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The Maintenance Geek is speaking at EASTEC on May 16th at 3:50 – 4:25pm
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…
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 4 of the 5 steps to a world class maintenance organization.
Step 1: Rank your Equipment and collect some simple data.
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..
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
Step 2 in Developing a World Class Maintenance Organization
Step 1: Rank your Equipment and collect some simple data.
Step 2: Control your critical spare parts.
Use these questions to decide what is critical.
- Is the item obsolete or likely to be obsolete in 6 months?
- Can you use something else that you have in stock as a substitute?
- Can you forecast when you will need it, using predictive tools?
- Can the item be delivered in an acceptable lead time (quick/local delivery, overnight)?
- Can the part in service be repaired in an acceptable lead time (repair rather than replace)?
- Is the item being ordered for a project or upcoming PM?
- Can the need for the item be eliminated (engineered out)?
- 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.
Robert Kravontka
The Maintenance Geek
5 Steps to a World Class Maintenance Organization for the Small Manufacturer
Maintenance Geek Video Book Report “Seeing the Invisible” Episode #5
What is the cost of compressed air leaks?
I Found a good article from C.E.D. Compressed Air Inc. 
For many organizations, compressed air comprises a large part of an ever-growing utility bill, so now companies are beginning to analyze the true cost of compressed air leaks within their facility. The results show that compressed air leaks affect expenditures in a range of areas.
Compressor Sizing
Industrial firms purchase their compressors based on the demand in terms of air in the system. Air leaks can cause higher than necessary equipment expenditure and can also mean that equipment must be maintained on a more regular basis to ensure optimal performance in meeting demand.
Water Intrusion
In addition to allowing air out of the system, leaks tend to let moisture in. Water migrates from the high humidity outside air to the compressed air. This water migration can potentially cause cracks in valves as large amounts of water enter the system and overload components. Companies must then dip into their budget to replace any damaged components and conduct moisture removal maintenance on their systems.
Reduced Accuracy in Air Profiling
When leaks occur, they can prevent plant managers from achieving an accurate read in terms of their air profile. In leaks where the total leak load exceeds 10% of the overall load capacity, the artificial demand caused by the leaks can prevent companies from seeing the full picture of their plant efficiency. Such leaks can lead to wasted money on air audits and other efficiency improvement measures.
What do we need to do?
By taking a proactive strategy in managing and repairing air leaks within our compressed air equipment, companies can not only improve the performance of their equipment, but save thousands of dollars annually in terms of repair and maintenance expenditures.
Try this.
A one bar (14.5 psi) decrease in pressure reduces energy consumption by seven percent. And, if there are leaks in the compressed air system, the same pressure decrease reduces the impact of the leaks by 13 percent.
Also consider that, off hours can account for 25% of your compressed air energy use. Look at minimizing this usage, segment your system and turn off areas not in use during off hours..
Access to the latest leak detection systems is now required for the proactive industrial firm.
Investing in an Ultrasound System should be high on your list.
A major advantage to ultrasound leak inspection is that as a high frequency, short wave signal, ultrasound emissions tend to be localized around the leak site. By scanning an area with an ultrasound instrument, a user will follow the sound of the leak to the loudest point. Once identified, the leak amplitude can be noted and used in a compressed gas reporting tool, this cost analysis can tie dollars, for the use of maintenance time to fix leaks.
I have used UE Systems units, but you need to use something. The leaks are eating into your companies profits.
Leave me a comment if you have found a good way to get rid of your leaks.
Rusty
Here is a link to the CED article: http://cedcompressedair.ca/blog/what-is-the-cost-of-compressed-air-leaks/
Maintenance Geek Video Book Report “Seeing the Invisible” Episode #4
Check out Episode #4 of the Maintenance Geek Video Book Report Series “Seeing the Invisible” by John Kravontka and published by the Greater Boston Manufacturing Partnership. This episode continues with the industrial safety theme, covering means of egress, wiring 5S, Pipe Insulation ,preventing slips and falls,open floor holes, lifting heavy components, ergonomics, simple green washers, and proper transport of loads.
Enjoy the Episode #4 of the video series.
Rusty Fixxer