Management of condition monitoring in large enterprise

8/7/2019 Management of condition monitoring in large enterprise

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Management of conditionmonitoring in large

enterpriseM P Srivastava


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Introduction

IMPORTANCE Condition monitoring lends reliability. If manufacturing

process is unreliable the planning goes haywire and we

loose something in the supply chain

Some loss data

Loss of 250 MW generating unit amounts to a loss of Rupess 2Crores per day

10 MTPA Refinery, Loss of key units reducing production to half

is equivalent to 15 Crores per day

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My experiencesThis presentation is based on my work experience in 3 differentroles in 3 different companies

1. Sale and implementation of Condition Monitoring systemat clients works while at IRD Mechanalysis.

2. Providing Condition Monitoring services to industries inIndia and abroad while at Indian Institute of Production

Management3. Implementation of Condition Monitoring at Essar Steel

complex at Hazira.

The views expressed are my own and do not relate to mypresent job at Essar

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The challenges Depend on

Organisation

Size

Culture

I have clubbed them into

three categories

Manpower and skill related

Organization related and

Internal marketing

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Manpower and skill related

Cadre building process Lack of managements confidence in condition monitoring

Reporting skill -Residual life assessment versus simple

interpretation

Manpower availability

Attrition

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Organizational matters Central versus Divisional

maintenance Equipment classification

Equipment details

Production is moreimportant than maintenance

In charge of conditionmonitoring function is not asenior person

Lack of Autonomousmaintenance culture

Outsourcing

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Marketing

of Condition Monitoring Condition monitoring is seen as know all department and its

services are requisioned to answer all questions

Lack of knowledge about condition monitoring

Lack of confidence of planners (SCM) in condition monitoring

Let us now examine these points one by one

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Cadre building process

Structured versus unstructured process Cond Monitoring a part of induction programme

Small organization should explore outsourcing of condition

monitoring

Competent trainers in induction programme will be required,

get outside help if needed

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Lack of Managements confidencein condition monitoring

Senior management unaware of condition monitoring CM limitations

Maintenance recommendations are not taken seriously

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Residual life assessment vis--vissimple interpretation of CM

readings

RLA is more popular in Power Generation industry and forCapital expenditure decisions

It is seldom applied for components and sub systems

Maintenance and CM talks about readings, trends, limits etc

Report residual life or time to fail

CM software design should incorporate this

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Manpower availability and attrition

I

n CM area competent manpower is really scarce Availability of jobs abroad

High salary and fancy designations

CM is niche and not really a career option

Need to take fresh graduates in excess on a continuous

basis

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Central versus Divisionalmaintenance

CM at department level CM in central maintenance

Clarity of roles

Detection

Analysis

Correction

At department levelAt Central level

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Equipment classification

A, B, C Classification System for adding new equipment and its classification

100 % Coverage

Clarity on measurement frequency for each type

Exceptions will be very sick machinery measurement

frequency to be decided by the CM department

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Equipment details CM needs HP, RPM, Gear teeth, damper opening, load and

similar details

Needs building up info with respect to time

DMS helps

If not CM / Maint Planning need to take initiative

Matter gets difficult if the equipment is sourced from severalcountries of origin. There should be clear emphasis on

supply of documentation

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Production is more important thanMaintenance

This is a loaded statement but by and large true

PM schedules and CM recommendations are seen as

hindrances

Maintenance opportunity window seems to be contracting

and opens at Production / PPCs plans or on unexpected

failures

Creation of a very fast acting and capable maintenance

organisation is the need of the day

Minute planning, use of project management tools and skill

enhancement are the solutions

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In charge of condition monitoringfunction is not a senior person

This is by and large true

Head of maintenance need to represent cond monitoring in

senior level meetings and get the voice heard

Lateral transfers make situation worse

Some times you get a person with absolute love for CM and

he becomes a respected GURU. He can then make his voiceheard even though not senior

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Lack of Autonomous Maintenance

culture

VERY POWERFUL TOOL

TPM is not very popular

More of marketing needed both to Govt. at policy making

level and to industries

With Autonomous maintenance safety, reliability and

continuity of operation is very much possible

Bringing this IN is actually a paradigm shift and needs to come

from absolute top level. However senior management needs to

assess its suitability and recommend this.

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Outsourcing

CM is costly and results take time

Small organisation may outsource condition monitoring and

inspection activity

Large organisation may have in house departments

Very large organisation need to have mix

In either case in house knowledge is required to control andmanage the process

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Condition Monitoring is seen as Knowall

CM is often asked to explain the problem

CM gives advance warning, it does not eliminate problem

Need to explain CM to others

Need to create a situation that its warning should be taken

seriously

Head of maintenance need to have very good appreciation ofCM

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Lack of knowledge about conditionmonitoring

Internal marketing

small sessions for senior management, 1 day session for all

in operations

ISO compliant training for all in CM with periodic revision and

certification

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Lack of confidence of planners(SCM) in condition monitoring

This comes from lack of knowledge about CM

The planners take equipment for granted

CM and PM is not given time, people virtually pray that the

plan goes well

If the PM jobs and CM recommendations are followed and

then the plans are drawn, it will have a very high probabilityof success

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Let us get on to the job You need to prove that you deliver, you actually deliver

Avoid big words, explain simple. FFT, Nyquist plot, Cepstrumanalysis, lines of spectrum, Frequency band trending whathave you

Simple is beautiful

Knowledge is essential

Fundamentals need to be sound Love for CM, use Training, retraining and weed out non

interested chaps

Last but not the least please do train all on CM with the helpfrom your bosses

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Advocacy for cutting edge

technology Technology gives information, cost saving and power

In CM newer technologies get introduced with passage of

time

Web based monitoring, real time data analysis, expert at

remote location aiding the local team, live time spectrum,

Instruments with internet connectivity are some of technology

items

Differentiate between CM and C&I requirements

C&I is bothered about level, this is 33% of information

Vibration is Amplitude phase and frequency

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The way forward Condition Monitoring to be included in Diploma Engineering

and B Tech level as an optional subject.

M Tech courses with specialization in Asset Management and

Reliability Engineering need to be offered.

MBA programmes with Operations as specialization can

also have Maintenance Management as a paper andcondition monitoring should form a part of this paper.

Technical Training organizations, Engineering colleges and

Condition monitoring equipment manufacturers should run

short duration courses on condition monitoring for following

levels: Technician / Junior engineer

The Analyst / Engineer

The Senior Analyst cum planner

Senior management very short appreciation courses

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Management of condition monitoring in large enterprise