IMC-2004 Workshop Schedule

IMC-2004 Expo

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IMC-2004 Home Page

This short course is about “learning from small things that go wrong.” Course concepts include "Big problems are caused by small problems", "Both big and small problems are caused by the same underlying issues" and "We can learn about these underlying issues by looking at small problems before they become result in big ones". A strategy and structure is needed to accomplish the vision. This strategy is discussed. Examples of completed Mini-RCA’s are given.

The PM Playbook includes a step-by-step process with illustrations, charts and worksheets that explain how the PM program is setup, implemented and measured.  Necessary process steps and analytical methods that can be used to review your existing PM program are included.  The playbook takes into account configurations of your CMMS that are necessary to manage your PM program.

See and hear many examples of 10X and how the 4 phases can get you to zero equipment stoppages. See where TPM, RCM, Six Sigma fit into those 4 phases, for maximum effectiveness.  This 2 hour session on Maintenance Excellence will cover these subjects and more…  with many pictures and real life examples.

This short course offers a brief summary of the main points regarding performing a fault current study and flash hazard analysis at your facility and establishing an electrical work program and related Personal Protective Equipment (PPE) and Clothing policy.

Learn about the Three Waves of Global Reliability Strategy at Alcoa. By using the Three Waves of Global Reliability Strategy, Alcoa is en route to achieve excellence in reliability across the 31 locations in the Primary Metals Business Unit. The Three Waves stress the importance of sponsorship through corporate and plant leadership, assessments and plant specific improvement model, and the implementation and sustainment of the improvement model for financial return.

This session introduces and outlines the implementation of Total Maintenance Management (TMM) at Oil-Dri Georgia. By using a disciplined approach to the everyday maintenance functions - a proactive strategy is being developed which “raises the bar“ to plant maintenance. Main objectives are: integration of Operations and Maintenance partnerships and transformation of maintenance practices from Reactive -to- Proactive mode. TMM is the vehicle being utilized to reach the higher level of equipment availability and utilization, however, the ultimate goal is to maximize production levels while keeping costs to a minimum.

Traditionally, outage performance for the maintenance organization is centered on the basic criteria of schedule attainment and/or cost. A different approach is suggested in this
session, which looks holistically at the outage. An adaptation of the
Weighted Average approach and the Eastman Kodak Safety Performance Index is applied to express the performance of the maintenance organization during the outage in terms of a percentage figure. The evaluation methodology is
based on quantitative and qualitative methods. The result is the
quantification of the maintenance effort towards the outage, which in turn lends itself to more effective management of this critical part of the maintenance philosophies applied today.

This learning zone session teaches three fundamental requirements that must be in place before companies can sustain an effective improvement management program including effective improvement management, the ability of management and the workforce, to accept change and the requirement of a sound Improvement Management System that fuels improvement identification and implementation.

Steve Turner teaches how a reliability incident management systems allows organizations to make better use of their time, control minor projects effectively and regain production time being lost to equipment and plant failures.

This learning zone session includes a detailed process description for reliability incident management.

This session demonstrates how data from various technologies has been used to detect problems in gearboxes.   By combining high frequency ultrasonic sensors with low frequency vibration transducers, gear box problems can be discovered and preventive action can be implemented prior to failure. These technologies have been proved to work on many different gearboxes and particular reference will be made to slow speed applications.

The learning zone session explores the use of the System Dynamics computer model to help maintenance professionals decide which best practices to implement and to determine how much their company should be willing to invest in the implementation based on the expected improvements. Savings figures are determined for implementing Planning, Scheduling, Predictive and Preventive Maintenance independently and also the savings for implementing them all in an integrated manner.

This practical "how to" session is for all persons involved in scheduled major mechanical outages of commercial facilities, manufacturing plants or major industrial process systems. The session will discuss plant shutdown frequency planning; milestone and task/activity scheduling; and selection and responsibilities of the turnaround manager and turnaround team. It provides details on the five phases of a plant turnaround; the master work list and work package development; and setting the formal work list cut off date.

Learn how Sea World improved equipment reliability by starting a precision laser alignment program for their rotating equipment. This presentation will cover information on how to create a precision alignment program from scratch and the potential savings which can be generated from implementing such a program.  You will also get a chance to view a brief presentation of a laser alignment tool.

Reliability Incident Management Open Discussion

Airborne
Ultrasonic Open Discussion

Maintenance
Benchmarking
Open Discussion

Plant Turnaround Open
Discussion

Electrical Safety
Open
Discussion

Well-designed business intelligence systems which are capable of publishing near real-time KPIs and metrics on a “push” basis to appropriate people in the organization can be very instrumental in achievement of business objectives.  Nobody wants to be bottom of a very visible totem pole.  A well designed system focuses management attention early on the “hot spots” which need attention [Can you imagine the Major Leagues without the stats?  How does your organization compare?  Do you have consistent real-time EAM management information available across the enterprise?]

EAM systems create masses of transactional data [the feedstock for business intelligence] which all too frequently just fills up hard disks where “nobody can see the forest for the trees”.  To drive results from EAM systems and continuously improve performance in the maintenance/EAM business function it is imperative to develop the right KPI’s / metrics and a business intelligence system which will deliver these automatically in near real-time across the maintenance/EAM organization.

This paper discusses key KPI’s and metrics for the maintenance/EAM function and looks at the system landscape to develop a business intelligence system in a modern EAM environment.

This session offers a broader view of Asset Management, built upon three core operating functions:  Lead, Execute and Enable.  The Execute function is always performed in the plant environment. Manufacturing success is relative to the competition however.  Whoever can make the best products at the lowest cost will win.  Lead and Enable are the great determinants of that relative success.

This paper explores the four integrated facets of the Execute function in the plant including Capacity acquisition and disposition, Production, Asset Healthcare and  Logistics.

Much is written and said about the condition monitoring methods of vibration analysis, oil analysis, NDT methods, and electrical plant tests, but performance  analysis gets very little airplay in comparison. This is the analysis and monitoring of the physical performance of both rotating and non-rotating plant items as an indicator of their condition.  Performance analysis also often enables the optimum time to be found to schedule maintenance to restore lost performance.  Based on many years of experience in fossil fired steam power generation, this paper  demonstrates the application of performance analysis by describing case studies on  pumps, air compressors, steam turbines,   mechanical control system components, boilers and heat exchangers.   

This session will be  hands on, as we will work with case studies, calculate OEE% and  Pareto losses.

No matter how effective a preventive maintenance program may seem, we always seem to have those unending numbers of small failures on some equipment.  But what can be done.  Through the establishment of a “Bad Actor” program and conducting failure analysis, we can whittle down these problems and implement measures to prevent reoccurrence.  The management of this program rests primarily with the plant Reliability Engineer together with inputs from a reliability team and other personnel in the plant.  This session deals with developing a bad actors program and how to form the team and conduct basic failure analysis. 

This session explains six common errors that organizations make when working through problems.  Examples of each error are provided along with why the error is committed, why it’s perpetuated and what specifically should be done to prevent it from occurring.  Suggestions for improving the understanding of these errors with both management and the people in the field are also provided.  Overcoming these errors is fundamental for improving results in any organization.  The six errors addressed in this session are: Focus on Prevention, not blame,   The Output of a Root Cause Analysis is Solutions - not a Root Cause, A Problem Description is not a Problem Analysis, Start an Analysis with the Impact to the Goals - not “the Problem”, Apply the Basics of Cause-and-Effect - not the Buzzwords and Utilize All the Knowledge in your Organization – not some of it.

This session focuses on actual motor testing case studies including rotor bar problems that were difficult to detect and several problems that were solved using  demodulation techniques.

This session will illustrate a unique methodology on cataloging and deploying standard maintenance job plans across a multi-site organization. Modern CMMS software allow maintenance professionals to design various types of job plans and link them to systems, equipment and networks. Also, the job plans can be segmented into operations, sub-operations, descriptors, etc. This session focuses on how to exploit this functionality to maximize maintenance productivity and at the same time ensure that the job plans can be managed efficiently and effectively.

This session covers Analytical Ferrography one of the overlooked tests available for used fluids analysis. Analytical Ferrography when performed with other analysis tests is capable of determining the Root Cause of failure, which can lead to failure prevention. Analytical Ferrography utilizes microscopic analysis to identify the composition of the material present. This technology will differentiate the type of material contained within the sample and determine the wearing component from which it was generated. This test method is used to determine characteristics of a machine by evaluating the particle type, size, concentration, distribution, and morphology. This allows a skilled diagnostician to determine the root cause of a specific tribological problem.

Root Cause Analysis Open
Discussion

Online
Motor Testing Open Discussion

Creating
Job Plans
Open Discussion

Oil Analysis
 Open
Discussion

Key Performance Indicators Open Discussion

The IMC-2004 Dinner Banquet sponsored by SAP, the solution for enterprise asset management.

SAP invites all IMC-2004 conference participants to attend the Dinner Banquet as the sun sets in the warm Florida evening air on the beautiful Waterfall Terrace at the Hyatt Regency Coconut Point.  The IMC Banquet will feature musical entertainment and will be one of the best networking opportunities at IMC-2004.  Wear your Florida (or Hawaii) shirt and bring your dancing shoes!

Many maintenance organisations are more reactive than they should be.  Part of their problem is that they are unable to complete the preventive maintenance they have or they do not have one that is formalized.  Some consider they have no preventive maintenance program at all.  In the absence of any better method, companies in such situations have turned to RCM only to find that it takes too long to complete and it is too labor intensive.   PM Optimization generates the same maintenance program as RCM but in 1/6^th of the time.  This short course offers an introduction to a formalized process of PM Optimization.

This session aims at presenting the concepts concerning Asset Management and Life Cycle, assessing the importance of them within the overall scope of maintenance management, while highlighting their financial impact. The life cycle of assets is born with the idea of conducting an activity that requires assets for its development and moves on through the stages of preliminary project, project, design, purchase, manufacture, installation, testing, start-up, operations and maintenance, until the eventual recycling, discarding or final disposal of the assets.

This session explains the benefits of using multiple technologies to solve rotating equipment problems.  By combining high frequency airborne ultrasonic detection and analysis with traditional Vibration Analysis to enhance machinery diagnostic capabilities.

Examples of ultrasound spectrum will be shown and compared to vibration spectrum in order  to illustrate the unique properties of demodulated high frequency signals to detect subtle bearing fault frequencies and other illusive machinery problems.

Management is always asking “show me the money”.  One way is to show the value of reliability is to relate it  to the Point of Failure Curve (P-F Curve).  The P-F Curve can be used to show how proactive, predictive and reactive maintenance strategies are be applied.

This presentation describes the approach use at Bristol-Myers Squibb Company to show the value and benefits of tying reliability to the P-F Curve.

This session will explore recent advances in breather technology and provide guidance on successful use and application of the various breather types. Also, the paper addresses how major cost savings can be achieved by controlling contamination ingress. Effectively controlling, or eliminating, contamination will have a significant impact on the reliability of lubricants and machinery. Total cost of ownership can be greatly reduced through proper lubrication maintenance which involves the use of contamination control breathers as a 'best practice.'

History tells us that Archimedes jumped out of his bathtub shouting “eureka I have found it” when he realized that a body displaces it’s own weight of water when floating. In a discussion of classic failure modes in major process units – specifically the bathtub curve, this session  will offer an alternative reason why he might have jumped out. It goes on to show owners where to look and how to apply their problem solving efforts to produce the maximum return for the least effort. 

Learn techniques for creating and maintaining a database for a professional Infrared Thermographic inspection program. A highly integrated thermographic inspection software has been developed that enables infrared thermographers to perform data logging during in field inspections within a camera. The software simplifies routine data entry, in field analysis and automates report generation and a master data base maintains comprehensive records of all assets subject to thermographic inspection.  A review of MIMOSA implementation will also be described.

The learning session teaches the basic principles in the lubrication of plain and rolling element bearings including Viscosity Selection for Plain Bearings, Lubrication Systems for Plain Bearings, Rolling Element Bearing Viscosity Selection, Lubrication Systems for Rolling Element Bearings, Greasing of Rolling Element Bearings, Bearing Lubricant Properties and Rolling Element Failure Analysis.

The NASA method provides an assessment of the general condition of all facilities and an estimate of deferred maintenance (DM) (or recapitalization) costs using a parametric estimating method.  The method is designed to provide consistent, auditable deferred maintenance estimates at the Agency and Center levels, and to provide an assessment of the general condition of a large number of facilities at the system and facility level.  Its intended use is as a facility performance metric which can be compared to, and trended against, other commonly used facility metrics, and as a support mechanism for maintenance budgeting. 

Reliability Centered Maintenance Open Discussion

Offline
Motor Testing Open Discussion

Asset Management Open
Discussion

Bearing Lubrication Practices Open Discussion

Maintenance Stores Open
Discussion

The maintenance concept of the US Army helicopter, CH-47D, Chinook is being transformed as current practices are challenged using Reliability Centered Maintenance (RCM). A facilitated group approach to RCM is currently being employed which necessitates the interaction of different disciplines and professional hierarchy that typically doesn’t occur using a single analyst approach. The driving element for the maintenance decisions is not the failure of a given item but the consequences of that failure and how if affects the safety of the crew and the successful completion of the mission.
The major points that will be covered in the presentation include a very brief overview of the RCM process, discussion of its application to aircraft, and a summary of the outstanding quantifiable and non-quantifiable results (using specific examples) achieved for the Chinook.

Significant progress has been made in transforming “maintenance cost” into a business “competitive advantage” in a multisite chemical company. Maintenance costs were reduced from 3.4% replacement value to 1.9% (world class target is 1.8% established via benchmarking) in a five year period and stores inventory reduced (0.32% RV to 0.24%) in two years. This was accomplished via a network of manufacturing site representatives, reliability engineers, and following an improvement framework consisting of 9 key areas (benchmarking, PPM, materials management, reliability improvement, maintenance work management, strategy/leadership, training, etc.). The improvement approach utilized implementing best practices along with some expertise via outside companies.

The overall approach, linkage with operations and business, and successfully competing with other important improvement initiatives, will be covered in this session.

This session will discuss how an Essential Care Program was developed at the Georgia-Pacific Corporation’s Palatka Mill. The presentation will show the detailed steps taken to improve the Mill’s efficiency and machinery reliability through technology. The presentation will show the detailed steps taken to implement this process.

The session also discusses selecting software that fits the process of developing an Essential Care Program, the use of automated collection devices and how a thorough lubrication survey/audit the ultimately led to the creation of our database within the software.

We will also cover the  training required to implement this process and to keep it moving in the right direction.

Learn about proactive methods of work identification that systematically identify the right work to be performed on an asset at the right time. This workshop shows how proper use of a variety of work identification methods, like Reliability Centered Maintenance (RCM), Maintenance Task Analysis, Failure Analysis and Predictive Maintenance Needs Assessment can help you to achieve optimal asset reliability at the lowest cost.

In complex process industries, the application of a risk based approach to Asset Integrity requires the combined skills of an amalgam of experienced experts. These are drawn from a number of disciplines, channelled by a systematic protocol  to achieve a common goal; the ‘Optimisation of an Inspection regime’.

This session will explore generically the rudiments of Asset Integrity and the elemental process of Risk Based Inspection (RBI).  It will then go on to illustrate through case histories how the methodologies have been applied in a multi-disciplinary manner to achieve  significant business improvements together with some distinctive beneficial by-products that emanate from the exercise.

MT10 - Reliability and Maintainability Courses Designed for Mastering the Maintenance Process, Norbert Jagodzinski and James Myers, Rochester Institute of Technology

Learn how students discovered the meaning of acronyms and definitions such as, MTBF, MTTR, RAM, Preventive Maintenance (PM), proactive maintenance, Availability, Reliability. It was quickly learned that critical to resolving maintenance issues is the credibility of data. The introduction of probability models, random variables and their important role in reliability was described in association with replaceable components and/or repairable systems.