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Many maintenance improvement efforts or “change initiatives” begin with good intentions. Senior leaders endorse the new program, “slap” the project leader on the back and say something along the lines of: “I’m here to support you. Let me know if you need anything.” Regrettably, that’s where leadership support often stops—leaving the well-intentioned change initiative to die an untimely death.
The question is then asked by senior leaders, “What happened to the maintenance improvement initiative?” Fingers begin pointing, the project leader ends up in the crosshairs, and the front line labels the initiative as just another “flavor of the month” by management. Sound familiar?
If change is not driven from above by senior management, it won’t gain enough momentum to be successful. People within an organization need to understand that change is required and be given reasons why they need to change. They need to have knowledge and accept that processes need to now work differently. They need to agree that there will be real benefit(s) as a result. Unless these important messages come from senior leaders—acting as “sponsors”—people may resist or only partially adapt to change. What, though, is meant by the term “sponsor?”
In uncertain economic climates, success is not optional; there can be no false starts or flavors of the month.A project sponsor is usually the person who sees the need for change and has the authority to make something happen. In a large-scale change initiative, there can be different layers of sponsorship in the organization. The “primary” or executive sponsor is usually the one who has the power and status to create and deliver the project and frame and communicate a consistent message to the organization. For critical business change initiatives, the message should come from the very top. The chief executive should be engaged as the prime source of sponsorship.
A compelling business case is typically sufficient to enroll the support of many senior leaders willing to act as sponsors. Nearly all leaders want to be perceived as being supportive of exciting new ideas for improving organizational performance—and they are under pressure to keep improving results. Unfortunately, many of them do not know how to act as a sponsor.
For an improvement initiative to be successful senior leaders must set examples from the highest levels within the organization. If they say one thing and then do another, people begin to doubt whether the organization is truly committed to the change initiative. Once a senior leader takes on the mantle of “sponsorship,” he/she must set the example by communicating a non-wavering message, modeling the new behaviors and reinforcing the message through reward and recognition of the workforce.
In uncertain economic climates, success is not optional—there can be no false starts or flavors of the month. Make no mistake about it: Successful change programs can only be achieved when senior leaders provide visible sponsorship through the life of the effort. Without committed, skilled sponsorship, strategic initiatives will under-perform. The time, the cost and the pain of changing will be greater than necessary, and expected benefits will not be fully delivered. MT
Marshall Institute is a Raleigh, NC-based management consulting company that has provided maintenance and reliability consulting and training services to industries of all types, worldwide for more than 25 years. Telephone: (919) 834-3722.
The opinions expressed in this Viewpoint section are those of the author, and don’t necessarily reflect those of the staff and management of Maintenance Technology magazine.
Expanded Line Of Heavy-Duty Actuators
A-T Controls notes that its expanded line of Triac THD heavy-duty scotch yoke actuators is engineered for the most demanding liquid and air handling applications, powering quarter-turn dampers and valves with up to 1,600,000 in. lbs. (180,800 nm) torque. Capable of operating ball, butterfly and plug valves, dampers or louvers (any device that requires quarter-turn movement for on-off or throttling service), they incorporate a symmetrical-design yoke that delivers maximum torque at both ends of the 90° cycle. This proven design stands up to hard service in industries such as oil and gas, power generation, chemical processing, water/wastewater, mining, primary metals and pollution control.
For more info, enter 37 at www.MT-freeinfo.com
Improved NDT For AC & DC Rotating Equipment
Electrom Instruments’ new iTIG Surge Tester-Winding Analyzer provides non-destructive tests for all insulating systems of rotating apparatus (AC and DC). According to the manufacturer, this portable, rugged and dependable device differentiates itself from other products by finding faults where other testers do not. This is because it more closely duplicates motor operating conditions. The iTIG is unique because it has two live surge channels pulsing at 60Hz. Live multi-phase testing at 60Hz creates a much smaller margin for error and eliminates weak insulation going undetected.
For more info, enter 38 at www.MT-freeinfo.com
Pump Controller Can Save Your Time, Energy & Money
The new S-Drive Simplex Variable Speed Pump Controller from Goulds Pumps features simple wiring, startup and programming. Pre-packaged in an outdoor NEMA 3R enclosure, it’s cUL listed to meet Canadian CSA safety standards. The S-Drive has been designed for a number of submersible and above-ground centrifugal pump applications, including providing supplemental water pressure in buildings up to 10 floors, on a permanent basis or during periods of peak demand. This is a true variable frequency controller in that it adjusts motor speed to match the hydraulic needs of the system in order to maintain pressure (up to 70% energy savings over fixed speed pumps is common).
A Brand of ITT Corporation
Seneca Falls, NY
For more info, enter 39 at www.MT-freeinfo.com
Multifunctional Meter Does Almost Everything
Extech’s new feature-rich, multifunctional 461880 is a combination vibration meter and laser tachometer that measures acceleration, velocity and displacement, as well as RPM and linear surface speed. A large LCD rotates the numerical readout 180˚ following the orientation of the meter. Among other things, the 461880’s vibration meter features a remote vibration sensor with a magnetic adapter on 39″ (1m) cable, a wide frequency range of 10 Hz to 1 kHz and RMS or Peak Value measurement modes. The instrument’s tachometer component features a laser for greater distance, non-contact measurements up to 4.9 ft. (1.5 m) and has the capability to store Last, Max. and Min. readings.
For more info, enter 40 at www.MT-freeinfo.com
For Data Acquisition Purchases
IOtech’s 2009 Data Acquisition Solutions Catalog, featuring, among other things, the company’s Out-of-the-Box data acquisition products, is now available for download from the IOtech Website. Included in it are the new 6000 Series of data acquisition modules with up to 24-bit resolution, high-speed sampling and built-in signal conditioning for measuring strain or voltage. Each module also includes Encore interactive measurement software. Encore is an all-new application that allows users to log data, analyze signals and produce test reports.
For more info, enter 41 at www.MT-freeinfo.com
Class I Division 2 Accelerometers & More
Wilcoxon Research has rolled out six new Class I Division 2 (Zone 2) accelerometers. All have a sensitivity of 100 mV/g, and a tight +5% sensitivity tolerance, commonly called general-purpose industrial accelerometers. The standard top exit model is the 786A-D2. The standard side exit model is the 787A-D2, which is also available with a metric M8 mounting stud, model 787A-M8-D2. The 780A-D2 is a compact sensor ideal for portable data collection. The integral cable model is the 786F-D2. The 786T-D2 is a dual output model that senses both vibration and temperature. In addition to these accelerometers, the company has introduced three compatible connector-cable assemblies, suitable for Class I Division 2 (Zone 2) environments. Each can be lock wired to prevent it from inadvertently backing off the sensor.
A Meggitt Group Company
For more info, enter 42 at www.MT-freeinfo.com
AODD Pumps Certified For Explosive Environments
Wilden has announced that its groundable AdvancedTM and OriginalTM X Series Metal and Plastic air-operated double-diaphragm (AODD) pumps comply with two ATEX 95 (European) directives for explosive atmospheres. Realizing that safety in potentially explosive areas can only be guaranteed by a close and effective working relationship among all parties, Wilden has taken responsibility for its pumps’ compliance with the necessary ATEX directives. The company’s metallic X Series pumps comply with ATEX 94/9/EC Group I, category M2 and Group II, category 2, zones G and D. Its plastic X Series pumps comply with ATEX 94/9/EC Group II, category 2, zone G. Wilden also offers ATEX Retrofit Kits for its metal and plastic pumps that utilize the Accu-FloTM, Turbo-FloTM, Pro-Flo® and Pro-Flo VTM air-distribution systems. These retrofit kits feature parts that are constructed of electrically and statically dissipative materials, with a wide variety of appropriate elastomer options. All of the parts feature a special ATEX marking that indicates the suitable ATEX categories where the pump can be installed.
Wilden Pump Company
A Member of Dover Corporation’s
Pump Solutions Group (PSG)
Grand Terrace, CA
For more info, enter 43 at www.MT-freeinfo.com
Greasing what may, at times, seem like an inefficient supply chain…
According to PumpBiz®, its advanced, online pump purchasing and servicing solution helps you save time and effort. It lets you purchase pumps directly or provide your purchasing department with the exact information needed to buy the right units. If your organization has multiple locations, PumpBiz can help you centralize and consolidate your pump buying. Most importantly, it also provides online operating and maintenance instructions (OMI) for the products it sells,
The PumpBiz online configuration and specification engine replaces meetings, telephone calls and faxes among buyers and sellers with a simple streamlined process. What’s that mean to pump users/pump buyers? You have less follow-up to do.
PumpBiz notes that it represents only recognized and trusted manufacturers—and that most of its clients have already purchased from these manufacturers in the old, traditional marketplace. The company says that its close partnerships with recognized industry associations and industry experts add benefits to end users. The PumpBiz call center, sales department and its partners all support the Website.
A streamlined process
- PumpBiz offers you side-by-side comparisons and reviews of your pumping options. Once you select a pump, you can instantly place the order via the Web 24/7 or by calling 1-800-PumpBiz.
- Through the PumpBiz “MyStockRoomTM” capability, you can set up instant access to past purchasing and related information for your account or your group.
- Among other things, PumpBiz can supply copies of manuals that always seem to get lost and a database of symbols, clip art and pictures for creating diagrams, as well as links to other useful Websites.
- PumpBiz provides customers with convenient repair authorizations, repair parts and status of repairs. It also can help you locate local installers, something that is particularly important for companies with multiple locations.
- With its “PumpU” function, PumpBiz eliminates knowledge barriers by helping you to not only choose the right product, but how to use, install and repair pumps.
- PumpBiz provides suppliers and affiliates with a dynamic marketing channel to showcase their products and technology, services and events.
For more info, enter 36 at www.MT-freeinfo.com
5 Tips To Reduce Your Water Footprint
More than 90% of the world’s fresh water is consumed in the agricultural and industrial sectors. Given this staggering number, their carbon footprint is not the only thing manufacturers should consider to achieve a sustainable future—it is important that manufacturers also identify solutions that will reduce their water footprint and increase efficiencies. As such, Siemens recommends the following five easy tips for factory and manufacturing facility owners and operators to reduce their water footprint and start reaping the savings.
- Do your homework. Annually review your water management strategy from intake to discharge. Where it makes sense, take steps to reduce your water footprint. Ask for expert advice. There are technologies available that offer sustainable solutions for manufacturers and communities alike to treat water to virtually any specification. By doing an audit, you can identify ways to reduce your water footprint immediately. Be sure to continue to monitor your usage closely. The following Website explains how a corporation can look at their water footprint: www.waterfootprint.org/?page=files/CorporateWaterFootprints
- Treat water as a valuable resource. Treated water isn’t free; it takes energy and technological resources to treat it. Statistics show that by 2030 almost 50% of the world’s population will be living in areas of high water stress. So, the more tightly managed the water usage, the better.
- Reuse and recycle. Capturing, treating and recycling water during the manufacturing process can reduce water use by millions of gallons per year, as well as save money. This can be achieved by looking at areas like your boiler feed water, utility water or, in the example of a major beverage manufacturer, water used in packaging preparation. The manufacturer was able to put new processes in place to recapture and treat the water used for bottle washing, ultimately saving 25,000 gallons of water a day!
- Reduce waste. An effective water management strategy can help reduce waste and discharge, while also helping to meet regulatory requirements. Even taking a closer look at wastewater and identifying other uses within the facility can result in great savings. For example, a major healthcare products manufacturer recovered its waste stream and reused its feedwater, enabling it to recover more than 52 million gallons of water per year!
- Consider the water/energy link. Energy costs account for nearly 30% of the operational costs at water treatment facilities. Technology advancements, such as better automation, reuse technologies and waste-to-energy technologies, can mean greater energy efficiencies. A major brewing company installed technology, which, by converting its waste to energy, was able to save the equivalent of $500,000 in energy costs per year at a single location. So, don’t just look at the water use, follow the electricity usage as well.
For more information from Siemens on reducing your water footprint, visit www.siemens.com/water_footprint
Siemens Water Technologies
For more info, enter 30 at www.MT-freeinfo.com
New Technology Offers A Breath Of Fresh Air
A new compressor technology from Dresser-Rand employs supersonic ejectors that, by reclaiming gases ordinarily vented into the atmosphere, offer environmental benefits and enable facilities to operate more efficiently. The tandem or two-stage ejector system captures gas leakage from a dry-gas seal at low pressure and recompresses it to a pressure equivalent to the fuel gas pressure. Reclaiming these gases by injecting them into gas turbine fuel systems reduces hydrocarbon emissions to the atmosphere. The ejectors are available as new equipment options and product upgrades for centrifugal compressors that compress hydrocarbon gases. They also work with any low-pressure, low-flow-rate vent streams, and high-pressure stream applications. Because the ejectors have no moving parts, seals, shafts or packing, they are practically maintenance free compared to mechanical compressors and vacuum pumps.
Dresser-Rand Group Inc.
For more info, enter 31 at www.MT-freeinfo.com
Business Case For Manufacturing Convergence
Manufacturing convergence—the merger of traditionally separate functions and systems across the enterprise—is helping manufacturers address key market drivers of productivity, globalization, innovation and sustainability to overcome strong economic headwinds, according to two new White Papers from Rockwell Automation. The first paper, titled “Manufacturing Convergence: Enabling Plant-Wide Optimization in Any Economy,” examines how manufacturing convergence and the advanced technology that enables it is helping manufacturers position themselves for prosperity in any economy. The second paper, titled “Manufacturing Convergence Practices and Trends: Perspectives from Providers and Customers,” summarizes a panel discussion involving executives from Cisco Systems, Dassault Systèmes Delmia Corporation, Microsoft, Alcoa, General Mills, PepsiAmericas and Tetra Pak. According to both papers, to succeed, manufacturers must extend their focus beyond productivity to bring innovative products to market faster, meet customer demands in a global market, and produce in safe and sustainable ways. That shift is requiring new manufacturing processes, but it’s also compelling forward-thinking companies to unify manufacturing with other functions throughout the enterprise and across the supply chain. The White Papers are available for download at www.rockwellautomation.com/solutions/convergence
Rockwell Automation, Inc.
For more info, enter 32 at www.MT-freeinfo.com
Balancing Program Keeps The Blades Turning
LUDECA has expanded its VIBXPERT Balancer and Analyzer to suit the wind industry and its balancing challenges. This new, built-in wind balancing program has been adapted to the slow rotational speeds of wind turbines, helping to improve the balance conditions and, according to the company, result in a significant increase in the uptime and availability. With its balancing program, combined with software, accelerometers linear to 0.1 Hz, speed sensor and balance grade tolerance chart (G16), the VIBXPERT is an ideal portable system for mass unbalance of wind turbine rotor blades.
For more info, enter 33 at www.MT-freeinfo.com
Energy Management eLearning
Coastal Training Technologies and DuPont Safety Resources have collaborated to produce a new training program titled Energy Smart. Available on DVD, this is the first course in Coastal’s upcoming DuPont Energy Management eLearning Series. Energy Smart helps promote general energy awareness and includes energy-saving tips that translate into real savings for an organization. It aims to change the misconception that energy is “just there” and encourages employees to treat energy costs with the same fiscal assertiveness as any other business expense. Content contributions by DuPont energy engineers and consultants are based on DuPont’s successful energy management experience that has resulted in $3 billion in cumulative energy savings since 1990. The new offering applies a three-pronged approach to energy management and presents a compelling business case for its adoption. It explains the impact of energy management on the economy, environment, customer interface, energy independence and emerging technologies. It also shows how every employee can improve energy efficiency, citing low-cost, easy-to-implement best practices of energy-efficient organizations. Energy Smart is the first of 16 courses in this soon-to-be-released eLearning Series. Coming this fall, these online courses cover the energy-efficient use of industrial equipment and systems. Titles include: Energy Management Best Practices, Energy System Instrumentation and Controls, Theory of Steam Generation, Fuels and the Combustion Process, Boilers and Auxiliaries and Emission Control and Ash Handling, among others.
Coastal Training Technologies
Virginia Beach, VA
For more info, enter 34 at www.MT-freeinfo.com
Test Leads Provide Wind Industry Solution
Megger has introduced a new KC series of test leads, which were developed in conjunction with leading wind turbine manufacturers. These test leads provide a solution to the problem of finding reliable test leads long enough to be used for testing the continuity of lightning protection conductors in wind turbine blades. KC-series wind turbine test leads are available in a 100 m version and are equally suitable for use on site or in the manufacturing plant. For convenience and ease of handling, they are supplied as standard on a heavy-duty cable reel that is fitted with a friction brake to avoid tangles when paying out the cable. The leads are terminated with large Kelvin clips that have been specially designed to offer ease of use while providing the consistently reliable connections needed to ensure accurate and repeatable test results. Included with each set is a 5 m cable fitted with a duplex handspike for probing the lightning receptors on the tips of the turbine blades. Additionally, KC-series leads are suited for use with Megger DLRO10HD low-resistance digital ohmmeters, which combine robust construction with high test current capability. The leads also can be used with most modern types of low-resistance ohmmeters.
For more info, enter 35 at www.MT-freeinfo.com
The reliability and maintenance community has often referred to the “half-life” of a repaired electric motor. The use of this term is based upon the belief that a repaired electric motor will have about half the expected life of a new electric motor. Could this be true?
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