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8:00-8:50am
Continuous Stress Wave Monitoring
for Failure Progression Analysis
William T. Shaw, Swantech
Failure of a bearing or other mechanical component within
a machine is usually a process that occurs over a time
span ranging from days or weeks to even months.
Unfortunately we don’t often become aware of the failure
process until it has progressed to the point of generating
metal particles in the lubricant or abnormal vibrations or
even a temperature rise. By that point the machine is entering
its latter phase of the overall failure process and it may
be too late for inexpensive remediation. The ability to closely
monitor the failure progression and to even make operational
changes, to ‘nurse’ the machine to the next less-inconvenient
outage time, may be the best available strategy. In
this session you’ll learn the about stress wave monitoring
and analysis which is based on measuring friction and provides
an earlier identification of degradation in the failure
process and the ability to monitor the failure progression.
9:00-9:50am
Managing Multi-technology Condition Monitoring
Program for World-class Results: Actual Results
from a Large Mining Operation
Fred Salmon, The Mosaic Company
and Andy Page, Allied Reliability
While challenging, there are many rewards for successfully
implementing a multi-technology condition monitoring
program. In this session, you’ll hear how The Mosaic
Company enabled a cultural shift, new work practices and
shifted the focus of an experienced maintenance crew from
a run-to-failure mentality to a proactive mindset. The effort
has paid off - maintenance costs and unplanned downtime
are way down. The work-flow models and software tools
that helped drive the measures will be shared as well.
10:00-10:50am
Natural Frequency Testing
Robert J. Sayer, Sayer Inc.
The excitation of natural frequencies (resonance) is a
common problem in industry resulting from the inadequate
structural dynamic design of machine components and/or
supports. Resonance produces excessive vibration, that can
adversely affect the mechanical reliability of equipment.
Resonance can also lead to catastrophic failure.
This session will introduce methods used to experimentally
determine the natural frequencies of mechanical equipment
and supporting structures, including impact testing,
variable speed harmonic excitation and start-up and coastdown
testing.
1:30-2:20pm
Reliability-based Spare Parts
and Materials Management
Tor Idhammar, IDCON
With the knowledge from this seminar, you will
achieve improved maintenance effectiveness and plant
reliability while reducing spare parts inventory and maintenance
costs.
This training focuses on building a partnership of your
maintenance and storeroom professionals with a common
objective of maximizing plant reliability through logical and
efficient management of the spare parts, materials and
information required by maintenance people.
8:00 - 9:50am
Movin’ On Up: Plant Managers
that Get Reliability
Plenary Panel Discussion.
10:00-10:50am
What Reliability Can Learn from TPM - and What
TPM Can Learn from Reliability
John Schultz, Allied Reliability
The TPM and reliability communities simply do not understand
one another. The truth is that there are very few documented
TPM success stories in North America and even
the successful TPM improvement plants report returns that
are only one-third to one-half the returns reported by successful
reliability improvement plants. In this session, the
integration of these two proven and complimentary methodologies
will be introduced as Total Productive ReliabilityTM.
We’ll break down the most common myths, misconceptions
and misunderstandings between these two important concepts
and show how to take advantage of their synergies.
1:30-2:20pm
Managing Business Risk with
Facility Reliability Reviews
Larry Cote, Dofasco Inc.
Utilizing Failure Mode and Effects Analysis (FMEA),
Dofasco has developed a process for describing failures and
assessing their impact on short, medium and long-term business
goals. Originally developed as a way to identify key reliability
contributors for capital planning, the process is known
internally as a Facility Reliability Review and uses several key
quality and reliability principles and some unique adaptations in
a customized FMEA analysis. For example, defining equipment
as failed by inadequate design or by poor condition helps to target
significant performance shortcomings that have become
the way of doing business, but really shouldn’t be tolerated.
2:30-3:20pm
The Move to Proactive Maintenance:
You Can’t Get There from Here
Terry Harris, Reliable Process Solutions
Many companies want to transition from performing
over 80 percent reactive work to corrective maintenance.
But how can they do it? In this session, you’ll learn multiple
methods for getting your maintenance work into the proactive
part of the curve and reducing your reactive maintenance
to less than 20 percent. The costs and the potential
savings that can be achieved will also be discussed. Learn
how to start the climb up the PF curve to success.
8:00 - 9:50am
Movin’ On Up: Plant Managers
that Get Reliability
Plenary Panel Discussion.
10:00-10:50am
Build Your Own Reliability Professional
Steven E. Boardman and
Robert S. Hill, II,
The Quaker Oats Company
With a high turnover rate in salaried maintenance staff
and a demand to do more with less, the Quaker Oats Cedar
Rapids, Iowa plant had to step up. Exit interviews indicated
that there was no where to go in the maintenance
organization. To build bench strength in maintenance,
something had to change. In this session, you’ll learn how
Quaker Oats turned things around by creating clear paths
of progression, identified qualification and performance
standards, implemented training to coincide with the standards
and performed incremental evaluations of each individual’s
development.
1:30-2:20pm
Reliability Achievements in the
North American Steel Industry
Jack R. Nicholas, Jr., MQS LLC
This presentation will describe validated improvements
in reliability in the North American steel industry as determined
by awards made during the years 1999-2005 by the
Association of Iron & Steel Engineers (AISE) and the
Association for Iron & Steel Technology(AIST). The driving
forces that caused the projects to be initiated and some of
the obstacles overcome by the project teams in achieving
their goals will be discussed. Companies such as Dofasco,
Timken, USS Posco, US Steel Gary Works and Nucor will
be highlighted.
2:30-3:20pm
Academia’s Role in Maintenance
and Reliability Education
Thomas V. Byerley,
University of Tennessee
Traditionally, U.S. universities have shied away from
education and research in the area of industrial maintenance
and reliability. Although some institutions have developed excellent capability in reliability statistics and
probabilities, there is a significant shortfall in the reliability
and maintenance knowledge and education of graduates.
As recognition of the importance of reliability and maintenance
within industry continues to rise, this fundamental
educational void is becoming more obvious and is raising
the question of how to deal with it. This session explores
the history of academia’s approach to maintenance and
reliability, along with recent trends in the academic world
that impact this void of education. It further explore the
current situation of academic offerings as well as delivery
methods. Finally, it will discuss various and appropriate
roles of both academia and industry in the world of reliability
and maintenance.
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