Abstracts

“Creating a Reliability Culture to Bring your Goals Alive”

Presented by Nancy Regan, The Force

Create a dynamic Reliability Culture within your organization by imagining four infinite quadrants. Successfully navigating three of these assures success, while one promises failure. Join Nancy on a journey through all four quadrants. Using two life lessons, a simple physics equation, a common business skill, and audience participation, you will discover how to foster the environment necessary to achieve most objectives. But creating a Reliability Culture isn’t all about technological details. Most improvement initiatives fail due to lack of buy-in because we often overlook the human element, the most significant factor in any Reliability improvement effort. While emphasizing the role people make in achieving technical objectives, Nancy reveals what is really causing the lack of buy-in and uncovers how to get team members on board. You will learn how to achieve your Reliability goals by creating a culture that supports successful implementation. Bonus – and if you dare – navigate one of the quadrants towards your own heart’s desire!

“What Does Good Look Like?”

Presented by David Sliger, Nissan North America

Your new job or assignment is to lead an organization operating in a reactive mode and where direction is based on the latest automation crisis.  You quickly notice vision is MIA, every significant event drives the next change of direction, morale is low due to an unsustainable work-life balance and lastly, expectations are so low most would consider them  insulting. After this quick assessment, you retreat to your office and contemplate your first move. You remind yourself that this is not a startup operation with a gradual ramp-up.  Nor is this an operation that has a previous history of success that you can study or reference.  Instead, this is an operation that’s been in business for over a decade and the demand for its product is very high and its imminent you turn the operation around immediately. You decide that the first order of business is to meet with your organization’s leadership that reports to you and the plan you have laid out to them is…?  How will this be communicated to the workforce?

This was exactly the situation I found myself in.  Providing vision, leadership and setting expectations were only part of the solution.  The other part?  Painting a portrait of what GOOD looks like.  During this time with you I will explain a few key lessons I learned in my journey to turn an organization from being in the red financially to being in the black, significantly improving morale, and becoming globally competitive in OEE performance.  Please join me as I share my keys to success.

“Use of Ultrasound on Low RPM Bearing Applications”

Presented by Joe Adam & Todd Sullivan, Roche Diabetes Care

In this presentation we will review our teams use of Ultrasound tools to detect and mitigate bearing failures in two areas of our production environment that run at approximately 165 rpm or less. We will review how we applied ultrasound as part of our asset strategy program and review the discoveries in two areas where we have found significant issues and the resulting return we have seen once the corrections were implemented.

“Lubrication for Aging Assets”

Presented by Terry Harris, Reliable Process Solutions

It would be great if we could replace all old or failed equipment with new equipment or state of the art assets. But unfortunately, that is not very cost effective except in the airline industry where the risk of failure is much higher. So, we must all learn about our equipment and learn to manage our 20 – 50-year-old equipment. A look at techniques and ideas to add some reliability to our aging assets – specifically in regards to our lubrication practices.

“The Journey to a Sustainable & Effective Ultrasound Program”

Presented by Eric Holt, Michelin

In my 17 plus years experience working in Maintenance & Reliability at Michelin, I have had the opportunity to attend numerous training classes, workshops, online seminars and a few conferences. Of course the knowledge gained, is only as valuable as the work you put towards implementing the lessons learned.

In my presentation, I will share how I’ve used my professional development opportunities to improve Ultrasound use at Michelin and sustain these improvements. Everything from improving our mechanical inspection and lubrication processes to changing the culture that air is not free, leading to savings over $250k a year in energy costs due to our Ultrasound leak detection program.

“Ultrasound – Change Agent…Money Maker”

Presented by Alan Knight, Mueller Co.

In any asset management program, reliability of the equipment is paramount. In order to improve and sustain reliability in the process, elimination of defects is key and identifying potential failures early in the P-F curve is a cornerstone in preventing unplanned downtime. In order to create a robust advance defect detection and elimination process, condition monitoring must be implemented.

There are many challenges to implementing condition-based monitoring programs into any facility. It is often these challenges that prevent organizations from even starting down the path – challenges such as it is expensive and requires special skills that may require years of training and experience to master. Another challenge that I have experienced – more than a couple of times – is the lack of trust people have in the various technologies. It is true that some disciplines, such as vibration analysis, are very expensive to start up and can take years of training and experience to master and can take some time to render a return on investment.

Other technologies such as infrared analysis can be less expensive but still require a fair amount of training in order to provide a return on investment. Additionally, infrared provides a visual representation of defects that can more easily convey the need for repair to those with little or no technical knowledge.

The one technology I have found that, in my experience and opinion, provides the fastest return on investment is airborne ultrasound. Ultrasound instruments are relatively inexpensive and the end user can learn the basics to operate them and be off checking for air leaks in a relatively short time. That isn’t to say that becoming proficient in using and analyzing ultrasound data is quick and easy – it isn’t. However, ultrasound provides immediate sensory detection of air leaks. Air leaks directly cause increased energy costs and eliminating them is finding real money. I have teamed up with many mechanics in many plants over the years and after less than half an hour, easily identified enough air leaks to justify the purchase the equipment and the training to go along with it. This presentation will explore how ultrasound can find the dollars that plant management wants and foster a proactive culture on the floor.

“Lubrication is the Life Blood of Your Plant”

Presented by David Lindlow, Lhoist

Lubrication is the life blood of almost all manufacturing plants. Almost 30% of all failures can be attributed to some kind of a lubrication failure. One of the best ways to increase equipment reliability and reduce maintenance costs is to establish good lubrication practices. When we start off with poor quality lube and apply it on a poor manner we end up with less than desirable results. Come learn what precision lubrication is and how an ultrasound grease gun can help achieve that. We will cover how to calculate grease volumes each bearing. We will review some of the mistakes that I have made and some successes in trying to set up oil filtration and filter carts on our gear boxes. We will review how to store lubricants even if you don’t have a climate controlled oil storage rooms or a warehouse. Do you have too many lubricants or more than one lube for the same application and can they be consolidated into one type and brand of lube? Review how to kick off an oil analysis program. What data to ask for and what to do with the data after you get a report back. Setting for your oil cleanliness alarms, because what is clean for one system may not be for another.

“Electrical Condition Monitoring with Ultrasound”

Presented by Charlee Lipham, Condition Monitoring Engineer at WestRock Company

Developing and implementing a successful electrical ultrasound program takes time and resources. However, if done correctly, the program can pay dividends in terms of improved workers safety, equipment reliability, maintenance cost, reduced downtime, and increased production. Some factors like safety, humidity, criticality, frequency, and documentation need to be taken in to consideration when developing an effective program and routes. You will see our program and electrical faults that were discovered and repaired before flash over.

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