Abstracts

“Disrupting Senior Leadership: Getting and Sustaining Executive Sponsorship!”

Presented by Suzane Greeman, Greeman Associates

It is well established that executive and board level sponsorship is a necessary ingredient for the success of an asset management culture. However, time and time again we hear that reliability and asset management are failing because the passionate groundswell movement keeps running up against a brick wall. Then the passion slowly dies, the light of management support barely ever shining on it. Management systems standards such as ISO 5500x places special responsibility on top management, such as executives, Board of Directors and elected representatives. This is because top management is responsible to stakeholders for driving value through the organization and hence, deriving value from assets. This requires the harmonizing the functions within the organization to contribute effectively to the value chain. What then is the role of the executives and the board in aligning operational and financial functions towards creating sustainable economic value from assets?

Let’s explore this on a journey through four key questions of executive sponsorship as seen from middle and frontline management:

1. Why is senior management sponsorship a key success factor for entrenching reliability and asset management culture within the organization?
2. Given its importance, why then is executive sponsorship for reliability culture so elusive?
3. How will we get senior management to champion asset management philosophies such as value creation, life cycle costing and risk-based decision-making and reinforce them constantly?
4. How can you disrupt senior leadership without breaking your career?

In this keynote presentation, I will show you how I have failed and succeeded at disrupting top management and securing executive support. I will share real world examples and insights that I gained over the years that middle management can use to attract and sustain sponsorship from the highest levels of decision makers in the organization. Specifically, I will outline the steps to communicate asset risks and opportunities using effective business language, educating top management in asset management and reliability, influencing senior leadership’s actions and driving value through the organization. The speech will focus on getting top management to create cohesion, disruption and collaboration within their own ranks and at the middle management level. This will ensure that these leaders model, embrace, support and participate in the asset management transformation of the organization.

Getting and sustaining executive and board level sponsorship requires disrupting senior leadership. Surviving the organization requires strategic disruption!

“Operations & Insight”

Presented by George Simonoff, Blackbird Engineering

This presentation will focus on successes and failures from an operations point of view.

How to be successful is a long-discussed topic within the reliability community.  There’s not a conference that goes by where some discussion isn’t focused on getting buy-in somewhere in the organization.

More than half of George’s career was in an operations roles and shop floor focused – most of that as maintenance manager.  In his most recent role, he was asked to head the newest Halos facility maintenance team in a turnaround situation.

Through his career, he’s experienced both successes and failures and will share some of his learnings with this audience.

“Proper Lubrication Practices for Common Equipment”

Presented by Terry Harris, Reliable Process Solutions

There are some basic rules to follow when performing Lubrication tasks on common equipment components in our facilities. Each component needs to have written guidelines developed so the component is properly lubricated when the task occurs. Doing improper lubrication tasks will result in the components life being reduced, sometimes by many multiples.

Care of the lubricant, care for the application equipment, proper techniques for applying, and proper frequency are just of few of the important items to consider. Should we lube when the equipment is operating or shutdown? We will cove all these topics and many more.

A Paradigm Shift using Ultrasound. Educate, Empower, Engage, Evolve, and Excite!!

Presented by David Butler, Hexpol

Hexpol, Colonial Rubber Works, Dyersburg, Tennessee has been in the rubber manufacturing business for many, many, years, longer than I have been alive.  I am 54 years young, and my name is David Butler. I have been employed for 35 years at Colonial Rubber.  I have seen many changes take place.  Some have been good and some not so good.   However, the change I am here to tell you about is “rockin” peoples world in the organization. Through the implementation of using ultrasound in our Preventative Maintenance program we are making a gradual paradigm shift in how we lubricate the bearings on our assets.  This has not been easy for maintenance associates to grasp.  The words I hear repeatedly is; “I get a pm and it is specific about location of asset so I just go and add 2 shots of lubrication to the bearings”.

I try not to upset anyone but I do try to educate as to how we can take those assets and create routes, set baselines, run the routes and show the maintenance associate that instead of adding those 2 shots of lubricant to the assets we just use our ultrasound and let the ultrasound decide if and when we apply lubricant.  Not only is it a time saver but most importantly, IT IS A COST SAVER IN THE END!!! 

You ask what a paradigm shift is, well the dictionary states that a Paradigm shift is an important change that happens when the usual way of thinking about or doing something is replaced by a new and different way.  This is just what I have been gradually doing within Hexpol, Colonial Rubber and would like to see this tool added to all Hexpol throughout the World.  I don’t think you just go in and say, “I am changing the way we grease our bearings”. NO, you show them and educate them along the way.  By a gradual shift you are less likely to create a monster from within.  This is not an overnight process.  It is just like eating an elephant.  There is no way you can devour an elephant they are too large.  But, with the one bite, or in our application, one asset, one route at a time we can eventually devour it.  Meaning yes you can eat an elephant. Yes, you can roll out an ultrasound program in your organization.

We initiated this ultrasound program in August of 2019. Year to date a potential cost savings of over $100,000.00 has been saved.  So, you tell me, is using ultrasound in all applications worth giving a shot in your organization?

 

“Best Practices for Electrical Asset Reliability & Worker Safety”

Presented by Tim Rohrer, Exiscan & Joe Gierlach, TEGG – An ABM Company

This presentation will cover best practices for the inspection and maintenance of Electrical assets. A multi technology approach to inspection, assessing severity, and recommended courses of action will be discussed. Proper safety procedures and practices will be outlined for the inspection and maintenance of energized Electrical assets per NFPA 70E and NFPA 70B

“How Reliability Centered Maintenance Reduced Maintenance Costs by 53%”

Presented by Lance Bisinger, T.A. Cook 

Chances are if you are responsible for managing maintenance you’ve been challenged to reduce costs.  This request may include well intentioned recommendations to review one of the latest “techniques” being presented or published.  Normally, Reliability Centered Maintenance (RMC) doesn’t enter into the conversation as an option due to its reputation of being a “Resource Consuming Monster”.  However, RCM is an excellent process for developing risk-based solutions that deliver sustainable results leading to cost savings.  This presentation will explain to participants how RCM was applied to execute maintenance task optimization, emphasizing the associated benefits of improved equipment knowledge, expanded equipment data, equipment criticality ranking, and increased equipment ownership leading to sustained reduction in maintenance costs.

“Case Histories on Using Ultrasound to Deliver Sensational ROI Across a Multitude of Plant Applications”

Presented by Ian Ware, CMRP, UltraTek

This presentation covers numerous real life applications of Ultrasound across Australian industry to detect areas of waste in compressed air systems, slow speed monitoring of bearings down to 0.15RPM, valve degradation of large GEHO pump sets and more. Significant return on investment accompanies and ultrasound has proven an extremely versatile technology that can be applied in all industrial facilities.

“De-Mystifying Variable Frequency Drives – Sifting Fact from Marketing Spin”

Presented by James Neale, PhD

VFD’s are being used more widely across industry, yet confusion often remains over when and how they should be installed, configured, tuned and maintained. Drawing on case studies across a range of pump, fan and compressed air systems you will leave with a clear answer to this key question and a few critical questions to put to your process engineers and plant automation technicians. An update on the on-going research into the use of ultrasound to monitor the condition of variable speed driven asset will also be presented.

“Is Effectiveness Killing our Maintenance Department?”

Presented by Joe Anderson, Reliability X 

Effectiveness in management is doing the right things or getting the right things done. This begs the question, what are the right things?

In this session we will focus on getting back to the basics and doing the right things, like development of a strategy, having systems and processes in place, how to get operator involvement, and set priorities as to what should be the true focus of the maintenance department.

We will focus on the top 10 things we see as most important to become the most effective in the maintenance space. Our goal is to help you with your true mission: reliable assets.

“Wisdom from a Techno-Savvy Dinosaur”

Presented by Dr. Klaus Blache, University of Tennessee

Practicable predictive technologies (PdM) have now been around for over 30 years. Actually, the first technological application of ultrasound was an attempt to detect submarines over 100 years ago. Yet today, about sixty percent of companies are still not satisfied with their current PdM program. What is it going to take? Condition based monitoring/maintenance (CBM) is helping some. Culture and knowing how to implement a top quartile and sustainable PdM/CBM process is still a challenge in most facilities. Is it not having identified what is critical to monitor, poor root cause analysis, lack of skills/training, etc.? Wisdom, lessons learned, trends (with data) and recommendations for successful and sustainable PdM/CBM implementation will be shared in a factual, yet entertaining way.

“Mechanical Reliability with the UE Systems 4Cast”

Presented by Doug Waetjen, UE Systems

UE Systems is excited to showcase the latest enhancements to our 4Cast system. The 4Cast offers 24/7 online condition monitoring of your most critical assets & we’ve made it even better! In addition to continuously listening to your assets the 4Cast will now automatically alert you when an alarm is met. With a simple (and instant!) text or email you’ll know when attention needs to be paid. We’ve also added in dashboards in our software to make it even easier for you to monitor and trend these critical points. Let us do the listening – we’ve got you covered!

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