miscon assoc mannheim siemens vibration analysis
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Siemens Solar Industries (SSI)Pdm Analysis on EquipmentTRANSCRIPT
Siemens Solar Industries and Shell Solar Industries Wire Saws Improved
Productivity Through Vibration Analysis
A Case Study
M Miskus Director FM&E (2001-
2004)
Siemens SI and Shell SI
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004)
Site Background on SSI
The increasing demand for renewable forms of energy is making photovoltaic
(PV) products an important part of the energy supply future.
The costs of producing photovoltaic modules have been significantly reduced
during the last 15 years as manufacturing costs per watt have dropped from
over $6 per peak watt to less than half of that value now.
Condition monitoring (vibration analysis) used in PV manufacturing has
contributed to this reduction.
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004)
Crystal growth improvements, both in yield and machine design, have reduced the PV manufacturing energy consumption by a factor of 3 and improved silicon utilization by 40%.
Wafer slicing process changes have resulted in 66% more wafers being produced for a given amount of silicon.
Cell production improvements in both automation and improved efficiency have reduced the labor cost contribution by over 40% per watt.
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004)
Larger modules and better materials have added another 10% reduction in the
cost to produce photovoltaics.
These improvements have contributed to a better energy payback time,
reducing it from over 5 years to approximately 3.
Reductions in cost and improvements in energy efficiency have made
photovoltaic products a commercially viable alternate energy source.
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004)
Why?
How?
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004)
Introduce Predictive Maintenance Practices
Subject Matter Expert – Miscon Associates
Mannheim
Identify high risk assets and failure modes
Correct application of sensors
Adequate data acquisition
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004)
Interpretation of data via report
Action to prevent breakdown
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004)
Identify Asset/Equipment for Pdm
Survey Asset/Equipment for sensor
Pre survey data for baseline
Install sensors, preliminary data
Review Data Collection Intervals
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004)
Review Data for Abnormalities
Review Baseline Data
Determine Asset Pre Failure
Run time to Failure
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004)
Scientific Maintenance
Life Cycle Cost Reduction
Increase Overall Equipment Effectivity
Operational Productivity Enhancement
Lean Manufacturing
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004)
Develop and manage five-year strategic plan
for equipment reliability through reliability
based maintenance. SOP review.
Implement predictive maintenance
technologies and interval based actions
Manage utility energy usage for Camarillo
Campus and Vancouver, WA
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004)
Manage long term utility energy use plan for
equipment
Manage routine review for ISO compliance
on all equipment preventive maintenance
procedures effectiveness
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004)
Manage performance based projects to
exceed PM/Downtime ratio for all areas –
measured 3.5/1
Establish OEE measurement for equipment
performance reviews
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004)
Develop Five-year strategic plan for
equipment reliability through reliability based
maintenance and introduction of sound
methods and systems
reduce $15MM expense budget by 15% per
year for 3 year period 2001-2003.
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004)
Integrate computerization with technical staff for on line equipment status.
Achieve uptime average of 96% from 60% in 2.5 years.
Administer review of all equipment preventive maintenance procedures
effectiveness. Manage ISO 9000 compliance for manufacturing support role.
Develop talent pool optimization for technical support of production areas.
Established OEE measurement for equipment performance reviews.
Exceeded PM/Downtime ratio for all areas – 3.5/1 from .5/1 in 2003.
Reduced redundant parts in maintenance stores and establish critical spares.
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004)
Developed talent pool optimization for technical support of production areas.
Established OEE measurement for equipment performance reviews.
Exceeded PM/Downtime ratio for all areas – 3.5/1 from .5/1 in 2003.
Reduced redundant parts in maintenance stores and establish critical spares.
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis
Solar Power Supply Chain
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis
Wire Saw Technology
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis (Typical Equipment)
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis (Typical Equipment)
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis (Typical Equipment)
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis (Typical Equipment)
Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis (Typical Equipment)