Reliability Based Maintenance

Practical Applications at

DuPont Teijin Films

Hopewell Site

Dave Van Aken

Reliability Manager

Maintenance’s Role

� Preserve the physical plant assets

� Ensure they are available to perform as good

or better than required

� Using the most cost effective means

available

Maintenance Business Impact

� Maintenance is largest controllable cost

� Potential Cost Savings

� Avoiding breakdowns (lost production)

� Avoiding costs associated with failures

�Materials

� Labor

� Avoiding cost of inconsistent quality

Regressive

Reactive

Planned

Defect

Elimination

Asset

Optimization

Don’t Fix It,

Delay The Fix

Fix it After

It Breaks

Fix It Before

It Breaks

Don’t Just Fix It,

Improve It

Don’t Just Improve It,

Optimize It

Cost

Focus

Productivity

Focus

Value Focus Optimization

Focus

The Journey to World Class Manufacturing

Behavior: Careless Responding Org. Discipline Org. Learning Inventing

World Class Manufacturing Continuum

Staged

Decay

Reliability Based Maintenance

� Three Main Components:

� Preventive

� Time based maintenance

� Predictive

�Condition based maintenance (technology based)

� Proactive

� Investigative analysis to extend machine life

Preventive Maintenance

� Time-based maintenance activities

� Inspections

� Calibrations

� Lubrication

� Changing filters (oil or air)

� Cleaning

Preventive Maintenance Concerns

� PMs can be intrusive

� Introduce failure mechanisms

� Conflicting priorities may delay

PMs

� Full production schedule

� Cost control

“Pay me now, or pay me later”

Predictive Maintenance

� Technology to detect faults

� Vibration analysis

� Thermographic analysis

� Oil condition monitoring

� Ultrasonic analysis

� Electric motor current

analysis

Proactive Maintenance

� Applying advanced techniques & technologies to

extend machinery life

� Root Cause Failure Analysis (RCFA)

� Precision Alignment & Balancing

� Reliability Engineering (design/modification)

� Purchasing specifications for equipment/parts

� Reliability Centered Maintenance (RCM)

Predictive / Proactive Maintenance Barriers

� Existing Plant Culture

� “We’ve always done it this way.”

� Need a Champion/Sponsor

� Involve Stakeholders early

� Cost

� Investment in people and equipment

� In-house or Contract

WHERE DO I BEGIN?

Tribology - Lube Oil Analysis

� Lubrication is part of our Maintenance foundation

� Changing the oil in your cars

� Our program:

� Equipment needing lubrication is identified.

�What types of grease / oil will be used.

�Grease compatabilities

�Who will do the lubrication?

� Top grade mechanic?

� Gearbox oil condition monitoring

Tribology - Lube Oil Analysis

Wear

Contamination Chemistry

Extreme

Alarm

Alert

High Normal

Normal

Trivector

Sampling and changing the oil in our gearboxes prolongs their life and

reduces our costs.

Report Recommendations:

The particle count results are much higher than desired. Iron and

tin content are elevated indicating wear occurring in this

system. Check for sources of abrasives/dust entry. The silicon

result indicates contamination with dust/dirt/abrasives. All other

results are within expected ranges or are consistent with established

history. Continue sampling at scheduled intervals to establish

trends.

Thermography

Thermographic Uses

Electrical Distribution

Mechanical Drives

Process Troubleshooting

Thermography

� Diagnostic technique

�Measures the thermal difference between various

components and their environment.

� Electrical Distribution survey

� Began in 1976

� Identify “hot spots” - loose or corrosion

� 2100 pieces of electrical distribution equipment

� “No surprises” in our distribution equipment

Thermography Examples

Motor Starter - 2 phases on line side of starter

• >125 F (#2) and >150 F (#3)

• Inspect, clean, tighten/replace connections

• Repair immediately

Thermography

� Augment vibration analysis program

� Helps to fine tune predictive “call”

� Energy Savings

� Steam trap surveys

� Piping or Building insulation problems

� Process Troubleshooting

� Heat transfer in process rolls or ovens

Troubleshooting Process Problems

� Roll had suspected heat

transfer problem

� Film sample between rolls,

showing thermal artifacts

of the spiral cooling

channels in the main roll.

� Roll confirmed to have

heat transfer problems and

was acid cleaned.

IR00227.ISI

Vibration Analysis

� Premise - All operating machines vibrate.

� Increase in vibration = deterioration in machine

� Vibration analysis is used to determine the cause of

the vibration.

� Each fault generates a specific vibration pattern

� Frequency of vibration is dependent on Machine

geometry & speed

� Collect 3,000+ data points on plant equipment

Vibration Analysis

L44C - EXTRUDER MOTORMT 51100 -M2H MOTOR INBOARD HOR. 22-C1

Route Waveform22-Aug-02 07:21:18

RMS = .8270LOAD = 100.0RPM = 613. RPS = 10.22

PK(+) = 2.32PK(-) = 2.36CRESTF= 2.85

0 50 100 150 200

-3

-2

-1

0

1

2

3

Time in mSecs

Acceleration in G-s

CF ALARM

CF ALARM

PK ALARM

PK ALARM

Fault diagnosed and plans made to repair motor.

Vibration Analysis

L44C - EXTRUDER MOTORMT 51100 -M2H MOTOR INBOARD HOR. 22-C1

Route Waveform26-Sep-02 09:00:28

RMS = .1572LOAD = 100.0RPM = 1061.RPS = 17.68

PK(+) = .5138PK(-) = .8079CRESTF= 5.14

0 50 100 150 200

-2.0

-1.5

-1.0

-0.5

0

0.5

1.0

1.5

2.0

Time in mSecs

Acceleration in G-s

CF ALARM

CF ALARM

PK ALARM

PK ALARM

Normal operation - same location. This is what it’s supposed to look like!

Precision Alignment

Others (10%)

Misalignment

(50-70%)

Imbalance

(30-40%)

� Misalignment causes excessive vibration

� Leading cause of machine malfunction and

maintenance downtime.

� But often not identified as a root cause

Misalignment Effects

Alignment Methods

Precision Alignment

� An alignment program results in:

� Increased bearing life (8X)

�Reduced vibration

�Reduced operating temperatures (longer lasting

lubricants)

� Increased seal life

� Reduced energy consumption (~11% reduction in

motor power requirements)

IncreasedIncreased $$$$$$

Web Transport Alignment

� Misalignment in web handling portions of

machines can cause quality faults

� Creases, wrinkles, etc.

� Alignment can be performed in house or through

a contract organization.

� At least every three (3) years on our transport

and winding equipment.

Root Cause Failure Analysis (RCFA)

� Common problem-solving tool

� “The 5 Whys”

� Defect elimination in our:

� Processes

�Machinery

� Performance

� Drive to the systemic factors

� The true root

Root Cause Failure Analysis

� Catastrophic Failures

�Management driven to know WHY

� Significant immediate impact

� Chronic Failures

� Smaller in nature but reoccurring

� Safety Incident investigations

Summary - Turning the Profit Lever

� Maintenance produces Plant Capacity

� Maintenance is a Process & can be Improved

� Our Improvement

� (1989) Total maintenance downtime = 9.3%

� Average of 815 hours per film line (8)

� Improvement to 4.4% for all film lines

� >50% improvement in availability

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