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    February 21, 2013 Operational Efficiency

    Welcome to the CP Panel Discussion:Operational Efficiency

    Mark your calendar for the 2013 CP Panel Discussion Webinars:

    March 21, 2013: Energy EfficiencyApril 18, 2013: Cyber SecurityMay 16, 2013: Dust ControlJune 20, 2013: Pump SelectionRegister for the 2013 Series at: www.ChemicalProcessing.com/cpseries

    For technical issues, please click on the TechSupport button on the bottom center of your screen.

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    February 21, 2013 Operational Efficiency

    Moderator Traci PurdumSenior Editor ChemicalProcessing.com

    CAN YOU HEAR ME?

    Sponsored by:

    The webinar has started. If youcannot hear me speaking:

    1. Please check to make sure your computer mute button is turnedto OFF

    2. Please log off and log back in3. If you still cannot hear me, please

    click the Tech Support buttonat the bottom of your screen

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    February 21, 2013 Operational Efficiency

    Moderator Traci PurdumSenior Editor ChemicalProcessing.com

    Joining us today:

    Sponsored by:

    Bernie PriceCEOPolaris Veritas Inc

    Renard Klubnik Applications Engineer Meggitt Sensing Systems

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    February 21, 2013 Operational Efficiency

    Bernie PriceCEOPolaris Veritas Inc

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    February 21, 2013 Operational Efficiency

    IMPROVING OPERATIONAL ACCURACY

    (A Few Precepts)

    The Journey to World Class Performance

    Potential to Gaining 10% + OEEThe Error & Issues PyramidWhy Operating Accuracy is Critical to Success

    Polaris Veritas, Inc

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    February 21, 2013 Operational Efficiency

    Polaris Veritas, Inc

    ResponsiveWork

    PlannedWork

    Proactive & DisciplinedRoutine Problem Solving

    Problem SolvingFocused Organizational

    LearningNATURE OF BEHAVIOR

    O P E R A T I O N A L

    P E R F O R M A N C E

    REACTIVE

    PLANNED

    PROACTIVEPRECISION

    WORLD CLASSOPERATIONS

    StableSustainable Cultures

    TYPICAL ACTIVITIES FOR THE FOUR

    STABLE OPERATING STATES

    Lead/Com - 0Planned work 24/yr.

    ORIGINAL MAT BYLEDET ENTERPRIZES

    Error Rate1: 40

    Error Rate 1 : 400 +

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    TRANSITIONAL ORGANIZATIONAL CHANGE TOWORLD CLASS

    T H E P E R C I E V E D N E E D F O R I M P R O V E M E N T

    >

    + REDUCING RESISTANCE TO CHANGE TIME >

    THE COMMITMENT THRESHOLD

    UNAWARE

    NON ACCEPTANCE

    IT IS OK BUT

    - TOO MUCH EFFORT

    A C C E P T A N C E

    E N T H U S I A S M

    A F T E R E A R L Y W I N S

    E M P L O Y E E E M P O W E R E M E N T G E T S S T A R T E D

    W E I N V E N T E D I T H E R E !

    INSTITUTIONALIZATION

    ADOPTION & OWNERSHIP

    IT ALL SEEMS TO BE WORKING ?

    COMPLACENCY

    DANGER ZONE

    FORMING TEAMS & EXPLAINING PROCESS

    AWARENESSSTARTS HERE

    START PLANNING & SCHEDULINGIMPROVING COMMUNICATION

    START CONDITION MONITORING

    ROOT CAUSE ANALYSIS TEAM WORKING

    DEVELOPING A PROBLEM SOLVING CULTURE

    LINKING WRITTEN BEST PRACTICES TO FORMA PROCESS RELIABILITY MANAGEMENT SYSTEM

    INCLUDES A STRONG AUDIT PROGRAM

    UNDERSTANDING DEFECT ELIMINATION

    90%

    80%

    75%

    65%

    65 %

    < 60%

    OEE

    ERROR PROOFING

    Polaris Veritas, Inc

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    Polaris Veritas, Inc

    FATALITIES

    SERIOUS

    MINORS &NEAR MISSES

    UNSAFEBEHAVIOR

    CATASTROPHICFAILURE

    MAJOR UNPLANNED

    PROCESSINTERUPTION

    MINOR DEFECTS

    EXTENDED PLANTS/D

    SERIOUS PROCESSUPSET

    MINOR DEVIATION AFFECTING OTHERPYRAMIDS

    POTENTIAL ERRORSUNDETECTED

    PRODUCT RECALL

    MAJOR ISSUEBEFORE DELIVERY

    ISSUE DETECTEDBUT RECOVERABLEIN PART

    UNRECOGNIZEDDEFECTS

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    Polaris Veritas, Inc

    ONEPYRAMIDFOUR

    FACES

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    Polaris Veritas, Inc

    SIMILARTECHNIQUES FOURFACES

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    Sources of Defects/Errors

    Maintenance materials Maintenance workmanship Raw materials Equipment / Process Design

    Operational Accuracy

    7%18%

    5%25%

    45% +

    Published research at MIT, DuPont and others discussesfive sources of defects and their ratio to one another:

    Polaris Veritas, Inc

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    Polaris Veritas, Inc

    Creating Awareness Errors are everywhere

    Our (societys) negative and confusing attitude toerrors:

    The banana skin

    Funniest home videos= Pain, shame and

    embarrassment for someone

    Cover mistake up as quickly as possible

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    Creating Awareness Limbic response Anger, Fear, Jealousy etc. Our addiction to the adrenaline rush

    Action and thriller movies, etc.

    The lightning fast limbic system will seek and create balance when there is none .

    Frontal Lobes Rational Thought, Sense of Purpose, Aesthetic Appreciation

    Like computers, the brain uses complex task sharing, short cuts and pastesinformation to speed operation (schema).

    At any point in time, it might have multiple mental processes going on that you are notaware of and have no control of.

    We have little personal control of how and why the brain does all of this.

    Limbic responses frequently seize control of your mind - (cerebrum) rather than youcontrol it.

    Frontal Lobe Hijacking Process Worry (Preoccupado) Stress, Fatigue AndBoredom makes the (downshifting) and error rate increase.

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    February 21, 2013 Operational Efficiency Polaris Veritas, Inc

    Creating Awareness & Non Penal

    Workplace Some Limbic behaviors can destroy cohesion of the Large Team.

    In football, nobody knowingly drops a pass.

    In life, nobody knowingly makes an error.

    But there still are many dropped passes and errors

    Criticism, blame and punishment destroys teamwork

    Refer to: www. Human Error. com - Professors Panko, Reppening, andStout www.serendip.brynmawr.edu

    See Book Reality Check What Your Mind Knows but Isnt Telling Youby David L. Weiner

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    February 21, 2013 Operational Efficiency Polaris Veritas, Inc

    STUDY ACTIVITY ERROR RATE

    Baddeley &Longman [1973]

    Entering mail codes. Errors after correction. Per mail code. 0.5%

    Chedru &Geschwind [1972]

    Grammatical errors per word. 1.1%

    Dhillon [1986] Reading a gauge incorrectly. Per read = 1 : 200 0.5%

    Dremen and Berry

    [1995]

    Percentage error in security analysts' earnings forecasts for reporting

    earnings. 1980 / 1985 / 1990. That is, size of error rather thanfrequency of error.

    30%

    52%

    65%

    Edmondson [1996] Errors per medication in hospital, based on data presented in thepaper. Per dose. = 1 : 60

    1.6%

    Grudin [1983] Error rate per keystroke for six expert typists. Told not to correcterrors, although some did. Per keystroke.

    1%

    Hotopf [1980] S sample (speech errors). Per word 0.2%

    Hotopf [1980] W sample (written exam). Per word 0.9%

    Hotopf [1980] 10 undergraduates write for 30 minutes, grammatical and spellingerrors per word

    1.6%

    Klemmer [1962] Keypunch machine operators, errors per character 0.02% to0.06%

    Professor Raymond Panko - The Human Error Expert

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    February 21, 2013 Operational Efficiency Polaris Veritas, Inc

    W O R S E N I N G P E R F O R M A N C E E F F E C T I V E N E S S

    ( e r r o r r a

    t e )

    TASK LOAD& FATIQUE

    1:2 5 (ORWORSE)

    EXTREME STRESSAND THREAT

    APPROACHING

    LOSS OFCONTROL

    HIGH STRESS

    UPSET

    OPERATINGCONDITION START UP / SHUTDOWN ACTUAL

    < 1: 250

    MODERATESTRESS

    NORMAL ACTIVITY

    LOW STRESS

    EXTENDEDUNEVENTFULVIGILANCE -

    INATTENTIVEBLINDNESS

    WHENTHE FREQUENCY OF OPERATING ERROR (THERP)

    OBJECTIVE< 1: 400

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    February 21, 2013 Operational Efficiency Polaris Veritas, Inc

    When? (% Time Risk %) Low Risk - STABLE OPERATION (95% - 5%)

    Extended uneventful vigilanceGetting locked into a sub routine (schema) - Inattentive BlindnessNormal activity Boredom

    High Risk - TRANSITIONAL OPERATION (5% - 95%)

    Start-Up and Shut-Down Continuous process plants Low level of Engagement Upset Operating Condition Emergency Operation Time of day / night

    High Fatigue

    Overtime - extended periods without breaks Counter progressive shift rotation Not warming up after long break lack of practice

    Unfamiliar Team Make Up

    Concentrate improvement effort on transitional situations after analyzing error patterns.

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    February 21, 2013 Operational Efficiency

    RELIABILITY / LIFE REDUCINGSTEPS

    When Are Most Errors Made-TRANSITIONAL HIGH RISK

    Polaris Veritas, Inc

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    February 21, 2013 Operational Efficiency

    How can we improve? A system that works..

    It must be non penal A method that most people are familiar

    with

    Assumes that Management has a major role in setting up the situation that allowserrors to be made

    Polaris Veritas, Inc

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    February 21, 2013 Operational Efficiency Polaris Veritas, Inc

    Operator Lead Team - Primary Analysis Write down:

    What/How the error was made When Where

    Why Estimate the cost of making it. Then classify the error for later analysis (see list)

    Lack of Planning Not enough Information, Lack of training, Lack of personal capability / attention / attitude / hurry / overload

    Indicate if it is unique - personal to you, or latent or systemic. (Haveother people made the same mistake?)

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    February 21, 2013 Operational Efficiency Polaris Veritas, Inc

    Dealing with our Errors as Individuals What/How: Hit a wayward shot Where: Approaching a green, ball lands among trees When: Anytime Why: Has an unrealistic belief in own golf skill Classification: Hurry / Judgment

    Antecedent: Doesnt practice Conservative Decision Making

    Behavior: Predisposed to rush / hurry. Inadequate level of Engagement

    Consequence: Ball hit tree and bounced into hazard + 4 Strokes

    Action to Eliminate Problem1. Solution Study and practice Conservative Decision Making2. Take lesson in course management3. Get more practice

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    February 21, 2013 Operational Efficiency Polaris Veritas, Inc

    C O M P E T E N T P E R F O R M A N C E

    OBSESSIVECOMPULSIVE

    OVER CONTROL

    NUMBERS OF INDIVIDUALS

    WHO Error Rates for the 95%INDIVIDUALS GIVEN ADEQUATE TRAINING AND SUPPORT

    EXPRESSIVE PERSONALITY

    COPYRIGHT ALLRIGHTS RESERVED

    A POKE YOKE APPROACH TO JOB DESIGN REMOVAL OF HURRY CONFUSION CLUTTER & STRESS

    STRUCTURED ERROR REDUCTION / REVIEW PROCESS

    SIMPLIFIED PICTORIAL S O P S

    THE USE OF CONSERVATIVE DECISION MAKING PROCESSES

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    February 21, 2013 Operational Efficiency Polaris Veritas, Inc

    OBSERVATION OF ERRORS

    THE OBJECTIVE

    VISIBLE

    INVISIBLE

    MANAGERS SEE ONLY8 OF 39,000

    POTENTIAL ERRORS

    THE NUMBER OF ERRORSHE CURRENTLY SEES

    Need Root Cause Analysis

    MINOR ERRORS

    SERIOUS

    MAJOR

    COR RECTABLEERRORS

    Need error proofing

    FULLY ENGAGED HE SEES ALL THEERRORS + POTENTIAL ERRORS

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    February 21, 2013 Operational Efficiency Polaris Veritas, Inc

    POTENTIAL OPERATING DEVIATION REPORT WEEK ENDINGSHIFT

    (Optional)

    MAXIMUM OF THREE ASSOCIATED DEVIATIONS

    ANALYSIS COLUMN LEAVE BLANK

    DESCRIBE SITUATION OR INCIDENT (50 WORDS) DO NOT INCLUDE NAMES

    Report Observed Actual Situation or Activity with

    Potential for Error - Example

    Hey ! This looks like an bear trap to me ?

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    February 21, 2013 Operational Efficiency

    THIS IS A BEAR TRAP

    OFI # 8431

    Date ReportedOriginators ManagerQHSE OFIReporting

    SystemSUMMARY INFORMATION Potential Operating Error Describe in 50 words or less ________________________________________________________________________ Product qualityOperational Process >>>

    Audit FindingSupplier QualityCustomer Complaint

    __________________________________________________________________________________________________________ KEY PHRASE Potential Operating error

    __________________________________________________________________________________________________________ Remedial Action What it will take to fix the problem Time and Money and when it will get done and by whom KAIZEN TEAM

    Action Results of Action-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------Investigation General comments

    __________________________________________________________________________________________________________ Root Cause - Quick Phrase

    __________________________________________________________________________________________________________ Corrective / Preventive Action fill out after job complete

    Actual Dollars Spent and saved

    Polaris Veritas, Inc

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    February 21, 2013 Operational Efficiency Polaris Veritas, Inc

    Some Typical Operational Mistakes Missing a step from a procedure Misreading a gauge Not sealing (or reporting) process

    leakages / blockage Using incorrect tool or apparatus Over / under fills vessel or tank Not receiving or passing on a report from

    interfacing shift team Transposing digits in a number series Incorrectly positioning valves Repeatedly resetting an alarm or other

    protective devices without action Slow delayed required action Not turning off idle equipment Not making a decision when one was

    required Ignoring a process oscillation / instability Failure to notify others of observed

    defects Misunderstanding a request and not

    asking the instructor to repeat request

    Change room shift changeovers Operating equipment without understanding or

    authority not having been trained Not leaving something in a secure mode Operating something too fast or slow Removing a safety device or identifying tab Operating equipment known to be defective

    without reporting it Improper feed rate or load Adding wrong material to batch Working on equipment while it is running Not referring to operating procedures as

    required Not using (and signing) the correct checklist

    where one exists Not preparing equipment / work permits for

    repair after written request Not understanding and being afraid to ask

    about the chemistry or physics involved Interrupting another person in the middle of a

    complex task

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    February 21, 2013 Operational Efficiency

    Error Proofing The Issues Why Operator Lead ? Endemic denial, cover-up and collusion around personal error (for good reason)

    Need a method of understanding and determining thetrue sources and nature of the errors

    Need a means to let the operating teams themselves focus on thebehaviors problems and reduce the number and severity of errors they makeover the long term

    This is CRITICAL if the level of ENGAGEMENT is to be lifted

    We use approaches and techniques first developed for safety improvement

    The methods work on all four - Safety, Quality, Operations and Reliability

    There are four inextricably linked triangles >>>>>> Polaris Veritas, Inc.

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    February 21, 2013 Operational Efficiency

    Having Collected the Data - the Analysis Phase

    Use the process facilitator and theOperator team Leader

    Polaris Veritas, Inc

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    February 21, 2013 Operational Efficiency Polaris Veritas, Inc

    Classifying Mistakes The Ten Buckets Not understanding the consequences of the action. Not using

    conservative Approach - judgment. Lack of clear work instructions Cluttered Presentation

    Confused Priorities Inadequate person-to-person and person-to-group communication Insufficient individual knowledge, accountability or skills training Inadequate tools and equipment Lack of a well defined Standard of Performance Lack of personal capability / attention / attitude / hurry / overload Lack of understanding of the risk of and management of change

    Insufficient recognition of appropriate effort * Lack of Tactical Administration (identifying the periods and

    individuals for High Level Engagement) - Leadership (vision) ** These are linked

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    February 21, 2013 Operational Efficiency

    Reducing the potential for error A kaizen like process

    Managed by operators for operators

    Polaris Veritas, Inc

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    February 21, 2013 Operational Efficiency

    Renard Klubnik

    Applications Engineer Meggitt Sensing Systems

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    February 21, 2013 Operational Efficiency

    Operational efficiency

    Where does vibration monitoring fit in?

    Operational efficiency represents the life-cycle cost-effective mix of preventative, predictive and reliability centered maintenance technologies.When combined successfully with equipment calibration, tracking andmonitored maintenance management can target reliability, safety, andsystem efficiency.

    In terms of vibration monitoring, operational efficiency includes how machinefaults are handled and how that effects the facilitys bottom line.

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    February 21, 2013 Operational Efficiency

    Managing vibration

    The first step to operational efficiency

    Treating each piece of rotating equipment as an asset Every asset has a value associated with it Asset value will be related to its importance to

    manufacturing process Documenting the vibration level of each asset Determining the significance of the vibration level of each

    asset Use known standards (ISO 10816) Compare within your own facility (or corporation)

    Determine the extra cost of running an asset at a highvibration level

    Operational cost for keeping a unit in service Repair/maintenance cost

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    February 21, 2013 Operational Efficiency

    Technologies for improving efficiency

    Vibration

    Thermography

    Alignment

    Oil analysis

    Wear particleanalysis

    Motor currentanalysis

    http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=wbXIwBFc1m_PRM&tbnid=iyeLbcneWn-S6M:&ved=0CAgQjRwwAA&url=http%3A%2F%2Fpredtec.com%2Finfrared.html&ei=pZIeUf3AAsSTqwG3oIHYCg&psig=AFQjCNHQM-prdnD4H1CSGLiDoV_2yU21xA&ust=1361044517184520http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=GTLF_l0xlfUVCM&tbnid=8B8kSp7PlxncgM:&ved=0CAgQjRwwAA&url=http%3A%2F%2Fwww.vibrationsound.me%2Fservices.htm&ei=32QeUYaOM8TdqQGhjYHICw&psig=AFQjCNErt_hqZLH9zVytKKvWEvVsGuOZ3g&ust=1361032799877649http://www.google.com/url?sa=i&rct=j&q=oil+analysis&source=images&cd=&cad=rja&docid=wtCu3x-LUzIhtM&tbnid=vHF7hL21h_f8tM:&ved=0CAUQjRw&url=http%3A%2F%2Fwww.avomeen.com%2Findustries%2Fmaterial-testing-services%2Foil-analysis-testingservices&ei=UVIeUfGGAePS2QWf-oHYBA&bvm=bv.42553238,d.b2I&psig=AFQjCNE6BHMpoZuqYGMYJzRyJhsLmaScvA&ust=1361027992448955http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=t1lBXhZkS4Kq4M&tbnid=HftnGPDEs9M49M:&ved=0CAgQjRwwAA&url=http%3A%2F%2Freliabilityweb.com%2Findex.php%2Farticles%2Fppm_distribution_is_it_better_than_iso_code_for_interpreting_particle_count%2F&ei=cWQeUZmYFsrvrQH-l4GIBw&psig=AFQjCNGsJ6uDdNTesUqxrugO3V_DUJUvsQ&ust=1361032689412703http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=-4PwJ5mzhdEWxM&tbnid=tDYIO__YRt4ECM:&ved=0CAgQjRwwAA&url=http%3A%2F%2Fwww.easylaser.com%2FSHAFT_D480.htm&ei=gmMeUcySFqiiyAHp5ICAAg&psig=AFQjCNG27lHykElu-q3b7HgBQf8i3aaM7g&ust=1361032450395551http://www.google.com/url?sa=i&rct=j&q=vibration&source=images&cd=&cad=rja&docid=SNxLfjRuOVQPmM&tbnid=e1p1dCL480jenM:&ved=0CAUQjRw&url=http%3A%2F%2Fndnr.com%2Fweb-articles%2Fmindbody%2Fgood-vibrations%2F&ei=o1EeUe_GFenM2gW-soDgCA&bvm=bv.42553238,d.b2I&psig=AFQjCNEHxoOndMpjcdVCv68qL85GcxrZRg&ust=1361027861840246
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    February 21, 2013 Operational Efficiency

    Why choose vibration?

    It has been stated by more than one source that the vibration signal containsthe most non-intrusive information about the condition of a machine

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    February 21, 2013 Operational Efficiency

    Why choose vibration?

    Of all the technologies available, vibrationanalysis casts the widest net of capturingthe most machine faults

    A partial list of faults that can be detected

    with vibration Balance Alignment Roller bearing wear Looseness Gearbox faults Oil whirl Pump cavitation Structural resonances Motor rotor & stator problems

    (loose rotor/stator slots) All or anyone of the above can contribute

    to poor efficiency

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    February 21, 2013 Operational Efficiency

    Maintenance programs

    Maintenance programs are usually grouped into three categories

    Reactive 55%Preventive 32%Predictive 13%

    This breakdown is opposite of what it should be...

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    February 21, 2013 Operational Efficiency

    Setting up a reliability centered approach

    Looks at maintenance as manageable cost not necessary evil Run to failure cost $$$

    Unscheduled down time Higher wages (overtime) Lost production Unsafe conditions for the machine and personnel

    Estimated savings on energy bills of 5-20% for plants that use some form of reliability centered approach

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    February 21, 2013 Operational Efficiency

    Reactive maintenance programs

    A run till it breaks mentality

    Advantages Appears to be low cost because nothing is

    spent until a unit fails

    Disadvantages Increased cost due to unplanned downtime

    of equipment High labor costs, especially if overtime is

    needed Cost with repair or replacement of

    equipment is usually higher due toexpedited last minute purchases

    Possible secondary equipment or processdamage from equipment failure

    Inefficient use of staff resources

    http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=QmVNL70K1QNmQM&tbnid=FcYk8mxTXgkCbM:&ved=0CAgQjRwwAA&url=http%3A%2F%2Fwww.chinadaily.com.cn%2Fregional%2F2008-06%2F12%2Fcontent_6756385.htm&ei=0mUeUb_RCI_aqQGgkICoAw&psig=AFQjCNGmi7P7umEiisU3vCPzMF3QKdUabQ&ust=1361033042173946
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    February 21, 2013 Operational Efficiency

    Preventative maintenance programs

    Actions performed on a time- or machine-run-based schedule that detect,preclude, or mitigate degradation of a machineAdvantages Cost effective Flexibility allows for maintenance

    periodicity adjustment Increased component life cycle Energy savings Reduced equipment or process failure Estimated 12-18% cost savings over

    reactive maintenance programs

    Disadvantages Catastrophic failures can still occur Labor intensive Includes performance of unneeded maintenance No data collected from machines Work can be pushed off by other needs

    http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=UfX-tv7QVPUEZM&tbnid=yBeNZO0vRETtGM:&ved=0CAgQjRwwAA&url=http%3A%2F%2Fwww.docstoc.com%2Fdocs%2F21100727%2FFabricated-Examples-Planned-Preventative-Maintenance-Schedule-200910&ei=-WUeUa6vH4fMqAHg1ID4Cw&psig=AFQjCNFc63-MhrUBtXq1QvA3kOhRtl6MDA&ust=1361033081583347
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    February 21, 2013 Operational Efficiency

    Predictive maintenance programs

    Measurements that detect the onset of a degradation mechanismAdvantages Increased component operational life/availability Allows for preemptive corrective actions Decrease in equipment or process downtime

    Decrease in costs for parts and labor Better product quality Improved worker and environmental safety Improved worker moral Energy savings Estimated 8-12% cost savings over predictive maintenance program

    Disadvantages Investment in diagnostic equipment Investment in staff training Savings potential not readily seen by management

    http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=nZBPhpRLE_FUrM&tbnid=XneChlcD_Sh32M:&ved=0CAgQjRwwAA&url=http%3A%2F%2Fwww.machinediagnostics.net%2Fpredictive-maintenance-company%2F&ei=hoEeUbnyA-qr2AWVoIDQCg&psig=AFQjCNHURo3uYw3FaJQ6gDBIap6xNnK4jg&ust=1361040134109573
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    February 21, 2013 Operational Efficiency

    Do machines need to be monitored?

    Consider the total cost of the machine Consider the cost of placing the asset on

    a condition monitoring program View the cost in terms of lost production

    plus repair cost Most successful plants using a balanced

    approach use Predictive (all technologies) 45-55% Preventative 25-35% Reactive 10%

    This is opposite of what must studies showto be the actual breakdown of thesetechnologies

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    February 21, 2013 Operational Efficiency

    Predictive (vibration) programs

    What types of vibration monitoring programs make sense for your plant?On-line monitoring

    Permanently installed sensors with constant dataacquisition

    Ability to store vibration data automatically for historicalrecords

    Post fault- identify behavior that led to a fault Pre fault- take correction action to avoid the fault

    Shut down capability real time decision makingprocess to prevent any type of catastrophic failure

    Costly- >$100,000 in install and maintain Training cost Requires cost of machinery monitored to be

    >$1MM or lost production to be of equal magnitude

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    Predictive (vibration) programs

    Hand held route based programs

    Labor intensive Possible permanently installed sensors for high risk locations Trending of vibration based on machine characteristics Historical record of data possible Does not provide shut down capability Equipment and on going training cost

    Initial investment hardware and training >$50,000 On-going training >$5000/yr/person

    http://www.google.com/url?sa=i&source=images&cd=&cad=rja&docid=iuyij_3Z-J8sJM&tbnid=7sltOyKi0oly2M:&ved=0CAgQjRwwADhL&url=http%3A%2F%2Fwww.hazardexonthenet.net%2Farticle%2F23863%2FHandheld-condition-monitoring-device-detects-imbalance-in-critical-tanker-exhaust-fans.aspx&ei=GoIeUc_ADMqd2QXg34GABQ&psig=AFQjCNEV_cH0Itn3YmXCWj0WkJ4hbuvIOw&ust=1361040282248431
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    February 21, 2013 Operational Efficiency

    Predictive (vibration) programs

    Loop powered sensors , 4-20 mA signal

    Process industry interface Provide continuous indication of vibration level Does not provide detail of vibration, only overall values Overall values used for decision making on go/no basis Minimal cost to implement and maintain

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    February 21, 2013 Operational Efficiency

    Benefits of implementing some sort of vibration monitoring program

    Increasedmaintenanceproductivity

    Reducedequipmentdowntime

    Savings withlower material

    Monthsaveragepayback

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    February 21, 2013 Operational Efficiency

    How to implement operational efficiency at your facility

    Increase management awarenessManagement buy in and awareness is crucial

    Develop a maintenance mission statement Formulate a maintenance plan Integrate key members from other departments that can participate

    http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=pvYJRuT-BxVNWM&tbnid=9FHYu2TRrtzn5M:&ved=0CAUQjRw&url=http%3A%2F%2Fwww.paintsquare.com%2Fnews%2F%3Ffuseaction%3Dview%26id%3D6310&ei=gZYeUaDAAeuq0AH-pIDoCw&bvm=bv.42553238,d.dmQ&psig=AFQjCNG6j9MflNoYqyr9YPrWUkRClGYoxQ&ust=1361045501103126
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    February 21, 2013 Operational Efficiency

    How to implement operational efficiency at your facility

    Track operations and maintenance activities Commit to tracking operations and maintenance activities by identifying your

    troubled equipment and systems Make a list of these systems and prioritize them in terms of criticality Commit to addressing at least one of these troubled systems

    Begin base-lining System operations and history System maintenance and history System costs, time to service, downtime, resulting overtime, etc.

    Commit to implementing some form(s) of diagnostic, metering, or monitoringequipment Commit to trending the collected tracking and diagnostic data Take to time to understand the data Develop appropriate cost justification metrics (usually plant specific)

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    February 21, 2013 Operational Efficiency

    Broadcast your success within your organization!

    Select, request funding for, and complete first Operational Efficiency project Start small, pick a project that will be a winner Carefully document all findings Present success in terms management will understand

    Strive to highlight this success Capitalize on visibility opportunities Consider writing an internal success story/case study

    Choo se the next p iece of equipm ent. ..and repeat!

    http://www.google.com/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=DMDWdJTSxUeKIM&tbnid=4NwYT7WMkTHdLM:&ved=0CAUQjRw&url=http%3A%2F%2Finfo.smglobal.com%2Fblog%2F%3FTag%3Dpreventive%2520maintenance%26BBPage%3D1&ei=_IMeUbaaJcTD0AG444Ao&bvm=bv.42553238,d.dmQ&psig=AFQjCNGbpiki8loFxn-X8BuM5pXk1aJO-w&ust=1361040758189715
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    February 21, 2013 Operational Efficiency

    View the 2013 CP Panel Discussion Webinars at:www.ChemicalProcessing.com/cpseries

    Thank you for attending todaysWebinar!

    Look for an email from us with a link todownload the entire Presentation fromtodays event.

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    Webinar Sponsored by:

    Bernie PriceCEOPolaris Veritas [email protected] 280 0550 (Office)281 793 5643 (Mobile)

    Renard Klubnik Applications Engineer Meggitt SensingSystems

    Questions for our Panel?