ensures that the Inherent Reliability is achieved

• Performance enhancement beyond original design is not a maintenance function

• It is not cost effective in an industrial environment to eliminate all equipment breakdowns.

AssetDisposal

Manage the “Asset Life Cycle”

Cradle Grave

Materials & Cost Management

•Design in-(Reliability, Availability & Maintainability)

•Training

•Equipment Life Plans - RCM’s

•Audits

•Organizational Design

• Supplier Partnering

•Operator Based Maintenance

•Condition Based Maintenance

•Problem Solving

•Performance Measures

•Change Management

•Spares / Inventory Management

•Planned Maintenance Management

•Breakdown Maintenance Management

•Reliability Improvement Management

Design &

Acquisition

Installation&

Commissioning

Useful Operating

Life

•Asset Disposal

• RAMS (Reliability Availability Maintainability and Safety)

• RCMs (Reliability Centered Maintenance)

• Inventory reduction

• Lubrication Program

• CBM (Condition based Monitoring) Program developed

• Management Commitment

Processes / Programs Implemented

Functional Failure

A Functional Failure is theinability of an item (or theequipment containing it) tomeet a specified conditionor performance standard

Potential Failure

A Potential Failure is somephysically identifiableevidence that a functionalfailure is imminent

Productive Maintenance Tasks

SERVICING AND

CLEANING

LUBRICATION

WALK ABOUTOPERATIONAL

CHECKS

(Hidden functional failures only)

SCHEDULED INSPECTION/ FUNCTIONAL

CHECKS

RESTORATION

DISCARD

OPERATING CREW

MONITORING

THE CONSEQUENCES OF THE FAILURE DETERMINE

THE MAINTENANCEEFFORT

THE CONSEQUENCES OF THE FAILURE DETERMINE

THE MAINTENANCEEFFORT

Building an RCM-based Asset

Care Program

History of RCM (Reliability Centered Maintenance)

� In the aviation industry, reliability became a major problem (aircraft crashes).

� In the early 1960’s, United Airlines commissioned two engineers (Nowlan & Heap) to investigate reliability.

• Their study, was published in 1978 by the US Department of Defense.

• It developed new concepts, and proposed a framework methodology for maintenance strategies.

• Applied correctly, the output is an optimum maintenance schedule.

� RCM, has been extremely successful in the aviation industry, military, and industries where machinery must be maintained.

Commercial Aviation Success

In 1968, United Airlines

Structural Inspections: 20,000 hrs.

� The DC-8 - Required more than 4,000,000 man-hours

� Boeing 747 - 66,000 man-hours for the same interval

Overhaul Items:

� The DC-8 traditional program had 339 overhaul items

� The DC-10 had only seven scheduled overhaul items by using RCM’s

Traditional Maintenance Preceptions

� Safety and reliability are highly correlated

� Reliability degrades with increasing age

� A finite unreliable age exists for each device

RCM Development

Objectives Of RCM

� Realize inherent safety and reliability

� Restore after deterioration

� Identify substandard components

� Perform the most effective maintenance at a minimum total cost

RCM Development

� There are seven basic questions used to help determine the causes of system failures and develop activities targeted to prevent them.

� Society of Automotive Engineers (SAE) Standard JA0111, 1998; The RCM must answer these questions (abbreviated).

1. What are the functions of the asset?

2. In what way can the asset fail to fulfill its functions?

3. What causes each functional failure?

4. What happens when each failure occurs?

5. What are the consequences of each failure?

6. What should be done to prevent or predict the failure?

7. What should be done if a suitable proactive task cannot be found?

COMMON SENSE

APPLIED BY MEANS OF

A LOGICAL PROCESS

COMMON SENSE

APPLIED BY MEANS OF

A LOGICAL PROCESS

Reliability Centered Maintenance

THE PARTITIONING

PROCESS

Condition Based Monitoring (CBM)

Condition Based Monitoring

� Why Use CBM?

• The most effective RCM/PM tasks for determining the condition of equipment is in the form of “Condition

Based Monitoring”.

• Condition of equipment can be monitored.

• Functional failures can be avoided.

• Outages can be planned.

• Planned maintenance is lower cost maintenance than unplanned maintenance.

Condition Based Monitoring – Cont.

� Tools Used

• Oil Analyses

• Vibration Monitoring�Marlin System

�Remote Systems

• Ultrasound

• Infrared

• Metal Thickness Testing

• Cycle Counting

• Timing Cycles

Oil Analyses

Vibration Analyses

� Detects:

• Bearing failures

• Looseness

• Imbalance

• Electrical problems

• Pump Cavitation

• Resonance

• Lubrication issues

Vibration Analyses

Equivalent to driving a Car:• On 15 “ tires• Hitting a 10” Pothole• Every 11 feet• Traveling 1000 MPH

Ultrasound

� High frequency sound waves

� Ultrasound is inaudible

� Hearing limits for adults is 20 kHz.

� Ultrasound is any sound above 20kHz

� Typical Range used in PDM is 30-40kHz

� Only 10% of noise is in the audible range

Size of Leak 100 PSI

1/64" 0.41 $ 94

1/32" 1.62 $ 375

1/16" 6.49 $ 1,501

1/8" 26 $ 6,013

1/4" 104 $ 24,051

3/8" 234 $ 54,116

1/2" 415 $ 95,975

5/8" 649 $150,090

3/4" 934 $216,001

7/8" 1272 $294,168

1" 1661 $384,130

Infrared

� Visible Light 390 – 750 nm

� IR Camera 800 – 1400 nm

� IR cameras use the heat emitted from an object to produce images

Visible Light

� Industrial Uses

• Electrical circuits

• Steam Traps

• Bearings

• Motors

• Pumps

• Gearboxes

Reliability Through Maintenance

Lubrication 101 – Lubricant Failure

� Insufficient Quantity

� To much lubricant

� Cross Contamination

� Using incorrect lubricant or grease may result inadequate lubrication and eventual equipment failure

� Dirt� Causes excessive wear and eventual equipment failure.

� Water� Water accelerated the degradation of lubricants and can cause

corrosion of metal surfaces.

� Can cause micro implosions under high pressure

Lubrication Handling

� Keep Oil Clean, Dry, and Cool.

• Airborne dust will violate the space between the ball and the race

� Cross contamination is detrimental to oil.

� Every 18-degree (F) increase in oil temperature in operation reduces oil life by half

Over Lubrication

Gear Boxes

Mount

Bearings

Seals

Case

Expansion

Chamber

Worm/shaft

Worm Gear

� Gear boxes use oil.

Leaks are potential problems to watch for

Do Not Overfill !!!!

Chain Stretch

� The chain doesn’t actually stretch. The holes become elongated

� The pins and rollers wear

The holes elongate

Maintenance Work Planning Planning, Scheduling, Resourcing

Problem Solving

Asset Care Auditing

Summary

Summary

� What a good Asset Care Strategy Achieves:• Greater safety and environmental integrity: • Improved operating performance • Greater maintenance cost-effectiveness:

• In addition, if RCM is correctly applied to existing maintenance systems, it reduces the amount of routine work usually by 40% to 70%.

Summary

� What RCM Achieves:

• Longer useful life of equipment

• Builds A comprehensive database for a maintenance strategy.

• A much clearer view of the skills required to maintain each asset.

• Greater motivation of individuals, and wider ownership.

• Better teamwork: RCM provides a common, easily understood technical language for everyone who has anything to do with maintenance

References:

� Coetzee, J. (1998). Maintenance

Republic of South Africa: Maintenance Publishers (Pty) Ltd

� Moubray, J. (1997). RCM II Reliability Centered Maintenance.

New York: Industrial Press Inc.

� Suzuki, T.(Ed.). (1994). TPM in Process Industries. Portland OR: Productivity Press

� Kelly, A. (1997). Maintenance Strategy. Maryland Heights, MO: Elsevier Publishers

Presented by:Michael Du Mont

DuMont Consulting LLCGoogle Voice (414) 604-6453 • Cell (414) 975-0696 DuMont.Mike@Gmail.com