Greetings,
I had a great time speaking at EASTEC Tuesday.
Here is a snippet of the talk…
Robert Kravontka
The Maintenance Geek
I got to Speak at EASTEC Tuesday
Reply
Tag Archives: air leaks
The Maintenance Geek has been asked to speak at EASTEC in May…
May 16-18, 2017 | Eastern States Exposition, West Springfield, Massachusetts
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
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
Putting Together the 5 Steps to a World Class Maintenance Organization
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 coming out next week.
Here are some highlights or 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
Putting it all together.
The Big Picture
Identify the Critical Equipment. Pick your top three pieces of equipment that will hurt the most in terms of production or cost to repair, or whatever is the most detrimental to the business if it goes down. Then pick the next two pieces of equipment that are the biggest pain in the butt in terms of taking your time and effort.
Collect Data Identify a cost per machine for maintenance and then OEE in order of criticality. With this data attack the 6 major losses starting with idling and minor stoppages
Control your spare parts and tools. Identify what you have, 5S the spare parts area so you can get rid of what you no longer need and can find what is left. Determine what must be stocked, 24 hour rule, and mission critical parts.
Address your Skills Gap Even if it is one person, what skills do they have and what are needed.
Predict failure before is occurs.Start using predictive tools, like Ultrasound for bearing anomalies and air leaks. Infrared for motor temperature issues and alignment.
Get out of the breakdown mode.Start to change your mind set. Instead of how do we fix this as quickly as possible, start to look at your most critical and troublesome pieces of equipment and think about “What do we do to keep equipment running”.
Where are you on the PF curve?
Understand the P-F Curve.
Reactive mode putting out fires, only doing repairs when the equipment is broken.
Predictive mode, using some predictive tools, like oil analysis, vibration analysis, or thermography.
Proactive mode. You have ranked your equipment, started collecting data and recorded it somewhere. You actually look at it and use it.
Get Money allocated: Work on convincing the corner office. Speak their language of dollars and cents to get funds available to update critical equipment, $1 dollar spent on preventative and predictive maintenance can translate to 5-10 dollars spend in breakdown mode.
This is how to get out of the breakdown mode.
5 Steps to a World Class Maintenance Organization is ready to be published next week.
Send me a note if you would like a discounted signed copy when it comes out. robert@maintenancegeek.com
Thanks,
Robert Kravontka
The Maintenance Geek
Step 3 of the 5 steps in Developing a World Class Maintenance Organization
Step 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.
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. 
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.
Robert Kravontka
The Maintenance Geek
Can a compressed air leak survey save your shop $10,000 to $50,000?
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.
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.
Thanks, Robert “The Maintenance Geek”
(203) 510 – 8575
What is EUA? And why should I care?
Energize CT’s EUA has been created as an economic development initiative for the manufacturing sector.
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.
Robert Kravontka
The Maintenance Geek
What are the 6 steps to optimize your compressed air system?
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.
The 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 ”
Introducing 5 Steps to a World Class Maintenance Organization
Planning a June 2016 release of my new E Book called “5 Steps to a World Class Maintenance Organization” This is designed for the smaller manufacturer with a maintenance group of one or a few who do it all, including building and equipment maintenance.
Are your best Maintenance People getting ready to retire?
Do your younger newer maintenance professionals need to work smarter not harder?
How would an increase in productivity benefit your company?
Would reducing your maintenance Costs Help?
Are you getting tired of putting out fires all the time?
Does your equipment go down when you need it most?
Take a look at the 5 steps to help you get out of that breakdown mode.
We are going to have some fun with a method to help yourself and your company.
Step 1: Look at the building blocks of Maintenance
Step 2: Control your spare parts
Step 3: Stop Wasted PM’s
Step 4: Focused Improvements
Step 5: Formal Training
Then we will put it all together.
Click in the upper right to follow my blog…
Thanks,
Robert Kravontka The Maintenance Geek
Just got approved by Eversource to fund my Air Leak Surveys
The Maintenance Geek LLC has been approved…
Energy costs are quickly going up. Our no risk plan. We will come to your facility, conduct an Ultrasound audit of your compressed air system including reports and tagging. If we do not find issues there is no charge. If we do find air leak costs, we will charge 50% of the dollars saved up to your exposure of $1400.00 for a system of over 50 HP and under 100 HP. We will also offer a proposal to repair these leaks off hours when possible. I have been fortunate enough to get Eversource to fund 50% of your cost for this program. In a facility of this size we typically find $3,500.00 to $8,500.00 per year in air leaks.
For $700.00 we can come in and find and tag and report your air leaks. Eversource is also willing to pay 40% of the cost to repair all your leaks whether you fix then or I do.
Approved by Eversource to fund air leak surveys