Mechanical Technology August 2015

⎪ Proactive maintenance, lubrication and contamination management ⎪

Quick wins in predictive maintenance In the Mario on maintenance column for this issue, Mario Kuisis discusses the pitfalls in adopting predictive maintenance strategies and how to avoid them. He goes on to suggest some quick-win techniques that can be easily adopted to garner management support for the principle.

Mario on maintenance:

I n the last article of this series we discussed the evolution of the various maintenance strategies commonly in use (passive, reactive, preventative, predictive and proactive). We also considered how maturity must be developed in an organisation by pro- gressively embracing these over time in order to arrive at an optimum, sustain- able mix. All of this must of course form a complementary part of a well thought out and structured asset management programme for the organisation as a whole, but our particular interest is pro- active maintenance. One of the more difficult stages to break through and succeed with in proactive maintenance is that as- sociated with predictive maintenance. Unfortunately many individuals are sold on the concept and embark down the path with great enthusiasm and good intentions, but abandon it when they become disillusioned with high costs, difficulty with respect to support, indif- ferent results and questionable value. There are many reasons for this, of

which the following are very common: • Costs are underestimated because renewal of software licenses, train- ing, calibration, time to implement, resource requirements and/or tech- nology upgrades are partly or wholly overlooked. • The equipment requirements are not properly specified up front so it is ill matched to needs. • The in-house champion who went for the training leaves the organisation and the successor is disinterested. • Even worse there is no champion at all. • The condition monitoring team works in a silo. Corrective action is not taken timeously, if at all. • In spite of considerable effort and investment, the apparent yield in meaningful ‘saves’ is low. • When there are meaningful ‘saves’, they are not well publicised in the organisation. • Management only sees the expense and not the avoided costs when there are ‘saves’.

• False positives undermine belief in the approach and/or the technology. • The necessity and importance of train- ing is overlooked or underestimated. • Outsourced services avoid many of the above problems, but result in data overload and real value remains elusive. Fortunately, there are also many suc- cess stories where organisations have realised great benefits over extended periods of time. So what makes the dif- ference? Words like foresight, planning, perseverance and the right combination of people, equipment and circumstances come to mind. These are all essential, but perhaps none is more important than management commitment. An attitude that says “I know it can be done, I want it done, get out there and do it and I will support you in it.” Of course this will eventually get the right result, but it can be made that much quicker and easier if a good start- ing point is chosen. A few quick wins that demonstrate what can be achieved validates management decisions, pumps up the champion, encourages the team and begins the process of winning over the ever-present doubters and unbeliev- ers. You may well ask, does such a thing exist? If you have plant and machinery to take care of, you better believe the answer is almost certainly yes, regardless of your situation. Take note that management commit- ment is not only important for launching the initiative but also for sustainability, because management can access infor- mation that quantifies and proves the ongoing value to the business. Like ev- erything else, you can only manage what you can measure, so too with predictive maintenance. The best systems weigh investment in predictive maintenance against avoided costs. The results are reported regularly in financial terms and discussed monthly in meetings involving top management. Now if truth be told, every peddler of predictive maintenance wares has

Thermography is an ideal quick-win technique for detecting faulty steam traps, heat loss to defective or inadequate lagging, overheated bearings, motors with bad cores, heat loss and leaks in buildings.

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Mechanical Technology — August 2015