I have been living the PdM dream for 15 years, I have some thoughts based on experience, so I thought I would share them.

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Archive for October, 2009
From Geoff Generalovic, Maintenance electrician at ArcelorMittal Dofasco Inc. 

My career in predictive maintenance (PdM) has evolved since my formative years in 1995 and my first exposure to it via simple Excel charts tracking resistance to ground readings on our runout table motors. This was actually the topic of my first-ever presentation at a conference. It was the Society for Maintenance & Reliability Professionals conference in Atlanta in 1998. I sweated the topic big-time. I was extremely nervous because the audience, I believed, would see huge holes in my presentation and ask questions that I could not answer. The presentation was received well and there were many questions that I was able to answer effectively and well. I know my success was due to the fact that I knew about my topic, I had lived with the program, and could give answers based on sound knowledge and experience.

One reason I believe I was effective in my first-ever presentation in front of an audience of my peers was due to a book I had read. It was Dale Carnegie’s “The Quick and Easy Way to Effective Speaking”. My wife and I were visiting relatives in the Atlanta area. We went to several small towns, and in one we found an old bookstore. I didn’t find anything to read, but my wife’s cousin presented me with one of the original copies of this book after we left the store because he knew I was presenting my paper and knew this was a good book to improve one’s presenting skills. The book was a bargain at $1.50. I read the book cover to cover before I presented my paper. It put my mind at ease, but didn’t stop the butterflies in my stomach. Upon returning home, I enrolled and then took the Dale Carnegie course which developed my skills in presenting even more. The course also gave me more confidence in all aspects of my career and personal life.

I have presented papers at many conferences since that first presentation - at AIST (steel manufacturers conference), PPM conferences, PdMA motor testing conferences, Snell Infrared events and others. My success at these conferences was due to me living my program, developing it and seeing through. I was confident in what I was presenting.

Looking back on my career, this confidence was not felt in executing my infrared program. I was a timid thermographer when I started. I stressed over the possibility of making a bad call. My first call as a thermographer came in our mill; it was diagnosing a press block problem using my newly purchased IR camera. It was only a 1.5-degree Celsius difference, but it was correct. It reduced the mill delay from being seven hours to three, saving several hours in downtime, and was instrumental in increasing my confidence in my abilities.

Like my presentation journey, my thermography journey followed the same pattern, I went from inexperienced and being somewhat unsure to a thermographer with confidence in my abilities. This came with knowledge gained through training, contact with others in the thermography field, and executing a sound program based on good information. My education continues even today.

When you surround yourself with people with your best interests at heart, you can only be a success. This is not something that comes easy. You have to attend courses, classes or conferences to develop and nurture a network of peers who will always be there to help you via phone calls or e-mails to determine what a problem may be or to just talk about all things predictive. This support allows you to put yourself out there while executing your program and to always be looking for new opportunities to apply to your thermography program.

May you be successful in your career in your chosen field. I hope you find it very rewarding

     Kindest regards, Geoff  
Posted by Geoff Generalovic on Oct 22, 2009 1:12 PM EDT

My career in Predictive Maintenance (PdM) in Dofasco’s HotMill started late in 1995 September to be exact.  It started with a question “Do you want to be involved in Predictive Maintenance??” I didn’t know what I was getting into,but it sounded a lot better than what was going on in my career at that time.  My manager saw that the way to go for maintenance in the future would be the Predictive maintenance one, so I was the lead in that direction with his support.

 

 My PdM career actually started with Jack Nicholas, who was part of PdMA at the time, he was brought in to train all of the electricians atthe time in motor theory, something which many electricians are not trained in very well in their apprenticeship programs. 

 

Jack was also consulting with us on our maintenance program as well, I saw the benefits and believed it would be a good idea to follow these classes closely and to listen to Jack about the direction PdM was going.  Jack was instrumental in my early PdM education, so under his tutelage I developed sound ideas on what I wanted to do in this program. 

 

My first introduction was using Excel to trend meggar readings on our Runout table motors, the program is still in use today.  We developed monitor, open and inspect and change out limits in our program, it was very successful.  We were able to reduce our delay time from over 800 minutes a year to a consistent 90 to 100 minutes for all of the 410 motors in the mill .

 

I presented my first paper at the SMRP conference in 1998 in Atlanta based on this program, I think it was 1998, I’m and older guy can’t remember back that far. So it began, I moved out of the mill into the PdM offices. 

 

It turned out we had bought a motor test unit, the silver case unit from PdMA, one of their first, I found out two of my bosses had attended the training in Tampa, Florida,I was not to be so lucky.  The tester was plopped on my desk without any manuals, neither of my bosses could start up thetester, it had been so long since they had attended the training.  I did find a 1-800-number for PdMA’s techhelp line, what a great benefit that was, I got to know Rudy very well overthat phone line, they still have one of the best Help lines I have ever come across, kudos to PdMA for maintaining that. 

 

So my motor testing career started, we had done RCM studies at the time so I utilized that and my cohorts knowledge to determine the most critical motors in the system, entered them into my Excel database and started my testing based on that.  Today we have both PdMA’s MCEmax, MCE offline and on-line testers and the Framtome, on-linetest equipment. My mandate was to develop an infrared program as well. 

 

There was money in the budget for an infrared camera, so we purchased one of the first cooled focal plane array cameras on the market, the Agema 550, with as many options as we could get, extra lensesand the like. That was and still is the best camera available the resolution was incredible for its time.  I started taking basic images, then took Level I courses, progressed to Level II  courses always getting better with the camera each time. 

 

I developed the program still in use today, using my cohorts knowledge, RCM data and data I picked local experts brains for, so I used their ideas and methods, then developed my own.Again all of that data was entered into my Excel sheets, which again are still being used to this day. I believe the ground work for any program is key to a sustainable program, whatever leg work you put into your program now pays off in spades in the future.

 

 Today I am part of the Central Predictive Technical Services team applying everything I learned in the Hot Mill plant wide. It has been an incredible journey, during which I have met many people in the field who still keep in touch.  I’m still on my journey. This Blog is the next step, I have many ideas based on experience, some work well some are OK, so if I can help send you in a direction that will save you time, money and frustration, then my talking to you is worth it \. 

 

Kindest regards, 

 

Geoff



Posted by Geoff Generalovic on Oct 5, 2009 6:12 PM EDT

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