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Work Execution ManagementPosts About Operator Driven Reliability (ODR)
ODR requires technology
RM Registered Member
Registered Member And trust me...no special technology needed here. Just basic skills. [ more ]
Registered Member Technology is not a requirement. Buy in (motivation) is not a requirement either. Some operators are motivated to do a good job so if they feel that the various little "tweaks" that most of them do to a machine actually makes a difference or impact and reflects on how they are viewed, they're going to do it. The trick though there is the feedback...the motivation. If the operator is highly silo'ed then your only feedback is when the technician comes by to work on the machine and that little... [ more ]
Registered Member From where I stand, understandable technology and training will always enhance and improve ODR. That being said ANY technology must be discussed and the operator needs to be 100% on board with the need to use it and be fluent in its use. There will always be a learning curve for both the operator and supervisors/management. However once the new technology is running effectively, most groups will quickly see the advantage of implementation. This is assuming of course the proper technology has... [ more ]
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Work Execution ManagementPosts About Operator Driven Reliability (ODR)
WELDING MACHINE PROBLEM
RM Registered Member
Registered Member The only problems that come to mind are, either the line voltages drop during the welding operation. Check line voltage when welding. or the transformer may not be generating the required voltages. Regards [ more ]
Registered Member Hi AMP Thank you for your speedy reply. As requested by you, I will elaborate on the problem I have with my machine: It is a Cemont TX 165 Lift Tig Inverter. It can also do ordinary Flux Coated stick welding ( Arc ) The problem I have is that it suddenly started losing it’s Arc strength while building-up a bearing journal on a gearbox shaft? After several attempts at different current settings I gave up. It would seem like it wanted to strike a good arc but immediately loose the arc. The... [ more ]
Registered Member Welcome to the forum, Could you please elaborate your problem a bit further. [ more ]
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Work Execution ManagementPosts About Operator Driven Reliability (ODR)
Qualification of Pumps in a System
RM Registered Member
Registered Member ❤️
Registered Member Thanks for the responses it is a centrifugal pump based on API-610. The gasket is made of Teflon. The question is, should the pump be tested on same pressure as the piping system has been qualified or just a leak check will be fine? For example, if the system was qualified on 10bar, should we give 10bar hydrostatic test to the pump or not? Regards [ more ]
Registered Member What pump type is it? [ more ]
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Work Execution ManagementPosts About Operator Driven Reliability (ODR)
ODR PRACTICALITY AND IMPLEMENTATION
RM Registered Member
Registered Member Vendor alert Skf Microlog Inspector is the only one I am aware of. It takes all sort of process inputs as well as safety procedures,checks and can even be set up to take basic vibration data like velocity and enveloped acceleration readings. [ more ]
Registered Member You may check out solution from SKF on ODR. Disclaimer : I do not have any affiliation with SKF. I am not aware of the standard related to ODR but people relate it quite closely to TPM. [ more ]
Registered Member ODR may include basic front line maintenance activities such as minor adjustments, tightening, cleaning, lubrication, etc. by operators within certain units or areas. [ more ]
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Work Execution ManagementPosts About Operator Driven Reliability (ODR)
ODR from SKF
RM Registered Member
Registered Member Without asking the deeper discussion, it can all boils down to selling tools like the FISH types. Also the more unfamiliar the user with the technology, the better. It will trigger more early bearing replacement... [ more ]
Registered Member SKF is nothing but crap in the maintenance services industry. Believe me it is not worth it giving too much of your budget to the experimental technology. Being from SKF formarly,i know the inside story but cannot go deeper in this discussion. [ more ]
Registered Member ODR is for me an elusive dream for many companies. Why i say this is because of my observation that people and system try to resist unprecendented procedures. Even if we say the top management is propelling to it, i still don't see it effectively implemented simply because it needs preparation and readiness. Questions are like: 1. Transition from existing SOP and accountabilities needs to be levelled 2. How we emerge the new scope assigned to the operators and are they willing and can cope... [ more ]
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Work Execution ManagementPosts About Operator Driven Reliability (ODR)
Operator Driven Reliability
RM Registered Member
Registered Member Hi Josh Yes, you are right. The operators already doing their walkdown within the plant. Already doing quick fixes or adjustments, cleaning, lubrication, etc. But will have hand-held tools, as I mentioned and the idea is to transform their routine walkdown with a sustainable program and compute information. For sure will be a training program, will be defined some route with specific alerts for any equipment, etc. Thanks for feedback [ more ]
Registered Member In our plant is a different story. Operators are placed on remote rooms. Production field engineers do the inspection.Anyway we integrated vibration monitoring for improvement [ more ]
Registered Member I thought operators always do their normal rounds around their designated plant units or sectional processes. Will your operators do some basic equipment care and do some quick fixes or adjustments, cleaning, lubrication, equipment owenership program, etc. on the spot or almost immediately as required? Will you implement proper equipement duty/standby option or rotated as you wish? Will your opeators be armed with hand-held tools? Ultimately, will the operators lead reliability programs such... [ more ]
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Work Execution ManagementPosts About Operator Driven Reliability (ODR)
Vibration pens, are they worthwhile?
RM Registered Member
Registered Member Vendor, If you for some reason feel the urge to have the classic pen type, and there are, it´s better than nothing, you have it here: http://www.vtab.se/index.php?page=79&lang=en Olov [ more ]
Registered Member The Type of "Pen" Planty mentions is the Marlin Pen, offically known as a MCD Machine Condition Detector. This device utilizes a magnetic base, and provides a repeatable reading. It has led indicators for two levels of alarm for Acceleration, Velocity, Enveloping and Temperature, and it's intrinsically safe. At it's current price point though, your in the range of a single channel FFT analyzer with more capability. I agree that the old style pens had limitations, but most new portable pocket... [ more ]
Registered Member We use Vibration pens specially for bearing lubrication assessment and have been able to save many breakdowns. Keep gSE value below 4 and the beaing will get enough food if lubrication is the reason.. Regards Irshad [ more ]
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Work Execution ManagementPosts About Operator Driven Reliability (ODR)
Combination of RCM/TPM
RM Registered Member
Registered Member I think RSAReliability is complimentary to this website in terms of content. Some take discussion offline for avoiding mentioning possibly sensitive issues publicly (simply to avoid lawsuits) or there is probably commercial interests. [ more ]
Registered Member Rolly Thanks and please - no need to apologize - we are just greedy for learning and you are a teacher. BTW - I do enjoy your web site (and email newsletter) a great deal and find very useful information there. Glad you are a member. Terry O [ more ]
Registered Member Terrence, Well noted,won't happen again. I apologize for this inconvenience. My Warm Regards, [ more ]
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Work Execution ManagementPosts About Operator Driven Reliability (ODR)
Equipment Tagging... RFID
RM Registered Member
Registered Member Dave, Just for interest what are you expecting to gain from the RFID's and are there currently any issues with associating work orders with the correct equipment etc at your plant? Thanks, Andy [ more ]
Registered Member Andy, Our company is implementing a Operator Driven Reliability program for 1500 conveyor gearboxes and motors in our facility. The PDA we are using is a SKF Marlin. I just ordered RFID tags to be installed at evey asset. The RFID will allow the operator to scan the tag and the PDA will bring up the points to be collected. We in our in house CBM crew have tested it and it seems to be just the ticket. We also have plans to do our steam trap audits using this technology. The SKF Marlin PDA... [ more ]
Registered Member Steven, I agree with you that it might well be a step to far and the main issue is getting the basics right. In particular providing asset tags that can be easily associated the database. Fundamentally its a people thing and not fancy tags will solve that! However the effort/ expense required to paint big letters on is probably the same as sticking and RFID tag on. But.... we know big painted letters work. So are the theorectical gains of RFID eg. less manual data entry, more accurate data... [ more ]
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Work Execution ManagementPosts About Operator Driven Reliability (ODR)
Difficulties In Implementing TPM
RM Registered Member
Registered Member Josh, Different pillars of TPM have different KPI's used example in Planned Maintenance we use MTBF, MTTR, Breakdown Occurence. However, the primary measure for TPM is OEE or Overall Equipment Effectiveness. My Warm Regards, [ more ]
Registered Member How to measure performance of TPM? Any KPIs for TPM? [ more ]
Registered Member Dear All, For those embarking on a TPM journey, would like to share my experiences on implementing TPM and its key factors that must not be overlooked. http://www.rsareliability.com/newsletternovember2007issue.htm My Warm Regards, [ more ]
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Work Execution ManagementPosts About Operator Driven Reliability (ODR)
Can equipment failures really be eliminated ?
RM Registered Member
Registered Member Dear All, Let me conclude my discussion here as to what I think is most relevant and appropriate : 1st : We can definetly eliminate failures by analyzing them through RCFA and RCA . My reply : Wrong !!! Failures cannot be totally elimated by analyzing them through RCFA and RCA. There are a variety of causes to understand and analyze and every single failure have their own unique causes and when we only treat a single cause then there is a likelihood of that same part to fail again in the... [ more ]
Registered Member hehe - thanks Robbie - but the space shuttle program is not what I would call a typical industry - the risks associated with being an astronaunt require a different set of rules and I'm sure their life insurance policies take that into account. Mike. [ more ]
Guest Josh, I am not sure I agree with this statement. As stated within this thread the technical integrity may not be worth safeguarding in some cases. (RTF strategies) We do maintenance because assets fail, and assets fail because thats the way the universe works. Check this out: www.secondlaw.com [ more ]
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Work Execution ManagementPosts About Operator Driven Reliability (ODR)
From TPM to RCM
RM Registered Member
Registered Member What are the 16 major losses mentioned in the article above? [ more ]
Registered Member RCM vs TPM article on Centre for TPM Australaisia site may be of interest. CTPM Website [ more ]
Registered Member Hello Mike, I have combined a well known RCM methodology with the PM pillar. I have done this for our industrial factories across the globe. If conducted correctly and implemented TPM and RCM can be better than simply doing one or the other. My opinion on this is that combined together the benefits are monumental in my experience. Basically it provides a documented maintenance program that creates equilibrium for the process, technology, and culture conundrum. As TPM does create a cultural... [ more ]
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Work Execution ManagementPosts About Operator Driven Reliability (ODR)
Moubray on OEE
RM Registered Member
Registered Member Perhaps RCM pros want to show the end results of their analysis to see how many will be maintenance or operation tasks. [ more ]
Registered Member Ok then, is it not because of the PMO analyst background from operations? [ more ]
Registered Member Josh, Neither PMO nor RCM "give" tasks to operators... both processes define the failiure modes and work out what is the best action to defend the organisation when that failure mode begins to happen or has happened. If it turns out that the operators can provide the best defense, then the task will be an operator task, if not the task will go to some other team or there will be no defense at all (No scheduled maintenance). In my case studies, it just looks like PMO shifts a lot of tasks to... [ more ]
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Work Execution ManagementPosts About Operator Driven Reliability (ODR)
Toyota Profits
G Guest
Guest Gents, I have been studying the LEAN process and how it applies to asset maintenance now for several years. I occurs to me that the approach most have taken is to directly transfer the concepts from LEAN used on production to the area of asset maintenance. I think this is fundamentally flawed and have a posting on this in my Blog which may be of interest. [ more ]
Registered Member I thought TPM was also mentioned as well as JIT and relentless defect elimination process. [ more ]
Registered Member I confess I didn't read this article in depth, but I skimmed it and it seems to me that there was very little about Toyota's maintenance efforts. While I agree with most of what the article contained, it more cited Toyota as doing lean. To do lean well you do need reliable equipment. It's my impression that many of the Japanese manufacturers achieve reliability by doing lots of PM, time based maintenance. The case study cited in the article is a bicycle manufacturer. [ more ]
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Work Execution ManagementPosts About Operator Driven Reliability (ODR)
TPM
G Guest
Registered Member So Kornel, have you finished yoru thesis? [ more ]
Guest You've suggested me really useful websites. Maybe you know them well, are you interested in TPM. Is your work in connection with TPM? What do you think about it? Do you use TPM3? Most of the companies use TPM with 5 pillars here. But we also have Unilever here, and they use I think TPM3 or similar one, but I think it is extreme to write a one point lesson about how to close the door. What is your opinion? [ more ]
Guest You've suggested me really useful websites. Maybe you know them well, are you interested in TPM. Is your work in connection with TPM? What do you think about it? Do you use TPM3? Most of the companies use TPM with 5 pillars here. But we also have Unilever here, and they use I think TPM3 or similar one, but I think it is extreme to write a one point lesson about how to close the door. What is your opinion? [ more ]
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Work Execution ManagementPosts About Operator Driven Reliability (ODR)
TPM in Processing Plant
RM Registered Member
Registered Member Since only 1 response so far, I like to chip in. I haven't been involved in TPM proper. But from what I understand, TPM with all its pillars implemented is indeed a major change. Therefore, like all other massive changes, I think a strong business-driven justification is needed and top mgmt support is crucial unless if you are one of them. I heard the margin for refineries is small (Is it 1 USD per barrel?) and with the high price of crude, maybe a good case for change if managed properly. [ more ]
Registered Member The concepts are not new but most of the literature I see is about TPM in a manufacturing environment. I work in a continuous process plant. We schedule one turnaround/repair session per year and are working on extending that. We perform vibration analysis, oil analysis, thermography and ultrasonic thickness testing on our process piping to reduce the number of "surprises" we get. TPM appears to be a potential addition to our maintenance plan, meaning the maintenance process could be... [ more ]
Registered Member If concepts are grossly new and you're in-house. Ensure your lubrication program is in order and make improvements there immediately. Lubrication is # 1. If you can't install machinery properly and/or rebuild machine; training is in order even moreso than normal. Positively make sure you have a good alignment program. PM's need to be developed and a Predictive Maintenance (PdM) program implemented. Your PdM must be hi-caliber and supported. Go for quality first, speed comes automatically. [ more ]
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