Category Archives: Small manufacturer maintenance

What Smaller Manufacturers need to do right now to grow their businesses.

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Right now, you need to get ready for some big growth opportunities.

  1. Identify what business sectors will expand and decline.
    1. Manufacturing will grow because of pent up demand. Restaurant / Hospitality will decline. Many restaurants will not survive the pandemic.  They will need to come up with money for all new inventory, and their patrons will demand more room between tables of strangers.  This means their density will drop nearly 40% and so will their profits. If they were hanging on before they will not make it now.
  • Who did you lose business to over the last 5 years and why?
    • If it was overseas, there will be a big push to buy America. Go after that business again, as buying decisions may have changed.
  • How will you go after all this new business?
    • Your website will need to talk about how you are doing business as much as what you do, and offer. Show your cleanliness efforts, you attention to your people and their protection.
    • Your supply chains will need to be looked at to assure you have all the materials and services you need to more business.
    • Where do you get the people?  Consider hiring displaced Food Service / Hospitality workers. Your prime hiring guidelines as always need to be will they show up and work hard. People with this background may be a good fit. Working on a line in a restaurant and dealing with point of service computers should be a good fit. You can train the rest.
  • How will your expenses change?              
    • Unemployment insurance will undoubtedly go up. Plan on it.
    • You will need to put money into your website to not only to attract new customers but also to attract a different worker. Show your cleanliness and quality work environment.
    • Adjust work hours to not only keep more space between your workers but to accommodate people trying to take care of their families. The right hours are a big reason Food Services / Hospitality workers do what they do.

These are exciting times… You have come a long way, staying in business and taking care of your people… Check out my video on this…

https://youtu.be/84zQ5kd2M_k

Get ready for some growth… If you are ready to go after it.

Robert Kravontka a.k.a. The Maintenance Geek

The Maintenance Geek is speaking at EASTEC on May 16th at 3:50 – 4:25pm

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Please mark you calendars:   Tuesday May 16th at 3:50 pm.

Register today and get ready for the EASTEC experience, including:

  • Hundreds of exhibitors showcasing the latest technologies,
    equipment and products
  • Keynotes and technical presentations with industry leaders and experts
  • Networking opportunities to meet new contacts and develop relationships
  • Resources that can solve your company’s biggest challenges

You already know how valuable a trip to EASTEC can be for your business. Register now and mark your calendar to attend in May 2017.

Visit easteconline.com to view the exhibitor list, floor plan, featured technologies and much more.

SHOW LOCATION:
Eastern States Exposition
1305 Memorial Ave
West Springfield, MA 01089

SHOW HOURS:
Tuesday, May 16
9:00 a.m. – 5:00 p.m.

Wednesday, May 17
9:00 a.m. – 5:00 p.m.

3:50 – 4:25 come and hear the Maintenance Geek speak on the 5 steps to get out of the BREAKDOWN mode.

Thursday, May 18
9:00 a.m. – 3:00 p.m.

 

Hope to see you there.

The Maintenance Geek has been asked to speak at EASTEC in May…

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May 16-18, 2017 | Eastern States  Exposition, West Springfield, Massachusetts

I was pleased to find out that I have been accepted to speak at EASTEC.

Here is the letter I received:

Dear Robert:

On behalf of SME, thank you for submitting an abstract for EASTEC 2017.  We are pleased to inform you that your abstract, “5 Steps to Get Out of the Break Down Mode“, has been accepted for presentation at this event taking place May 16-18, 2017 at the Eastern States Exposition in W. Springfield, MA. You play an important role in the educational program, and we look forward to working with you in the coming months. Specific details regarding the day and time of your presentation will be sent to you within the next few weeks.

As soon as I find out the date and time I will put it up here.

Register today and get ready for the EASTEC experience, including:

  • Hundreds of exhibitors showcasing the latest technologies,
    equipment and products
  • Keynotes and technical presentations with industry leaders and experts
  • Networking opportunities to meet new contacts and develop relationships
  • Resources that can solve your company’s biggest challenges

You already know how valuable a trip to EASTEC can be for your business. Register now and mark your calendar to attend in May 2017. Simply click here to update your contact information and complete your EASTEC 2017 registration.

Visit easteconline.com to view the exhibitor list, floorplan, featured technologies and much more.

SHOW LOCATION:
Eastern States Exposition
1305 Memorial Ave
West Springfield, MA 01089

SHOW HOURS:
Tuesday, May 16
9:00 a.m. – 5:00 p.m.

Wednesday, May 17
9:00 a.m. – 5:00 p.m.

Thursday, May 18
9:00 a.m. – 3:00 p.m.

Thanks,

Robert

The Maintenance Geek

5 Steps to a World Class Maintenance Organization is available

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5 Steps to a World Class Maintenance Organization for the Small Manufacturer

5 Steps to a World Class Maintenance Organization for the Small Manufacturer

Are your best maintenance professionals ready to retire? 

Do your younger people need to work smarter not harder?

In General, breakdowns are 5 to 10 times more expensive that preventing it in the first place.

 

My new book 5 Steps to a World Class Maintenance Organization is out and available on Amazon.com   http://amzn.to/2c78hia

If you want a signed copy send me an e mail at:    robert@maintenancegeek.com

I will get it out to you quickly.      Let me know who and where.

Here are some highlights of what to expect.

Step 1:  Rank your Equipment and collect some simple data.

Step 2: Control your critical spare parts.

Step 3 Stop Wasted PMs

Step 4 Focused Improvement  Events

Step 5 Formal Training

Step 4 of the 5 steps to a world class maintenance organization.

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Step 1:  Rank your Equipment and collect some simple data.

5 Steps to a World Class Maintenance Organization for the Small Manufacturer

5 Steps to a World Class Maintenance Organization for the Small Manufacturer

Step 2: Control your critical spare parts.

Step 3 Stop Wasted PMs

Step 4 Focused Improvement Events 

 Set up an event with one of your most critical pieces of equipment.  Who should be the Players in your focused improvement event?  Maintenance Personnel , Operations Management,  Operators,  Engineering, Finance, Material handlers, getting someone from the “C” suite will add a lot of credibility to the program.

Develop the “keep it running” mindset vs the “fix it when it breaks” historic plan.

Sit back and look at these critical pieces of equipment, once you have them  running in like new condition, ask what it will take to keep them running? Not what do we need to keep on hand to fix it the next time it goes down.

The focused improvement event plan is to shut it down, take it apart, clean it, then put it back together in like new condition. Put it in its most productive state.

Now the goal will be to develop countermeasures to contamination, lubrication and access.

Here is what you should include in a typical focused improvement event:

  • Put together a cross functional team.
  • Measure and calculate OEE.
  • Your goal is zero equipment stoppages.
  • Measure your repetitive failures
  • Open up the equipment
  • Look for:
    • Contamination
    • Lack of Lubrication or too much lubrication
    • Air Leaks
  • Stabilize the equipment
  • Put countermeasures in place to keep equipment in like new condition
  • Close up the equipment.

Duplicate this effort on the next most critical machines

Here is an example of a walk around sheet with visuals to help even new operators see what they are looking for, and alert maintenance when something of out of spec..visual walkaround1

 

 

 

 

 

 

 

 

 

5 Steps to a World Class Maintenance Organization is ready to be published, in August 2016.

Send me a note if you would like a discounted signed copy.

 

Thanks,

Robert Kravontka

The Maintenance Geek

robert@maintenancegeek.com

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Step 3 of the 5 steps in Developing a World Class Maintenance Organization

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Snapshot_24Step 1:  Rank your Equipment and collect some simple data.

Step 2: Control your critical spare parts.

Step 3 Stop Wasted PMs

Typically 50% of PM’s are wasted.

An example would be doing a PM in an electrical panel, the goal is to tighten the 100 or so connections, typically 1 or 2 will need tightening. This is mind numbing work, and can lead to damaged connectors.  Unintended consequences. If predictive tools were used, like an infra-red camera, only the 1 or 2 connections would need to be tightened,  and the broken connector would have been avoided.7

Predictive Equipment:

Ultra Sound for air leaks, proper bearing lubrication, and steam trap health.

Infra-Red for motor life, any motor over 150 degrees needs to be watched, motor life drops off exponentially with each 20 degrees of temperature increase. Loose electrical connections, are a safety and fire hazard. Process anomalies like furnace insulation, along with facility monitoring like roofs and air infiltration can pay for the equipment with lower energy costs.

Oil Analysis to extend intervals between changes. Accomplish this by a route based oil testing program.

Vibration Analysis to predict a host of motor, connector, and bearing issues.

Operators can be very predictive. They must own their machines and communicate the health of their machines to maintenance.

This picture is a Zebra card that shows oil level. This also shows quality, as it is not milky or speckled with contaminants, or discolored from  heat. Zebra Cards

Get trained in Oil Analysis, Thermography, Vibration and Ultrasound. There is lots of free training available from the equipment manufacturers. You can hire this equipment out or rent it.

 

Want to know more, go to the upper right and sign up for the next exciting episode of the Maintenance Geek Blog.

Look out for my upcoming book.   5 steps to a World Class Maintenance Organization.

 

cropped-snapshot_001.jpgRobert Kravontka

The Maintenance Geek

robert@maintenancegeek.com

 

Step 2 in Developing a World Class Maintenance Organization

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Snapshot_24Step 1:  Rank your Equipment and collect some simple data.

Step 2: Control your critical spare parts.

 

 

 

Use these questions to decide what is critical.

 

  1. Is the item obsolete or likely to be obsolete in 6 months?
  2. Can you use something else that you have in stock as a substitute?
  3. Can you forecast when you will need it, using predictive tools?
  4. Can the item be delivered in an acceptable lead time (quick/local delivery, overnight)?
  5. Can the part in service be repaired in an acceptable lead time (repair rather than replace)?
  6. Is the item being ordered for a project or upcoming PM?
  7. Can the need for the item be eliminated (engineered out)?
  8. Can we use someone else’s stock (share/pooling)?

Rule-of-Thumb:

If you must have it to satisfy customer demand, stock it.

If it cannot be obtained within 24 – 48 hours stock it.

The cost has No Impact stock it.

 

Want to know more, go to the upper right and sign up for the next exciting episode of the Maintenance Geek Blog.

cropped-snapshot_001.jpgRobert Kravontka

The Maintenance Geek

robert@maintenancegeek.com

 

5 Steps to a World Class Maintenance Organization for the Small Manufacturer

5 Steps to a World Class Maintenance Organization for the Small Manufacturer

 

Can a compressed air leak survey save your shop $10,000 to $50,000?

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 Yes it can…

Try  spending the money you save from a good air leak survey on some tools to keep you out of the breakdown mode.

Air leak nozzle 1

Scenario #1      200 HP of compressed air, 100 HP full time and 100 HP as backup. house pressure is 107 to maintain 100 PSI throughout the system. 150 gallons of accumulation, typically we like to see 4 gallons per HP. This is a 3 shift operation  300 days per year. Operations include machining centers, screw machines and plating.

 

Over $50,000.00 of wasted air leaks were found, nearly 17% of their total energy bill.

 

Scenario #2   40 HP plus 25 HP 90% loaded at 110 PSI.    200 gallons of accumulation was available. This operation ran 3 shifts per day and 360 days per year. This anodizing operation was greatly automated, lots of air controls.

Over $18,000.00 were found in wasted compressed air.

 

Typically we find between $80 – $160 dollars per Horsepower per shift in waste. How many Horsepower does you shop run.  Leaks are cheap to find with the right equipment and cheap to fix.

 

How could you use an extra $10,000 to $50,000 per year to grow your business or improve your maintenance department?

Give me a call at the Maintenance Geek LLC to find out more.

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Thanks,                                                                                                                 Robert   “The Maintenance Geek”

(203) 510 – 8575

What is EUA? And why should I care?

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Energize CT’s EUA has been created as an economic development initiative for the manufacturing sector.

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Sponsored by Eversource the assessment helps manufacturers qualify and identify specific energy reduction opportunities and the efficient measures needed to reduce kWh and CCF consumption. This study that looks at how much, where, and when you use energy.

This assessment will include an overview of the following areas:

 Motor Systems,

 Air Compressors

 HVAC Systems

 Process Equipment

 Lighting

 Other significant energy-consuming areas.

Once the study is complete, an Energy Usage Assessment (EUA) analysis with recommendations is provided. A fixed price for work for each project is reviewed by the utility and customer for approval. The proposal will include all the Energize Connecticut incentives such as; a 50/50 cost sharing for the EUA program and potential reimbursement for implemented Energy Opportunities.

10 – 20 % in potential energy cost reductions

Detailed analysis of your energy use and costs

Identification of “Idle Load” energy waste

Efficiency analysis of facility systems.

Equipment upgrade recommendations

ECM financial impact and ROI analysis

Access to programs,resources, and funding.

Each event will consists of: Training                                                                                                                                                             Assessment                                                                                                                                                       Analysis

 

 

Click in the upper right corner to get each blog episode sent to you when it becomes available.

Or contact me for more info on any of the Energize CT programs.

 

snapshot_001Robert Kravontka

The Maintenance Geek

robert@maintenancegeek.com

What are the 6 steps to optimize your compressed air system?

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Engineered Air Nozzles by EXAIR

 

Compressed air leaks, and inefficient blow offs can waste thousands of dollars of electricity each year. This affects your companies production costs and bottom line.

 

 

What are the 6 steps to optimize your compressed air system?

  • Determine the main compressed air users in your facility
  • Find and fix the air leaks with Ultrasonic Leak Detection
  • Upgrade your blow off and cooling operations with engineered products for less air use and lower decibel levels.

     High efficiency nozzles                                                                                                                    High efficiency air knives                                                                                                                  High efficiency  blow offs

  • Turn off compressed air when not in use, or put it on a timer to only run when required
  • Use intermediate storage next to the point of use
  • Control the air pressure near the point of use.

exair_footerThe Maintenance Geek LLC is proud to be a stocking distributor for Exair the home of intelligent compressed air products

 

E Mail me for a catalog and to get 10% off of current pricing.     robert@maintenancegeek.com

 

Click in the upper right hand corner to get this blog sent to you as soon as it is published.→

 

Robert Kravontka    “The Maintenance Geek ”

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