Archive | July, 2009

199

2:00 am
July 2, 2009
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How To Kill A Bearing

ken_bannisterI continue to be amazed at the shameful way many plants abuse—make that “kill”—their bearings. Designed and lubricated in accordance with their actual operating conditions, bearings often outlive their parent machine’s usefulness. Unfortunately, there’s no thrill in this scenario. So, to bring in some excitement, we overload our equipment, speed it up, run it 24/7 and forego proper maintenance. If, however, you really want to kill a bearing outright, the following modi operandi are quite effective.
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315

9:59 pm
July 1, 2009
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A New Performance Measure: Timed Production Effectiveness

 

In the new world of multifunction manufacturing teams, limited resources, and relentless pressure on costs, managers are wrestling with three common issues: How to prioritize the use of limited resources. How to manage for optimum results. How to measure progress. If what you measure is what you get, perhaps we had better begin from this perspective. Unfortunately, there are several weaknesses to many of the popular measures.

Maintenance cost as a percentage of replacement asset value, a common metric for benchmarking, establishes cost objectives with no regard for operating intensity or age of assets.

What value is created by performance defined by a high percentage of scheduled to total maintenance if the scheduled tasks are unnecessary or improperly performed?

How valuable is reliability as a performance measure when required availability is significantly less than 100 percent or when there are substantial system redundancies?

Overall equipment effectiveness (OEE) and asset utilization measure availability and production output, but fail to include the cost of attaining increased availability and production.

To rectify these shortcomings, I would like to propose another measure of performance: timed production effectiveness (TPE). TPE can be applied as a measure of effectiveness of individual components as well as an entire facility.

TPE = timed availability x production output x conversion effectiveness.

  • Timed availability is the time a facility, system, or component is capable of producing a required result divided by the time windows in which production is scheduled or required. Timed availability adds two conditions to the conventional definition of availability:
  1. The target or objective is the actual time in which operation is required.

  2. In the event of a failure that slows or interrupts production, the interruption does not end for the purposes of calculating timed availability until production is fully restored.

  • Production output is production delivered in specification divided by the production objective. The concept of a production time increment also is applied so that the term reflects output when required to meet scheduled demand. Because actual output can be greater than scheduled output, production output may be greater than 1. If off-specification production is sold at a lesser price, a constant is applied to account for diminished income.
  • Conversion effectiveness is a conversion cost objective divided by actual conversion cost. The calculation must include all applicable conversion costs, including those for utilities (electricity, steam, water, etc.), operations, maintenance, administration, and waste disposal.
  • Production output is production delivered in specification divided by the production objective. The concept of a production time increment also is applied so that the term reflects output when required to meet scheduled demand. Because actual output can be greater than scheduled output, production output may be greater than 1. If off-specification production is sold at a lesser price, a constant is applied to account for diminished income.
  • Conversion effectiveness is a conversion cost objective divided by actual conversion cost. The calculation must include all applicable conversion costs, including those for utilities (electricity, steam, water, etc.), operations, maintenance, administration, and waste disposal.

Several people who have been introduced to TPE have commented that their enterprise prefers real numbers rather than normalized values. This requirement is easily accommodated. The denominator of conversion effectiveness divided by the numerator of production output results in conversion cost per unit output, a valuable performance measure in its own right. There are other vital measures that can be derived from TPE provided the information structure is properly designed.

During several discussions of TPE, the difficulty of obtaining accurate cost information has been cited as a major barrier. There are two answers:

  • First, it is imperative to know exactly how much it costs to deliver a given product. Lacking this knowledge it is easy to sell a product at less than the manufacturing cost, especially in today’s highly competitive climate where fractions may be the difference between profit and loss.
  • Next, regardless of whether accurate cost information is available today, competitive survival mandates it tomorrow. Those who cross the information bridge separating “guesstimated” and actual costs will have an enormous competitive advantage as well as crucial information with which to prioritize activities.

Whatever the measurement criteria and benchmarks for asset management, they must connect directly to unit objectives and profit, be familiar and understood by senior executives, and lead to optimized management decisions. Nothing else will attract the attention of those who control the funds. MT

  • To preserve the functions of our physical assets throughout their technologically useful lives
  • To the satisfaction of their owners, of their users, and of society as a whole
  • By selecting and applying the most cost-effective techniques
  • For managing failures and their consequences
  • With the active support of all the people involved.

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99

6:00 am
July 1, 2009
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Problem Solvers

Reduce Costs With This New Mobile Diesel Gen Set

caterpillar_mobile-gen-setCaterpillar has introduced a mobile diesel generator set to its line of towable compact products. Rated at 175 kW, the new XQ175, with a fuel-efficient Cat® C6.6 engine, offers ease of use and improved monitoring. The control panel is collocated with the distribution panel. Analog gauges are easily readable for oil pressure, engine temperature, voltage, amperage, frequency, fuel level and battery voltage. Indicators alert operators to low coolant level, low fuel level or fuel leak, low oil pressure, overspeed and emergency shutdown. According to the manufacturer, the unit’s ability to switch between 480/277 V or 208/120 V 3-phase operation via a voltage changeover board, instead of a voltage selector switch, reduces components and costs, which means less ‘wear and tear’ or opportunity for downtime. The new XQ175 is available exclusively through Cat dealers and The Cat Rental StoreTM locations.

Caterpillar Inc.
Peoria, IL

For more info, enter 261 at www.LMTfreeinfo.com
Next-Generation Industrial Wastewater Recycling Technologies

water-maze_ja09Water Maze has introduced its “Innovator Series” of products, next-generation automated wastewater recycling equipment that uses electro-coagulation and chemical treatment to remove emulsified oils, heavy solids and metals from a broad range of waste streams found in industrial washing applications. The four new patent-pending products are modular and can be used individually or together for a more complete filtration process. The new EC2-20A integrates electro-coagulation (an electrolytic process) and chemical flocculation to speed up the process of removing suspended solids to emulsified oils and heavy metals. The CoAg2-20A employs chemical coagulation and chemical flocculation technologies, similar to the EC2, that are designed to speed up the process of removing suspended solids and emulsified oils. The Indexing Polishing Filter (IPF), used as a pre-treatment or post treatment to another water treatment technology, employs various micron-size media paper to filter out particulates in water. The final component in the Innovator Series is the Clean Water Recycle Module, which simply manages the flow of water in and out of the system. For example, if treated water will be used with a pressure washer, the Clean Water Recycle Module serves as the holding tank to deliver water to the washer.

Water Maze
Camas, WA

For more info, enter 35 at www.LMTfreeinfo.com
Current Diversion Ring Protects VFD-Controlled Motors

inproseal_0709VFD-controlled motors inherently produce destructive shaft currents that must be redirected around the bearings. Otherwise, unmitigated electrical currents initiated by the VFD and induced by the motor shaft destroy the bearings. Inpro/Seal’s Current Diversion Ring (CDRTM, patent pending) safely diverts these currents and saves the motor bearings. Available through all major motor manufacturers worldwide, as well as EASA repair facilities, the new device can be furnished either as a “press-in,” a “Clip-on,” a “split” configuration or an “MGS” design, which prevents contamination from entering the motor bearing enclosure while diverting destructive shaft currents.

Inpro/Seal Company
Rock Island, IL

For more info, enter 36 at www.LMTfreeinfo.com
Self-Adjusting Locking Pliers

rapidvise_0709New Crescent RapidVise pliers from Cooper Tools automatically lock onto objects of different thicknesses at a preset pressure without user adjustment. The jaws’ strength stands up to that of standard locking pliers; their angled tooth pattern provides a superior grip over traditional models; the nickel-plated finish protects against damaging rust and corrosion. The RapidVise product line currently includes a 10-inch “curved jaw with wire cutter” model and an 11-inch ‘C’ clamp in swivel pad and regular tip versions. By late 2009, the line will expand to include 5-inch and 7-inch curved jaw styles and 6-inch and 9-inch ‘C’ clamps with swivel pads or regular tips.

Cooper Tools
Apex, NC

For more info, enter 37 at www.LMTfreeinfo.com

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