The Evolution of Reliability by H. Paul Barringer, P.E.

Paul Barringer is a reliability, manufacturing, and engineering consultant.  His consulting practice involves worldwide travel, consulting, and training with a variety of discrete and continuous process manufacturing companies in a variety of industries.   He is author of the basic training course Reliability Engineering Principles,  Process Reliability, and Life Cycle Cost. 

Barringer has more than forty years of engineering and manufacturing experience in design, production, quality, maintenance, and reliability of technical products. Note his experience in both the technical and bottom-line aspects of operating a business with an understanding of how reliable products and processes contribute to financial business success.   At IMC-2003, he will kick start the conference with his unique perspective of the evolution of reliability and maintenance.

Presentations with yellow backgrounds show recent schedule changes or additions.

9:00 am – 9:30 am  Learning Zone Sessions

RZ1: A Systems Approach to Failure Modes and Effects Analysis by Eric Newhard, CMRP & Elton Ray Ebersole
Bristol-Myers Squibb

Failure Modes and Effects Analysis (FMEA) can be cumbersome, costly and overwhelming for many companies.  Learn how Bristol Myers Squibb transformed their reliability using a systems approach to FMEA.

Alignment is among the necessary but time consuming items on the list of proactive  maintenance activities where traditional work methods allow time saving changes. Learn why laser alignment should be part of your maintenance program.

New maintenance and reliability initiatives often meet a wall of human resistance as people are entrenched in the status quo.  Learn how to successfully accomplish change and improve your company in the process.

Many plants have collected year’s worth of operating and failure information without analysis.  Learn to differentiate two types of statistical reliability models:  throughput-based and equipment-based and how to apply them.

PdM2: The New Role of Current Analysis in Plant Reliability Present and Future Opportunities by Noah Bethel PdMA

Learn how motor current analysis technology operates, how the data is assimilated and the effects of demodulating the signal.  Each type of fault that can be identified with this technology will be explored.

Creating priorities for maintenance work can be a daunting task.  In this session learn how to design and use a Ranking Index for Maintenance Expenditures (RIME) as developed by Albert Ramond and Associates.

Learn about the journey of a Water Utility Company that created an overall maintenance lost reduction of over 10% while improving all major maintenance metrics.

Learn how a design team has developed and deployed a strategic practical parameter design optimization model for improving the precision, reliability and robustness of a pneumatic paint marker system.

PdM3: Vibration & Ultrasound Technologies: A Possible Integrated Inspection Tool? Stuart Courtney
SKF

Learn detailed techniques for integrating two valuable technologies.  Vibration data collectors and ultrasonic systems extend the capabilities of the condition monitoring technician and provide additional diagnostic confidence.

Maintenance professionals from around the world travel to learn about the development and operation of the award winning World Class Maintenance Model of Alumax South Carolina operations.  The program has continued to mature and delivers impressive results to this day.

The cost of carrying unnecessary inventory is significant.  Learn about a spares optimization initiative that increased reliability while simultaneously decreased cost.  Tools and techniques are introduced that will satisfy maintenance managers as well as financial managers.

Crow/AMSAA reliability growth plots use failure information for maintenance systems to apply a visual tool with straight line graphs for predicting the next failure in systems or humans can influence the results.

Reliability is not just about rotating systems.  Steam is critical to many processes.  Learn practical testing information and a decision logic tree to diagnose steam trap condition.

If foreign materials enter your system, critical responses are necessary to minimize the effect of destructive contaminants.  Learn about the signs and systems of contamination as well as creating an action plan to effectively control contamination.

Learn an effective method for calculating Overall Equipment Effectiveness (OEE) using CMMS data to achieve peak performance.  Participants will also get a six step plan to reduce and eventually eliminate waste.

Learn how customer complaints can often be created by ineffective maintenance and reliability.  See how Root Cause Analysis can be used to trace such complaints back to the “Root Causes” to avoid repetition in the future.

A case history relating to a power plant that requested assistance to provide absolute thermal growth measurements.  Using a new dynamic measurement system the mission was accomplished.

Learn to identify and utilize the essential and core elements for a truly effective maintenance program  This session delivers information about preventing self induced failures, identifying and prioritizing maintenance work, backlog management and work scheduling.

Learn how modern proactive maintenance operations are using oil mist technology to achieve a 90% reduction in bearing failure.  Applications and systems details will be thoroughly explained.

PdM6: The Complimentary Roles of Reliability-Centered Maintenance and Condition Monitoring by Roger Collard,  Veridian Engineering
 

Discover how reliability centered maintenance (RCM) analysis not only advised the administration of the correct Condition Monitoring technology but also the acceptable interval for the inspections

Learn to identify and utilize the essential and core elements for a truly effective maintenance program  This session delivers information about preventing self induced failures, identifying and prioritizing maintenance work, backlog management and work scheduling.

A case history about ArQule, a chemistry based drug discover company, early years when maintenance programs where virtually non-existent.  This session will discuss the development and implementation of an instrument maintenance program in a high throughput production drug discovery environment.

RZ7: The Business Case for Reliability by Saxon Smith, Management Resources Group
 

There is an overwhelming business case associated with doing maintenance and reliability right.  Learn how a Total Equipment Asset Management (TEAM) initiative can create an ROI of 50:1.

Learn techniques and methods to make sound maintenance decisions at critical times based on integrated information.  Open connectivity to condition based maintenance systems allow integration into other manufacturing execution systems and automation systems for control.

Learn about electronic performance support systems and how military maintenance communities utilize “information superiority” to conduct exemplary maintenance under time pressure.

6 Sigma has traditionally been used to improve quality in various manufacturing and process industries.  Learn how to apply the basic principles of 6 Sigma as an improvement tool to optimize maintenance work.

This case study is based on a sour gas plant where Availability, Reliability, Throughput and Cost analysis have been used to perform upgrades to the plant by simulating the proposed design changes allowing the return on investment to be accurately determined.

Learn more about the breakthrough value of the instantaneous torque signal versus time signal to assess mechanical failures in the field.  Comparisons between the instantaneous torque and the instantaneous current signals will show why the classical current approach did not succeed in diagnosing the failure.

A case history relating to the business decision making process of one large industrial facility as they work to solve the shortage of highly skilled maintenance employees.  The facility has a full time equivalent load of over 500 maintenance employees in several craft lines.

Learn the key elements for sustaining change including the 5 steps to managing change, the key factors in sustaining change, and the transition from "top support" to "floor driven".  Proven models for sustaining change with TPM will also be introduced.

Leadership Role in Reliability Journey by Bert Coffman

Mr. Bert Coffman is Director for Facility Operations and Maintenance at Arnold Engineering Development Center (AEDC), Tullahoma, TN., the DOD’s largest  aerospace and propulsion R&D test center. Bert joined Sverdrup Technology Inc., AEDC’s test operations contractor, in June 1997 after a 37 year U. S. Navy career in aircraft maintenance management.  Mr. Bert Coffman manages a challenging and innovative maintenance and reliability program at Arnold Air Force Base Development Center, a critical government test facility with multiple contractors and very unique equipment found nowhere else.  He shares his special methods of leadership to set the tone for the second day of learning at IMC-2003.

9:00 am – 10:00 am   Learning Zone Extended Sessions

RZ9: The Controversy About Reliability Centered Maintenance Methodology, Its Variants and Derivatives by Jack R. Nicholas, Jr., Maintenance Quality Systems LLC

This session will be presented from the perspective of a neutral but experienced observer who is no longer engaged in RCM analysis and does not endorse any given approach.  The discussion is constructive and not critical of any RCM methodology or practitioner.

PdM9: Benchmark your Lubrication Program, Drew Troyer, Noria Corp.

Benchmark your lubrication program using the Noria score which compares your current practices against a “Best Practice Standard”, with a simple and intuitive output that enables the user to see precisely where lubrication program strengths and weaknesses exist.

MB9: Lean Maintenance Panel led by Lee Peters, Jim Ross
 

Lean Manufacturing revolutionizes our thinking for producing quality products.  In this session you can enter a panel discussion with Lean Maintenance experts about implementing Lean Maintenance to eliminate waste and increase productivity.

MM9: Special IMC-2003
Maintenance Benchmarking Panel
Panelists include: Ricky Smith, LCE, Dave Thompson Alcoa, Gene Nicholas, Broward County Water, Ramesh Gulati, AEDC

The panel and participants will join in this roundtable discussion to explore the results of the online maintenance benchmarking survey that was conducted at Reliabilityweb.com. Learn to identify important elements and metrics to measure maintenance and reliability performance.

RZ10: Deploying EAM and Reliability Best Practice Early in the Life Cycle of New Capital Projects by Chris Fynn, New Dimension Solutions, Inc.

Learn the advantages of deploying Enterprise Asset Management (EAM) and reliability best practices early in life cycle design phase of new capital projects along with appropriate (SAP) support systems.  This creates a huge financial benefit over the full life cycle of the asset. 

PdM10: Motor Reliability Testing by Douglas K. Smithman, EMP Engineering Services

Learn motor reliability testing and methodologies from an electrical perspective.  Potential problems, trouble signs and tests to detect them will be discussed.  The discussion leans towards large and small DC equipment and high voltage equipment.

Learn about new technologies and tools such as palm top PCs and intelligent software that eliminate paper work and arm technicians with more information at the point of performance.  Discover how management functions are also enhanced as maintenance work completion data is captured in real time.

MM10: Achieving Continuous Improvement…Through Software & Process Reviews by Steve Pitsos
FBO Systems, Inc.
 

Learn about the importance of post implementation for maintenance software.  Strategies and techniques relating to software and process reviews are explored in order to achieve continuous improvement.

RZ11: Achieving Best-in-Class Reliability Through Asset Performance Management by Ken Latino
Meridium

Learn how the strategic focus of asset performance management is centered on the measures and incentives that must be in place to ensure that plant operating problems and failures are analyzed in order to ascertain the underlying root causes.  This becomes the basis for establishing enterprise wide asset strategies.

PdM11: Evaluating Time to Failure of Insulation Systems Using Motor Circuit Analysis Techniques by Howard W. Penrose, Ph.D., ALL-TEST Pro, A Division of BJM Corp.

Learn guidelines to determine the time to failure following changes in the trending of motor circuit analysis readings.  This method allows for the reconditioning versus the rewinding of the electrical equipment. The session includes low voltage random wound induction motors and medium voltage form-wound induction motors

MB11: Maintenance Benchmarking by David P. Bolton, Charles Brooks Associates
 

Benchmarking maintenance can be an effective method to drive a maintenance improvement program. Learn a step by step methodology to access all the aspects of a company’s maintenance department and then benchmark them against similar companies and world class standards.

MM11: Web Based Maintenance Tools by Joseph R Ahumada, Alaska Supply Chain Integrators, LLC
 

Learn how new tools and technologies allow maintenance personnel to perform material acquisition and acquire critical data with minimal time invested with one of the leading maintenance supply information system.

RZ12: Design Management: Reliability from the Start by David V. Abecunas

Planning for new systems should always take reliability into consideration.   Learn to define the inputs, reviews and actions required to ensure maintenance and production issues are addressed during the design process in an easily understood format.

PdM12: Keep Motors Turning via Motor Current Signature Analysis by Professor W. T. Thomson, EM Diagnostics

Motor reliability is critical as induction motors are the primary source of motive power used in industrial processes.  Learn how to use on-condition based maintenance strategies in parallel in conventional planned maintenance schemes to reduce unexpected failures increase MTBF and reduce cost.

MB12: To Contract or Not to Contract – That is the Question by Ron Moore, The RM Group, Inc.

This case study presents one company’s failed efforts to reduce maintenance cost by bringing in contractors.  As maintenance cost doubled a considerable effort was required to return to original levels.  Lessons learned and a “Best Practice” approach for contracting will be presented.

MM12: Collaborative Asset Management (CAM): A case study by Mr. Luiz Marcelo Piotto - VCP Jacarei, Brazil & John Yolton, SKF Reliability Systems

This case history demonstrates how a pulp and paper producer has used integrated maintenance services to reduce cost and increase capacity.  Learn the elements of successful collaborative asset management.

RZ13: Why Companies Should Implement Reliability-Centered Risk Management by John F. Wright  eXegeSys, Inc.

Learn how risk management complements reliability centered maintenance by classifying the criticality of equipment, the likely modes of failure and the effects a failure might have on equipment, the environment and/or personnel.

PdM13: Automated Spectral Analysis by Jason Tranter
iLearnInteractive

Diagnosing vibration spectrums can be difficult and has required a great deal of experience.  Learn how new technologies and tools are automating spectral analysis functions to improve machinery condition diagnostics.

MB13: Equipment Can’t Talk Back But People Can and Should (How to Get to Human Performance Root Causes for Equipment Problems) by Andy Marquardt
System Improvements, Inc.

As we all know equipment can’t talk back.  Learn how to conduct a thorough troubleshooting and failure analysis effort to determine the actual path to failure and to identify human performance issues and root causes of equipment problems.

MM13: The Maintenance Storeroom - Keys to Efficient Maintenance Operation by Jeff Zeiler, York Consulting Group Inc.

Discover why the maintenance storeroom is the enabler for maintenance to excel.  Learn elements of “Class A” inventory accuracy to eliminate time spent searching for parts and to reduce fewer stock-outs.  This session delivers methods and practices to achieve storeroom excellence.

RZ14: Using Reliability Engineering Methods as a Tool for Continuous Process Improvement by Bill Keeter, ARMS Reliability Engineers - USA, LLC
 

Learn about using Reliability Block Diagrams and Failure Modes and Effects Analysis (FMEA) to drive continuous improvement methods throughout a plant.

PdM14: Wireless Data Collection for Condition Based Maintenance by David Wolfe, Techkor Instrumentation and Constantine Yiannakakis, Reliant Energy
 

MB14: How Fluor Global Services Tapped into the Web to Train its Maintenance Technicians: A New Technique that Makes Web-based Training Work in the Manufacturing Environment by Michael Eddings, PRIMEDIA Workplace Learning

This case history exams how Fluor overcame the obstacles to implementing web-based training by blending it with instructor-led, hands-on, evaluations and instruction to insure that maintenance technicians could effectively apply the skill they learn online.

Learn methodology to identify obstacles and barriers to outage and modification project work productivity.  In addition recommendations will be made to improve work efficiency, reduce costs and reduce outage duration.

RZ15: Beyond “No Scheduled Maintenance” by Douglass J. Plucknette, Reliability Solutions Inc.
 

Learn how the result “No Scheduled Maintenance” does not indicate a conclusion of the reliability analysis by implementing a consequence reduction strategy that ensures system functions and communicates reliability to all stake holders.

PdM15: Motor Troubleshooting Basics by Terry Ledbetter, Lewellyn
 

This session teaches the proper methods for teaching 3-phase, 9 lead induction motors including safety procedures.  Techniques for detecting shorted windings, open windings, motor grounding and use of a Megger will be explained.

MB15: How to Write a Purchasing Spec that Will Increase Plant Reliability, Decrease Overall Costs and Drive Your Vendors Crazy! by Michael Holloway, Certified Labs - NCH Corp.

Learn a simple process to prepare comprehensive procurement specifications to ensure that your company receives the highest quality goods and services at the lowest possible price while simultaneously increasing reliability.

MM15: Leveraging University Programs to Enhance Reliability Programs by Tom Byerly
University of Tennessee
Maintenance & Reliability Center

Our nation’s universities offer a vast array of resources to assist maintenance and reliability programs.  Learn about educational opportunities, intern programs and research projects available to your company.

Learn how companies are able to accomplish more with less resource by implementing enabling technologies and expertise that supports a reliability driven approach to maintenance. Explore new technology that analyzes CMMS data to enhance maintenance decisions.

Discover more about the characteristics contributing to CMMS flexibility.  Some of these characteristics include Workflow enabled documents, Windows customization, Navigation configuration, Report manipulation, Integration and Scalability.

The Machinery Information Management Open Systems Alliance (MIMOSA) is a trade association that advocates open systems for the exchange of equipment condition and performance data for maintenance.  The requirements for MIMOSA compliant product certification will be discussed.

Learn how simple corrective measures during installation, repair or rebuild during a systems life cycle can significantly alter its degradation curve.  This session deals with simple, practical and low cost proactive measures