ems july/august 2008

THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

ISSUE 6

JULY/AUG 2008

BUYERS GUIDERECRUITMENTVIBRATIONANALYSIS

w w w . e n g i n e e r i n g m a i n t e n a n c e . i n f o

INDUSTRY NEWS

PLANT MANAGEMENT

CMMS

COMPRESSED AIR

– the antidote to recession?

MAINTENANCE

Dustcontrol UK Ltd.Old Barn, Home Farm Business Park, Church Way, Whittlebury, Northants NN12 8XS, EnglandTel: 01327 858001 Fax: 01327 [email protected] www.dustcontrol.co.uk

STOP DUST AT SOURCE

GRINDING MATERIAL TRANSPORT CLEANING

Dustcontrol can help in improving product quality, environment and the efficiency of your factory with its high quality modular extraction equipment specifically tailored to meet your needs. For more information:

CALL 01327 858001

Centralised high-vac dust extraction systems for on-tool extraction and general cleaning.Typical industry customers include:Printing, Manufacturing, Pharmaceutical,Electronics, Aviation and many others with applications such as:

• Cutting • Grinding • General Cleaning • Sanding • Machining• Material Transport• Particle Extraction SANDING

For more information quote EMS Enquiry No. 101 on IBC

Consumer prices are rising, but I guess little of the moneyis filtering down to themanufacturing base.

One company Italked to lastweek, whoasked not to benamed, told methat supermarketsare preventing allprice rises due to rawmaterials, energy, andtransport fuel, and at the same time they are threatening to ‘walk away’ from theirsupplier partners unless prices are reduced. No wonder the German for partnership is‘partnerschaft.’ I could be wrong, but I dowonder, what with milk up from 98p to £1.44 in less than a year, exactly who in the supplychain is making the financial gain?

To read the full article please turn to page 21.

9PAGE

28PAGE

18PAGE

11PAGE

6PAGE

3PAGE

Published sixtimes per yearby EMS

Annualsubscription:

UK FOC Rest of World £90

© 2008 EMS

EDITORIAL/CONTRIBUTING EDITORS: Jon Barrett, Christer IdhammarAlan France, Mark [email protected]

ADVERTISEMENT SALES: Michael [email protected] [email protected] [email protected]

WEB MANAGER: Oliver [email protected]

DATABASE MANAGER: Steve Hill

TECHNICAL MANAGER: Igor Seke

CREATIVE:Ric [email protected]

ARTWORK PRODUCTION:Elaine [email protected]

EMS MSL GroupCobalt House, Centre CourtSir Thomas Longley RoadRochester, Kent ME2 4BQ+44 (0)1634 731646

www.engineeringmaintenance.info THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

Articles appearing in this magazine do not necessarily express the views of the Editor or the publishers. Every effort is made to ensure the accuracy of information published. No legalresponsibility will be accepted by the publishers for loss arising from articles/information contained and published. All rights reserved. No part of this publication may be reproduced or storedin a retrieval system or transmitted in any form without the written consent of the publishers.

WHAT IS THEANTIDOTE TORECESSION?INDUSTRY NEWS

PM PROGRAMS

INDUSTRY NEWSCredit crunch drives market for hired instruments

PLANT MANAGEMENT

PLANT MANAGEMENT

OEE

DUST CONTROL

PM PROGRAMSMaintenance optimisation

PLANT MANAGEMENTSharpening your competitive edge

PLANT MANAGEMENTReducing downtime and improving overall machinery health

OEEThe fight back begins

DUST CONTROLSolve problems associated with dust pollution

Atlas Copco Compressors LtdSwallowdale Lane Hemel Hempstead Herts HP2 7HAPhone: 01442 261201 Fax: 01442 234791e-mail: [email protected]

Jump to the next level of performanceRegardless of your field, staying ahead means having an edge over your competitors. In the same way, an efficient and reliable compressed air supply for your manufacturing facilities is a key element in successful business operations.

With its superior screw element, unrivalled reliability at temperatures of up to 55°C / 131°F,3.5 to 14 bar (e) / 65 – 200 psi(g) pressure range and optional integrated air treatmentequipment, the new GA range will keep you one jump ahead.

Extreme efficient screw element with the Atlas Copco patented asymmetric rotor profiles.

Highest compressor package efficiency according to ISO 1217 ed 3 annex C (includingwater separator). Energy recovery system recovering up to 94% of the compressor shaftpower in terms of hot water.

Variable Speed Drive (VSD) with 80-85% flow turndown yielding 35% energy savings.

If you want to know more about the new GA compressors visit www.airforwinners.com orcall 0800 181 085.

Committed to your superior productivity

Introducing the amazing new GA / Beyond a superior screw element


The company has decided to replace thebearings once a year during the annualshut down. They had always done that buthad still had three break downs of thebearings during the last ten years.

The manufacturer’s handbook said“Once a year, open top of screen, idlescreen and listen to the bearings with astethoscope or similar device. If thebearings sound bad, replace bearings”

To install transducers for vibrationanalysis of bearings is an obviousalternative. To do that will cost Euro 1500.The financial decision maker said no to themaintenance manager’s request to installthe transducers because she thought itwas too expensive and the maintenancemanager had not provided a financialjustification to install transducers. Besidesthat, she referred to the instructions in themanufacturer’s handbook and claimed thatmust be right.

This example is a true case from manyplants with an almost identicalmanufacturing process. To help themaintenance manager optimizemaintenance of the bearings in the screen,we made a short consequence of failureanalysis of different scenarios that mightoccur and then put a financial value toeach of them.

If we accept the failure developingprinciples described in the May/June issueof this magazine we can use this as a

methodology to bridge the gap between atechnical solution and financial language.It is obvious that the manufacturer’srecommendations are wrong and you donot need to be an expert on theirequipment to prove this fact. Attaching avibration transducer in each bearinghousing and pull wires to a point outsideof screen is of course a better and morefinancial viable solution.

As a case study I like to use a discussionI have had in many plants with groups ofexperienced maintenance professionals.

There are three options we can choosefrom to maintain the bearings:� O.T.B = Operate To Break Down� F.T.M = Fixed Time Maintenance� C.B.M = Condition Based Maintenance

If we chose O.T.B. the job to changebearings and very possibly also V-Beltdrive and other damaged components canbe planned, but not scheduled. We canmake sure we keep spare parts in store,our people know how to do the job, whatspecial tools are needed etc. This oftenleads to that we keep some veryexpensive parts in store to prepare for theworst case scenario. It is likely to occupy atleast six people to correct the break down.They will not all work, but because scopeof work was unknown when thesymptoms of the broken down screenfunction was noticed, all availableresources would migrate to the broken

Choosing the most cost effectiveMAINTENANCE PROCEDURE

3EMS July/August 2008 www.engineeringmaintenance.info

The picture shows a rotating screen where incomingmedia is separated in good product, and reject. Theinside rotary assembly rotates with 350 rpm inside astainless steel basket with drilled holes. The diameterof stainless steel basket is one meter. The insidebearings are lubricated through two pipes. The rotaryassembly is driven by an electric motor and V-belts. Ifthe function of the screen ceases, it will shut down aprocess at a cost of Euro 20000 per hour in lostproduction. A break down of the bearings might causethe rotary assembly and the stainless steel basket tobe destroyed at a cost of Euro 100000.

Your Inefficient Motors are Wasting Money

Whitelegg Machines, Dorking RH5 4LQtel: 01306 713200 www.whitelegg.com email: [email protected]

Are your motors overrated, are they running at their most efficient, perhaps their load is adversely affecting their operation?Unless you test your motors you will not know the answers. With Baker condition monitoring equipment, data from on andoff-line motors can be quickly collected and analysed and action taken to improve efficiency and avoid critical failure.

The Baker Explorer on-line testeroffers a comprehensive view ofmotor health whilst the motor isrunning. It will also identify rotorbar, power quality, bearing andother mechanical issues.

FREE Guide

Call now for yourcopy of How to

Prevent MotorFailure and Reduce

Energy Costs

The AWA Winding Analyser offers anautomatic testing programmeenabling less skilled staff to completetests successfully, combining surge,polarization index, DC Hipot,megohm and winding resistancetests in one field-portable unit


Perfect for industrial maintenanceand utilities applications, the newMIT400 series of insulation andcontinuity testers offers so much� CATIV 600 V

� True RMS voltage measurement

� Combined dual digital and analogue display

� PI, DAR and timed testing

� Capacitance measurement

� Result recall

� Bluetooth® download capability

� And much more

Find out more ask your instrument supplier, or call01304 502101

The Bluetooth word mark and logo are owned by the Bluetooth SIG, Inc. and any

use of such marks by Megger is under license.

Megger Limited Archcliffe Road Dover CT17 9EN UK

T +44 (0) 1304 502 101F +44 (0) 1304 207 342E [email protected]

WW

W.M

EG

GER

.CO

M


down screen and it is likely we would callmore people than necessary for overtime.In most plants the unscheduled breakdown is 76.2% likely to happen when themaintenance crew is not there. So theyhave to be called in on overtime or youfall into the bad habit of havingmaintenance people on shift. This is ofcourse not only because of this equipmentbut because most maintenance is reactivein nature.

If we choose F.T.M. we can both planand schedule the job. In this case theprocess line has scheduled clean up andprocess material shut downs every fourweeks during eight or alternating twelvehours. It will be easy to plan and schedulethis job during one of these shut downsthus avoiding any lost production due toscreen maintenance. We would still haveto keep a very expensive exchange part instore because without it, it would takelonger time to replace bearings thanallowed by the scheduled shut downs. Thedisadvantage of F.T.M. is that we will overmaintain the screen, work has to be donemore frequent than necessary. It is alwaysthe risk that we will induce failures tocomponents when they are disassembled

and assembled. The fact is that theestimated life of new bearings is 1–15 oreven 1–25 years so it is obvious that wewill never know if we replaced goodbearings with good once.

If we chose C.B.M. we optimizemaintenance of the bearings in the screen.The assumed break down frequency usedto calculate cost for O.T.B. will be thesame. You can not detect more failuresthan you assumed would occur. The failurefrequency might not be right, but thecomparison between costs for O.T.B. andC.B.M. is right.

With the above example we haveshown the financial impact of OptimizedPreventive Maintenance. The difference incost can be 1–100 as in the example above.

It must be made clear that in mostcases an analysis like the one describedhere is not necessary to do. Only about 5%of all components require an analysis todecide the most cost effectivemaintenance method, for most othercomponents the best maintenanceprocedure can be decided in a much less time consuming way.

� Reader Reply Number: 300

Christer Idhammar is a world renownedexpert in Reliability and MaintenanceManagement best practices. He started theIdhammar group of companies in Sweden in1972 and IDCON, INC in USA 1985. In 2002 hereceived the Euromaintenance IncentiveAward for outstanding internationalcontributions to improve Reliability andMaintenance in industries worldwide. In May2008 he received the Salvetti Foundationreward for best speaker among 158 speakersat Euromaintenance 2008 in Brussels. He canbe reached at [email protected]


In the table above a break down frequency of one failure per year will occur. On an annual cost basis that is 1/5 or 0.2 failures per year. In the O.T.B. case thefailure will develop to a break down. Repair time for break down is 12 hours with six people. Cost for crafts people is 40 Euro per hour (Plus extra cost for verylikely overtime and management/supervision time). The material cost is the cost for bearings and V belt drive. If it is estimated to take 12 hours to repair, it will cause 15 hours of lost production @ 20000 Euro per hour before process is up running making quality product. The worst case scenario is that the rotaryassembly will destroy the stainless steel basket which will cost 100000 Euro to replace, in the best case scenario this will not occur. In the example above wehave assumed a 50% likelihood that worst case scenario will occur.

In this example cost to carry spare parts is not included. In the O.T.B. alternative a full set of the rotary assembly and screen will be stocked at a carrying cost of 30000 Euro per year. In the other cases this cost will be much lower or even 0.

To do C.B.M transducers at a cost of 1500 Euro must be installed and it is apparent that it will pay off. If this had been specified when the screen was purchasedthe cost would have been 700 Euro and two break downs would have been prevented.

Operate to Fixed time Condition basedbreakdown maintenance maintenance

Number of failures per year or (Overhaules for FTM) 0.2 1 0.2

Risk of breakdown despite maintenance procedure 100% 20% 5%

Repair time 12 6 6

Number of people put on the job 6 2 2

Cost for craftsman/hr 40 40 40

Material cost per breakdown 600 600 600

Equipment downtime (hrs) if on planned shutdown put “0” 15 0 0

Cost for one (1) downtime hour 20,000 20,000 20,000

Risk for other damages if breakdown occurs (%) 50% 50% 50%

Cost for other damages due to breakdown 100,000 100,000 100,000

Direct maintenance cost/year (labour + material) 696 1,080 216

Downtime cost/year 60,000 0 0

Cost for other damages/year 10,000 10,000 500

RELIABILITY AND MAINTENANCE COST/YEAR 70,696 25,219 716

Christer Idhammar,president Idcon Inc

INDUSTRY NEWS

FREE thermography forumThe FLIR User Group is now a firm fixture on thethermography calendar. It has become a focus forthermographers from a rangeof disciplines to exchangeideas and deepen theirknowledge. And it is not just

an event forFLIR camerausers,

everyone involved in thistechnology is welcome. This year’s event pushes theboundaries even more withsessions on medical andveterinary thermography aswell as those on conditionmonitoring and buildingscience. Another new additionis a seminar on the costbenefit of thermography andhow to get the best return on

a camera investment.The day’s event on 11thSeptember is free of charge

to FLIR customers.It starts

at 9.30amand thevenue is theWindmill

CG Flooring Systems (CGFS) hassuccessfully completed its biggestand most demanding project –upgrading the 6000m2 floor of aniron foundry to narrow-aislewarehouse standard suitable forracking up to 12 metres high inless than six weeks.

As part of a major re-organisationof its manufacturing operations,the Baxi Group decided to closethe cast iron foundry at its plantnear Preston, Lancashire, and usemost of the building as its centralwarehouse. The company is aleading European manufacturer ofspace and water heating products.

Following removal of the foundryequipment a detailed floor survey“ including seven large pits up to3 metres deep, a number ofvertical steel columns, horizontalI-beams and steel bolts withinthe floor, damaged expansionjoints, and low and high areasspread throughout the building.

All columns, beams and boltswere removed, and around 150linear metres of expansionjoints were repaired. The sevenpits, totalling nearly 500m2 insurface area, were filled withconsolidated hardcore, and thencovered with a waterproof

membrane and meshreinforcement. The edges of thepits were cut to provide clean,vertical surfaces, and thenapproximately 1000 600mmlong dowel bars were insertedin the walls to provide a loadtransfer mechanism to supportthe new floor. Nearly 100m3 ofconcrete were poured in fivehours to bring the pits up tofloor level.

Elsewhere in the building abase screed was used to buildlow areas up to floor level,while high areas were scabbledto lower them. The entire floorarea was then shot-blasted toprovide a positive key for thewearing surface.

The wearing surface selected byCGFS consisted of a nominal10mm-thick pumpedcementitious screed and wascompleted in five days. Oncethis had cured, all existing floorjoints were transferred throughand sealed with a specialisedfiller in order to reduce thepotential for cracking caused bysubstrate movement. Finally, aclear acrylic seal was applied tothe entire surface.

� www.cg-flooring.com


The current economic climate doesnot seem to have affected themarket for instrument hire; AshteadTechnology Rentals, reports a"boom in demand" over the lastfew months as oil prices rise, houseprices fall and economic forecastbecome ever gloomier.

Ashtead rents instruments forenvironmental monitoring, forhealth and safety checking, fortesting materials in constructionand manufacture, and for remotevisual inspection in a wide varietyof industries.

One might suspect that worrieswith the economy might forcebusinesses to cut back on allexpenditure, but as Ashtead'sGeneral Manager James Carlylesays, "Nervousness and uncertaintycertainly causes companies toreduce or delay capital expenditure.However, testing, monitoring andinspection work is vital for anumber of reasons includingregulatory compliance, qualitycontrol, health and safety, andenvironmental protection. So, evenin difficult times, this work still hasto take place and undertaken using

CREDITCRUNCHDRIVESMARKETFOR HIREDINSTRUMENTS

Village Hotel in Coventry. Onthe afternoon of the precedingday FLIR Systems is holding aseminar designed to showusers how to get the mostfrom its Reporter 8.3 softwarepackage. At the same venueon 12th September there willalso be a workshop forthermography in fire and floodrestoration - the cost forexisting customers is £100 +VAT per session.Anyone wishing to register for any of these events shouldcontact FLIR Systems on 01732 220011 or visitwww.flirthermography.co.uk.

� www.flirthermography.co.uk


MAJOR FAST-TRACKFLOOR UPGRADE


INDUSTRY NEWS


A key element of the design process wasto deliver exceptional efficiency in termsof energy usage. With views for offshoreusage and the power issues theseinstallations and vessels have regardingthe amount of wattage they use, Midland-ACS set themselves the task tobetter a power consumption rate of 5watts. Through various trials and tests afinal power consumption figure of 3.5watts at an ambient temperature of -50°Cto +60°C was achieved, almost halvingtheir original benchmark.

Compact, reliable and of increasingimportance to offshore facilities andoperations, lightweight at only 3.2 kilos,the valve design removes the potential for leaks and reduces the risk of hazardous contamination.

Available in 12v, 24v, 110v DC options and 24v, 110v, 230v AC options, thisdirect-acting solenoid valve has alreadybeen incorporated into a manifold solutionand at time of writing Midland-ACS wereinto the late stages of testing the 250 barhydraulic version to complement an everwidening range of Midland-ACS valves.

� www.midland-acs.com


EFFICIENCY DRIVE AND WORLD CONCERNSAID INNOVATION Energy and fuel conservation has been oneof the worlds most talked about topics fora number of years. Whether it be the needto conserve fuel and increase the MPGfrom your car, or simply turning off thelights and appliances when you go to bedto save energy, companies, organisationsand governments the world over are allpushing efficiency initiatives and theirgreen credentials. This drive hasstimulated the growth of innovations forUK based manufacturer Midland-ACS.

Utilising research into the marketplace andassessments of client demands their new 70series valve has been engineered to providecustomers with higher flow rates, while atthe same time consuming less power thanboth traditional solenoids and competitorvalves alike. Using 316 stainless steel in thebody construction to offer maximum internaland external protection from liquid andgases the 70 series is a direct-acting 3/2hazardous area solenoid valve for the oil,gas and petrochemical industries.

Designed for actuator control the 70 seriesis available with connections from 1/4” –1/2” NPT and is EExd IIC T6 with IP67Ingress Protection classified, for use inhazardous environments. Compliant withthe ATEX directive and entitled to bear theCE mark, the valve is also IECex certified.

appropriate technology.

It follows therefore, that there should be amove to instrument rental rather thanpurchase as renting lowers financial risk andfrees valuable capital.

Of course this applies in normal marketconditions, but in times of recession businessesexamine their cost structure more closely thanusual and quickly draw the conclusion thatrenting will help put them in a strongerposition to weather any potential storm."

A further reason for the growth in instrumentrental, is growth in the market itself; Ashteadhas seen a steady trend away from instrumentpurchase to rental for the financial reasonsoutlined above, in addition to an expansion indemand for particular instruments employedin environmental monitoring, occupationalhygiene and quality control.

Ashtead’s fleet of instruments for health andsafety assessments include toxic gas detectors,particulate monitors, HVAC monitors, andinstruments for the measurement of noise andvibration. These instruments come from worldleading manufacturers such as RAE, BWTechnologies, TSI Instruments, Thermo, Questand Casella.

Companies with emissions to the environmenthave to comply with a raft of regulations thatrelate to the management of waste andemissions to air, land and water. Complianceinevitably involves monitoring with the mostappropriate technology; this may involve thepurchase of on-line monitors, but frequentlynecessitates an initial assessment followed byregular spot checks, so renting provides anopportunity to do so without investment inexpensive instrumentation. It also enablesprocess operators to deploy the best availabletechnology whenever they need it.

In summary, as house builders, manufacturersand high street shops start to experience a fallin turnover, Ashtead's instrument rentalbusiness is joining the ranks of those that canhelp ease the burden of a credit crunch

� www.ashtead-technology.com� Reader Reply Number: 303

Portable, powerful,transferable.Tank Wash Systems � High impact cleaning. Consistent

repeatable performance.

� Easily moved from one tank to another. AA190 automatic tank washer with900mm shaft extension weighs 6.4kg, inserts through 95mm port.

� Air or electric powered. Quick connections.

� Big savings in water, chemicals and waste disposal costs.

Modern tank cleaning solutions for every industrialneed - from simple self-rotating nozzles to fully automated TWS-2050 cleaning systems that put youin control of every aspect of the cleaning cycle... maximising savings in water, energy, chemicals andwaste disposal costs. Better for you. Better for theenvironment.

Ask for our new TWS-2050 tank wash systems leaflet.

TWS-2050 cart mounted controller / pumping system

TWS-2050 enclosedcontroller / pumping system

T: 01252 727200 E: [email protected] UK website: www.spray-uk.com

Spraying Systems LimitedExperts in Spray Technology

®

SprayNozzles

SprayControl

SprayAnalysis

SprayFabrication


Get Shear Mode Technologyfor Less Than £100Compact, Durable, Industrial Vibration Sensors Now Direct in the UK

L O W - C O S T I N D U S T R I A L V I B R A T I O N S E N S O R S

Quality Products:� Advanced shear mode construction for improved measurement stability� Half the footprint size of a conventional industrial accelerometer� Hermetically sealed housings; case isolated� Hazardous area approved models� Ideal for use with permanent installations and

continuous online monitoring systems� Full line of handheld calibrators, armoured and

conventional cables & accessories

PCB Piezotronics Limited7 Paynes Park Tel: 01462 429710Hitchin, Herts SG5 1EH Fax: 01462 429798Email: [email protected]

Models Availablein Stock forFast Delivery!

Actual Size

©20

08PC

BGr

oup,

Inc.

Sens

orLi

neis

ase

rvic

em

ark

ofPC

BGr

oup,

Inc.

PCB,

ICP

and

IMIw

ithas

soci

ated

logo

are

regi

ster

edtra

dem

arks

ofPC

BGr

oup,

Inc.


REGULAR FAN SERVICING MEANSIMPROVED EFFICIENCY

PLANT MANAGEMENT

Industrial fans are at the heart of industriesthat produce large volumes of dust as a by-product. Quarrying, woodworking andfood processing companies, for example,have to ensure dust is efficiently extracted inorder to comply with health and safety laws.

Being energy efficient and aware of theimpact of your business on the environmentis a responsibility companies are now takingvery seriously. Today’s businesses areexpected to make an effort to reduceemissions, minimise energy usage, avoidaccidents and consider all the environmentalimpacts of their work.

A regularly serviced and well maintainedfan is by definition an energy efficient pieceof machinery. And even greater energysavings can be achieved by having highefficiency electric motors fitted when theregular service is carried out.

Minimising your energy usage in thisway could entitle you to certain taxincentives, Enhanced Capital Allowances,designed to benefit those who are energyefficient. However, neglecting to have fansserviced could impact on a company’s abilityto meet its environmental targets.

Why you should have your fans servicedClearly, the old saying ‘prevention is betterthan cure’ has never been more true, asmore and more companies sign up for fullfan servicing contracts in a bid to maintainefficient production schedules and smoothoperations. After all, why would anyoneneglect a piece of equipment that is criticalto the efficiency of their business?

Depending on its application an industrialfan can have a life span of more than fortyyears, during which time numerous potentialproblems can occur. Dirt and dust can collecton the impeller, for instance, throwing thefan out of balance, and the bearings andmotor can fail.

Should a fan unexpectedly break down,as well as the danger from critical failure ofrotating parts, there is also the additionalcost associated with repair and lostproduction time.

Annual fan service and maintenance is avital plant maintenance function. Oftencarried out during shut down periods, fanmaintenance can be done quickly andefficiently and does not have to interferewith production output.

To stay in business and keep the fansworking, regular servicing and maintenanceis essential. It’s surprising how quickly thingscan start to go wrong once you stop servicingfans and businesses can’t afford to have theirfans out of action for long periods.

What does a typical service involve?Regular on-site maintenance and servicingby experienced engineers can help to detectand prevent faults to all types of industrialfans, reducing the risk of breakdown, savingtime and money as well as ensuring the lifeexpectancy of the machine is maintained.

A typical service takes a full day andnormally involves:� inspecting the overall condition of fans � inspecting fan bearings for wear and re-

greasing or replacing where necessary

� inspecting, adjusting or replacing drivebelts on belt driven fans

� inspecting and checking alignment ofcouplings on direct coupled fans andreplacing couplings if necessary

� removing access doors and checkingimpeller for wear or damage

� test running fans and monitoringvibration levels. Leading industrial fan manufacturer

Woodcock & Wilson, based in Huddersfield,West Yorkshire, has seen significant growth inits fan servicing operation this year, as moreand more companies realise that having theirfans maintained and serviced regularly canprevent serious health and safety issues, isbetter for the environment and saves timeand money.

This growth also reflects the fact that theengineers at Woodcock & Wilson understandthe construction principles of fan manufacturingand design, allowing them to draw on their in-house expertise when inspecting fans on site,crucial when fault-finding and problem solving.

In order to maintain a competitive edge,more and more companies from a widerange of industries are realising the real andtangible benefits of having a contractmaintenance and repair service for their fans,enabling them to maintain and maximiseproduction performance levels at all times.

Setting up a repair and servicing contractgives you full security and allows yourbusiness to be more competitive.

� www.fanmanufacturers.com



How can you sharpen your competitive edge, improve health and safety standards

and monitor your energy efficiency? Answer: By having your industrial fans regularly

serviced and maintained. This reduces down time and minimises lost production

How can you sharpen your competitive edge, improve health and safety standards

and monitor your energy efficiency? Answer: By having your industrial fans regularly

serviced and maintained. This reduces down time and minimises lost production

www.elcomponent.co.ukt 01279 503173 f 01279 654441 e [email protected]

Unit 5, Southmill Trading Centre, Bishop’s Stortford, Hertfordshire CM23 3DY

aM&T Sub-Metering SystemsFlexible cost-effective metering for all utilities and every type of business. We have the hardware, software, networking and installation skills to supply the package you need, on time and on budget.

alarm signalling

Power Quality AnalysersHigh performance instruments for the most demanding energy and powerquality analysis applications designed and built to the highest quality standards.Supplied complete with the latest windows software.

Energy Data LoggersEasy to use portable data loggers forelectricity and general utility monitoring.Safe, non-invasive.

(3 phase analysers)

Power Factor Correction

fast payback and real savings.


Corus Northern Engineering ServicesFurther information from David Scatchard, Marketing Manager, T: 01642 498041 E:[email protected] W:www.corusnes.com

A whole world of engineeringexpertise concentrated intoone handy package – and it’s free.This CD showcases what we can do for you in� heavy machining and fabrication� engineering for industrial processes� design, build and project manage

– new build projects– upgrading projects

� condition monitoring� process control� CCTV, RFID, ANPR security systemsand a great deal more besides.

Your copy is ready for you now; simply let us knowwhere to send it


PLANT MANAGEMENT

piezoelectric properties through a processcalled poling. Poling is a process where ahigh electrical field is applied to thematerial at elevated temperatures,producing a net polarization. Each materialhas unique properties, which offeradvantages in particular applications.

This article shall outline designstrengths and challenges associated withboth shear and compression-basedindustrial vibration sensor designs, as wellas highlight some transducer selection andmounting considerations.

Shear vs. Compression: What’s the Difference?

What is Shear Mode?As the name implies, shear modeaccelerometers stress the internalpiezoelectric crystal in a shear, rather than acompressed, manner. In this type of sensordesign, crystals are “sandwiched” betweena center post and the mass (or masses),depending on the specific type of sheardesign. They are held in place, either by apreload stud, or a compression ring, as thecutaway, shown in Figure 1.

What is Compression Mode?Compression mode is a fairly simplisticdesign, in which the crystal sensing elementsits between a flat base and an inertialmass. There is typically a preload studthrough the center of the mass and crystalto hold it in place.

The earliest piezoelectric accelerometerdesigns incorporated mostly compressionsensor design technology, mainly due to therelative ease of manufacturing for thisconfiguration, and subsequent sensorassembly. However, most modernaccelerometers now use shear designs,because they significant performanceenhancements over compression types.


The implementation of industrial vibration monitoring sensors and associated signal

conditioning as an integral part of industrial predictive maintenance programs has

proven for many maintenance and plant engineers to be an effective strategy for

reducing downtime and improving overall machinery health

Industrial accelerometer performancecomparison and considerations: SHEAR VERSUS COMPRESSION DESIGNSVibration monitoring technology is widelyused because of its ability to detect anddiagnose a wide variety of machineryfaults, such as bearing faults, gearproblems, misalignment, looseness, massimbalance, and others, on a wide variety ofrotating machinery, and its relative ease ofintegration with data analyzers, PLC, SCADAand Plant Information (PI) systems.

For the proper implementation ofsensors into a vibration monitoringprogram, one first must understand thedifferences in the two most commondesigns of industrial piezoelectric sensors,as well as various considerations inselection and mounting. A piezoelectricaccelerometer produces a measurableelectrical signal when an inertial massstresses, or applies a force to, its integralcrystal sensing element. The two maintypes of piezoelectric sensor designs mosttypically used for industrial vibrationmonitoring applications are shear andcompression, which define the actualmode, or crystal axis, in which an inertialmass stresses the piezoelectric crystal.While both types operate in a similarfashion, one of these designs providesmuch more reliable and repeatableperformance when there are certainexternal influences within the demandingindustrial application environment.

Sensor design and performance varydepending on the type of crystal used.Crystalline materials such as quartz andtourmaline are naturally piezoelectric. Morecommonly used in modern accelerometerdesigns are ferroelectric ceramic crystals,like lead zirconate titanate, because of theirhigher electrical output and lower noiselevels. Man made ceramics achieve their

Figure 1: Shear design cutaway of an ICP®

vibration sensor, with integral internal amplifier.

Types of sensors and sensing elements – flexural,tri-shear and compression

How Do These Compare?In principle, both accelerometers work in asimilar fashion. When acceleration is sensedin the vertical axis, the mass exerts a forceon the crystal, according to Newton’sSecond Law of Motion, F = m x a. Thus, thelarger in size of the mass, the more force isgenerated for a given acceleration, and thehigher the sensitivity of the accelerometer.

All things being equal, compressiondesigns offer a higher stiffness than shear.This means they have a higher natural (orresonant) frequency, which results in anaccelerometer with a slightly higherfrequency response (10 to 20%). On theother hand, shear cut crystals produce about

PLANT MANAGEMENT

40% more electrical output forthe same input force ascompression cut crystals. Thus,it takes less mass for a shearcut crystal to produce thesame amount electrical outputthan compression.

Since the natural frequency(ƒn) of a sensor is based on thesize of the inertial mass (m)and stiffness of the crystal (k),

ƒn 1 k2x m

the output and frequencyresponse of shear and theoutput and frequency responseof shear and compression modeaccelerometers are very similarfor a given package size.

Compression designs sufferfrom high base strain sensitivity.This strain may be caused bythe base bending of a structuralsurface, or by thermaltransients. Meaning, when thebase of a compression modeaccelerometer is strained in anyway, that strain is directlytransferred into thepiezoelectric crystal, producingan output totally unrelated tothe acceleration measurementbeing taken by the sensor,which can lead tomeasurement uncertainty.

As stated earlier, crystalsproduce an electrical outputwhen stressed. Thus, anythingother than the vibration to bemeasured that stresses thecrystal produces unwantedelectrical output and errors. Thecrystals in compression modesensors are easily stressed bybase bending and thermaltransients. The output producedcan be very significant instructures having a largeamount of flexure or whenplaced in a hot or coldenvironment and not allowedto thermally stabilize prior tomaking measurements. Thisoutput can be very significant,resulting in large measurementerrors, and can cause “skislopes” in the FFT, particularlywhen integrating sensor outputto velocity.

In shear mode designs, thepost to which crystals and

masses are attached isessentially isolatedmechanically from basebending and thermal stresses.Thus, they are much lesssensitive to these errors, andprovide readings that are morereliably reflective of the actualvibration to be measured. MostIMI Sensors industrial vibrationsensors are manufacturedutilising shear mode technology,to offer customers the benefitsof increased performance.

Although shear designs aremore complex thancompression, using modernmanufacturing techniques,they also can be easily andeconomically built. In fact,embeddable piezoelectricshear mode accelerometerunits, such as IMI SensorsSeries 660 (also referred to aspellets) are able to be massproduced, resulting in very lowcost units which may be usedin many typical high volumeand commercial OEMapplications. These includesuch embedded applications asland surveying equipment;homeland security/bordercontrol monitoring devices;and assessing the shock andvibration impact of packagesor components. The units alsoemploy field-proven solidstate, piezoelectric sensingelements, for durability andbroadband performance.


Industrial Vibration SensorSelection ConsiderationsWhen selecting the rightpiezoelectric vibration sensorfor an industrial applicationenvironment, importantconsiderations includefrequency response, signal-to-noise ratio and sensorsensitivity, as well as themeasurement environment,and its characteristics (e.g.,hazardous area operation,temperature, corrosiveenvironments, or submersionin oil, water or cutting fluids).

As stated earlier, selectionof connector and cables canhave a direct impact on sensorinstallation, ruggedness andreliability. Erroneous signalscan be induced into sensorsystems through ground loopsor electromagnetic or radiofrequency interference (EMI orRFI). Connections to the sensorrequire two leads, one for thepower and signal, and theother for the common andsignal return. A looseconnector can result in asensor intermittently turningon and off, causing drift in theDC bias, and resulting in largeoutputs which are unrelated tothe measurement being taken.Another consideration withcables is the terminationmethod of the shield to avoidground loops. Generallyspeaking, it is recommended

to use a twisted pair, shieldedcable for sensors, as this typeof cable is less susceptible tonoise than a standard coaxialcable, such as RG58. In orderto avoid ground loops, it isrecommended that the shieldbe grounded once in thesystem, typically the analyzerend, and not the sensor end.The shielding of commercialcables made by IMI Sensors isnot grounded on the sensorend, to avoid such loops. IMISensors also providesarmored cables, for use inenvironments where there isrisk of cables being cut, suchas machine tooling.Permanent installationsrequire twisted pair shieldedcables, to ensure cleanvibration signal transmission.

Industrial Vibration SensorMounting TechniquesThe chosen mountingtechnique of an industrialvibration sensor directly affectsits frequency response, as thenatural frequency of the sensorsystem decreases, dependingon mounting method utilized.The mounting method chosenshould provide flat frequencyresponse throughout thefrequency range being studied.Typically, stud mounting on aclean, flat surface with a goodfinish will provide the highestpossible frequency response.The mounted resonantfrequency, and thus the sensorsystem frequency response,decreases progressively whenusing adhesive and magneticmountings, and is generallythe lowest, with handheldaccelerometers (i.e., stinger orprobe) being the exception.The useable frequency rangedepends on many things,including mass of theaccelerometer and magnet;magnetic pull strength;thickness of adhesive; andmaterial and length of theprobe. “Rule of thumb” tables,such as the one shown below,are only approximate valuesfor typical cases. Thesenumbers could vary widely.

√

Series 660 embeddable sensors feature shear mode design in a small,durable package

The rugged Ti25 and Ti10thermal imagers help youidentify the exact problemarea

The Fluke Ti25 and Ti10 make

thermal imaging easy to

understand and help you solve

problems in industrial

applications. With patent-

pending IR-Fusion® you can

view a full thermal image,

or one combined with a visual

image, to identify the exact

problem area.

• Even small temperature

differences and fine details are

revealed on the wide, full VGA

display

• Engineered and tested to

withstand a two metre drop

• Voice recorder simplifies

adding comments to each

image (Ti25)

• Store over 1,200 IR-Fusion®

thermal images with

temperature data and voice

comments

• Measure up to 350°C (Ti25)

IR-Fusion®:Now put problemsclearly in the picture

Full IR

Blended

Picture-in-Picture

New

Order yourTi25 or Ti10 now!

Checkwww.fluke.co.uk/ti

for your nearestdistributor

� 020 7942 0700

Fluke. Keeping your worldup and running.®


There are speciallydesigned cases, such as theIMI Sensors Model 621B40,where a combination ofdesign parameters areemployed, allowing the sensorsystem to achieve frequenciesas high as 30k Hz – even witha magnet.

In summary, industrialaccelerometers are thepredominant workhorse of asound predictive maintenanceand vibration monitoringprogram. It is imperative that

a sensor will meetrequirements of theapplication environment. Avibration analyst must reviewan application with sensorselection criteria in mind, tohelp a vibration analyst toselect the proper sensor,cabling and mountingtechniques for a givenapplication environment.While there are multiple typesof sensor technologiesavailable, shear mode designs,such as those offered by IMISensors, when used withproper surface mountingtechniques and attention toconnectors and cabling, willprovide reliable, repeatableand accurate performanceacross a wide variety ofindustrial applications.

� www.pcb.com


PLANT MANAGEMENT


ABOUT THE AUTHORS

David A. Corelli is Director of ApplicationEngineering for PCB Piezotronics. Hisnearly 35 years of experience in vibrationanalysis includes working as a testengineer for the United States Air ForceAvionics Laboratory and as a field engineerfor Hewlett Packard, Entek and IRDMechanalysis. A Category IV VibrationAnalyst in accordance with ISO 18436-2,Mr. Corelli serves on the Board of Directorsfor the Vibration Institute, as well aschairman of its Certification Committee.He is the author of dozens of technicalpapers focused on the successfulapplication of industrial vibrationmonitoring technology.

Molly Bakewell is Global PublicRelations, Advertising & Image Managerfor PCB Piezotronics, Inc. With nearly 15 years of expertise in global press andpromotional management, she hasoverseen development of more than 300 articles worldwide on behalf ofPCB®. Ms. Bakewell serves as a freelancedirector of PR & Media Relations forLeading Edge Events & Media, based in the United Kingdom, and is a pro bonotechnical trade publicist for the North American Eagle World Land SpeedRecord Challenger.

The Model 621B40 high frequencyaccelerometer from IMI Sensorsoperates to 30k Hz, even with amagnet. Because of its widefrequency range, the sensor can beused to diagnose a variety ofmachinery fault conditions, includingbearing and gear problems.

Table 1: Approximate frequency spans for 100 mV/g accelerometers, for most typical sensor mounting methods.

Method Frequency Limit

Handheld 500 Hz

Magnet 2,000 Hz

Adhesive 2,500 - 4,000 Hz

Bees Wax 5,000 Hz

Stud Mounted 6,000 – 10,000 Hz

(Table reprinted with kind permission from the Vibration Institute, www.vibinst.org)

For more information quote EMS Enquiry No. 110 on IBC For more information quote EMS Enquiry No. 111 on IBC

PLANT MANAGEMENT

tightening process of a threaded assemblyhas been concluded, the clamp load isretained by the pre-load of the bolt. Yet,the absence of a locking ‘mechanism’, canlead to the loosening of the fastener, whenshock, alternating loads, thermal changesand vibration are introduced into thesituation. And it is the loosening that resultsin the clamping load being compromised.

When that occurs, there is a goodchance that machinery will fail - with allthe aggravation that any engineer wouldwant to avoid.

Mechanical solutions such as locknuts,spring washers, nylon inserts, split pins, andtab washers are sometimes used as themeans of combating this loosening effect.However, their effectiveness can be limited.

A much more reliable solution can be foundin the employment of engineeringadhesives. For some engineers that couldbe a bold claim – but there are some prettystartling facts to back up that assertion.Shocking resultsAn independent assessor used a transverseshock test machine that enabled anaerobicthreadlockers, spring washers, patch bolts,distorted lock nuts and nylon ring nuts tobe compared under controlled conditions.

The test involved assembling a 3/8”,16-grade bolt in the machine and thentightening it to a controlled tension. Oncethat was done, air hammers wereactivated and the bolt tension plottedagainst time.

As the accompanying graph reveals,


Bob Orme, a Senior Technology Specialist at Henkel, the manufacturer of Loctite brand

products, reveals how adhesives help fasteners withstand high levels of vibration

Adhesives overcomeVIBRATIONSVibration has caused bolts to work loosesince threaded joints first came intoexistence. Of course, many and variedmethods of resolving the problem havebeen tried, yet the most successful hascentred on the application of adhesives.

It was back in 1953 that Dr VernonKrieble - the pioneer of Loctite adhesives –set about finding a way to lock and seal athreaded component. He was able to fulfila need within the automotive industry –that of securing a screw in a car’scarburettor in such a way that it couldwithstand severe vibration. Dr Krieble wasvery successful in his experiments – somuch so that anaerobic adhesives werequickly established across a variety ofindustries as the trusted method ofprotecting parts against the potentiallydisastrous effects of vibration.

Why bolts?Let’s begin an examination of whyadhesives work so well by going back tobasics and asking a simple question: Whatis the function of a bolt?

Three important purposes of a bolt are:1. A bolt provides a means of locating

components within an assembly. 2. It creates a clamp force. 3. It allows a joint to be readily

disassembled and reused (unliketechnologies such as welding andriveting).When it comes to producing a

vibration-proof assembly, the last twopoints are the relevant factors.

Creating tensionAs already stated, threaded fastenersprovide a clamping force. After the

PLANT MANAGEMENT


the adhesive offered betterprotection against the boltworking loose than any of theother methods. That’s not all,the results show that everytested mechanical systemfailed while the adhesivecontinued to remain effective.

For example, it didn't takelong before the tension in thebolt was lost when secured bythe nylon ring nut. However,the adhesive-treated assemblyproved permanently secureand the tension in the boltwas maintained.

Addressing adhesivesIt can be readily seen, therefore,that engineering adhesives –especially, anaerobic products –provide a superior vibration-proof system than themechanical threadlockingmethods that were tested.These single part adhesives curein the absence of air when incontact with a metal. (The air isgenerally excluded from thejoint when two mating surfaces– whether threaded or not – arebrought together.)

Further, these adhesivesfill all the spaces between thethreads of a bolt and a nut –thereby sealing the assemblyat the same time.

Threadlocking adhesives areavailable in a variety ofstrengths. The criteria formaking the selection dependson whether or not thecomponents need to be regulardisassembled – say, for servicingor maintenance. Low strengthproducts allow easy

disassembly, higher strengthadhesives are used for morepermanent constructions.

However, because thelocking action does not dependheavily on the shear strength ofthe adhesive, a relatively lowstrength product can be readilyselected without compromisingits ability to withstand highlevels of vibration.

Alongside the range ofproduct strengths, anaerobicsare available in a selection ofviscosities to suit differentpurposes. Where anapplication includes finethreads, a low viscosityproduct should be considered.On the other hand, coarsethreads call for high viscosityalternatives to ensure largerthread clearances are filled.

In summaryThere is more than sufficientproof that adhesives offer anadvanced vibration-proofsystem when it comes tolocking joints.

But there is a cost-savingimplication, too. Through the useof adhesives, any fastener canbecome a locking fastener –without the need to maintain aninventory of varying sized lockingaids to suit different applications.

In fact, engineeringadhesives present really good news for engineers who need to ensure theyproduce and maintain avibration-proof system.

� www.loctite.co.uk


BEKO TECHNOLOGIES LTD.2 West CourtBuntsford Park RoadBromsgroveWorcestershire B60 3 DX

Phone +44 1527 575778Fax +44 1527 [email protected] www.bekotechnologies.com

EFFICIENCY AND RELIABILITY ARE THE

BASIS OF OUR SUCCESS.

For more than 25 years, compressed air users throughout the world have trusted BEKO’s competence in compressed air and condensate technology. Perfectly understandable.

Because as far as innovation, energy saving and dependability are concerned BEKOMAT®

has, and will continue to be, THE name in cost effective condensate discharge.

BEKOMAT® condensate drains. Our all-encompassing range covers pressures up to 63 bar and includes stainless steel, EX-area, vacuum and special versions for multi-stage compressors- the biggest range on the market!

MILLION

INSTALLED WORLDWIDE

BEKOMAT®

CONDENSATE DRAINS

1.5 MILLION WORLDWIDE

1.5


email: [email protected]

for even more see

Tel: 01664 567226www.dualpumps.co.uk

More than just pumpsBall Valves & Taps�� Polypropylene �� Nylon or PVC�� Brass or stainless steel�� Pressures up to 500 Bar�� Sizes from 1/8" to 3"

Filters & Strainers�� Polypropylene �� Nylon�� Brass�� Sizes from 1/4" to 3" �� Massive range

Pipe Fittings�� Polypropylene�� Nylon�� Brass�� Pressures up to 250 Bar �� Sizes from 1/8" to 3"

Rotary Cleaning Heads�� Water powered �� Pneumatic�� Electric driven�� Flow rates up to 120 Lpm �� Pressures up to 250 Bar

Connectors & Couplings�� Polypropylene�� Nylon�� Brass or stainless steel�� Pressure up to 250 Bar �� Sizes from 1/4" to 3"

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hose Reels�� Water or compressed air�� Manual or retractable�� Stainless or powder coated steel�� Plastic or aluminium �� Hose capacity to 120 metres


��



So, price persecution and the clouds of

recession, is there a way to fight back?

There is really only one defence; make

more and more effort to drive out waste

and all forms of wasted effort

If we measure OEE and make the lossesvisible, we’re well on the way to financialimprovements.

If we can work hard on improving whatwe have, we can significantly reduce theneed for new capital equipment. In order toachieve output, companies often have toinvest in new additional capacity becauseexisting plant is operated poorly. If weoperate three lines at 33% OEE and thenadd a fourth, also operating at 33%, thegain is far less than just improving the threelines. It is well proven that improvementsto existing plant are 10 times moreeffective than the installation of newcapacity. One company I spoke to recently

had invested only £60k on simple processimprovements and taken over £1m ofcosts out of the system within 12 months- and those savings reoccur every year.

So, where do we start?Before we can improve we need twomeasures, effective performance and itsfinancial impact.

OEE or Overall Equipment Effectivenessis a simple concept, which measures justthree elements:� Actual plant availability against

planned availability� Actual performance against design

performance� Actual good, saleable products against

total products By multiplying these elements together

we compound the effect of failure andhighlight opportunities for improvement.

So where is the clear financial benefitfrom OEE?Most businesses face stiff competition,new sales are difficult, and companiesusually need to achieve the same outputin less time. Let’s create a fictitious plantthat fails one third of the time due toequipment breakdowns, no staff and/orno materials resulting in an availabilityscore of 67%. When actually running, theperformance score is slightly worse at 65%due to poor changeovers, minor stops andslow running. Fortunately our quality scoreis good at 98%. The figures don’t look too

With raw material prices rising, try to useevery bit in the finished product.

With energy costs rising and overtimebeing paid, try to increase performance andfinish earlier, reducing expenditure on both.With materials and energy costs up by largepercentages, it’s prudent not to reduce stafflevels too quickly. There could well befinancial advantages in keeping peopleinvolved in the continuous improvementprocess, to ensure materials and energy areused effectively. If wasted materials amountto £3m a year, keeping a young, keenperson in the CI team, on £30k a year willbe pretty good value if they can helpreduce waste by £500k a year.

OEE


OEE –The antidote to recession?

DURA TREAD

Tel: +44 (0) 1255 423601 Fax: +44 (0) 1255 435426 [email protected]

FIBREGLASS GRATING LTDHigh Performance Composite Construction

Applications:- Stairs- Industrial Flooring- Walkways- Platforms- Assembly Lines- Wash Bays- Work Stations

Benefits:- Light weight- High strength- Easy installation- Anti-Slip Surface- Corrosion/Fire resistant- Impact resistant- Zero maintenance

Prevents trips, slips and fallsin the workplace

BS EN 124 APPROVED

Anti-slip Fibreglass Floor Grating

Range includes:- Standard Grating- Covered Grating- Pultruded Grating- Structural Stair Treads- Tread Covers- Solid Fibreglass Plate

For more information quote EMS Enquiry No. 118 on IBCFor more information quote EMS Enquiry No. 117 on IBC


www.maintain-europe.com

Hotline (+49 89) 9 49–5 53 68

International Trade Fair for Industrial Maintenance

14–16 October 2008 • M,O,C, Munich

Order your ticket online now and save up to 50%!

Maintenance – Your key to success. MAINTAIN is the leading

marketplace for momentum, strategies and service con-

cepts in the industrial maintenance sector. As the industry’s

most important gathering, it brings together decision-

makers in the manufacturing and processing industries

who use the international trade fair as a communications

platform. And they have a common goal: to promote

innovations and service solutions in close dialog.

MAINTAIN – The trade fair for industrial maintenance.

Pattern Ltd., Richmond, Surrey TW9 2LL

Phone (020) 8940 4625, Fax (020) 8948 1442, [email protected]


T: 01767 691812 • F: 01767 691802

• www.easi-dec.co.uk

per month buys you thisEasi-Dec Roofline System

- interest paid!Now you can turn your hire costs into profit!By using wasted money to buy your first Roofline System.The benefits are outstanding.

• Huge time savings on site

• Leaves your customer’s

garden untouched

• Very professional image

• Over conservatory access

• Dormer access

• Corner access

• Full training included

• Delivery included

and more!

…call us for a demo

£195 +VAT

Field Sales vacancy for North West area



bad, but the compound effect of OEEcalculates to 43%. So, for more than 50%of our time, we’re wasting labour, energyand materials.

Let’s assume we have orders for75,000 units per week at £5 each and thedesign speed of our plant is 1,000 unitsper hour, energy costs are £400 per hour,labour £100 per hour and materials £1per unit. We have to operate 3 shifts over6 days to achieve the output, because ofour poor performance.

What if we use OEE as the key driver,analyse the losses, action smallimprovements and increase the OEE by asingle percentage point to 44%?

We save £750 in materials, require 3hours less production, save £292 in labourovertime and reduce energy costs by£1,168. With small changes, we havereduced our costs by £2,210 per week,amounting to£114,909 per year, simply bybringing about a 1% improvement in OEE.

That’s a saving of £114,909 per yearthrough a 1% improvement in OEEFurther progress to the mid 50’s wouldallow us to fulfil the orders in 5 days andwhen we reach the mid 60’s we couldsafely reduce operations to a 2 shift pattern.

OEE 43% 44% Plus 1%

Actual units 76,500 75,750 Less waste

Hours to produce 118 115 3 hours saved

Rejects 1,500 750 Quality improvement

Energy costs £47,077 £45,909 £1,168 saved less running hours

Labour costs £11,769 £11,477 £292 saved less running hours

Materials cost £76,500 £75,750 £750 saved less waste

Saved per week £2,210

Saved per year £114,909

The illustration highlights theimportant link between OEE and energy.Notable energy reduction techniquesinclude price negotiations, componentchange, load shedding and timedependent tariffs. But the greatestbenefits can be achieved through OEEimprovements and better productscheduling.

With customers gaining and holding20% improvements, it is easy to see whyOEE, as a key driver for change, hasgenerated so much interest recently. Onecompany in the pharmaceutical industrystarted with only 27% OEE on the dayshift and 11% on nights. After using OEE

as the key driver for improvements, theyreduced to a single shift operation within6 months.Do we need additional hardware togain these improvements?It depends on an accurate assessment ofthe current OEE. If the value is low, saybelow 50% - 65%, significant gains canbe made by manual data entry. If thecurrent value is higher it is likely thatmost losses are minor stops which aredifficult to capture manually. At this pointa simple touch screen system, linked to

machine running signals and productcounts will prove the best solution.

The touch screen approach captures dataaccurately, with no paperwork, and providesfeedback of critical information to theoperator such as current performance, timeto finish this product at the current rate, andworst losses this shift. More critically it keepsthe operator fully involved in the process.

Three key principles can make thedifference - visibility, accountability andaction.And there are 10 basic rules:� Set big targets: at least a 10% - 20%

OEE increase in 3 months�� Make losses highly visible as they occur� Calculate and show the cost of

those losses�� Make OEE & losses key drivers in daily

review meetings�� Monitor OEE by shift, which are the

best and worst?�� Monitor OEE by product, why is

product x so hard to make?�� Who will deliver improvements for

each loss?�� What can we do to achieve those

improvements?�� When can we deliver those

improvements? �� Constantly monitor progress

So there is an antidote, and we shouldall take a big dose:Accurately measure your OEE, discoveryour loss structure, convert those losses tocash, cost justify improvements and monitorthem to resolution.

� www.idhammarsystems.com� Reader Reply Number: 308

ABOUT THE AUTHOR

Alan France is Operations Director of Idhammar Systems Limited.

Contact him by e-mail:[email protected], or visitwww.idhammarsystems.com for more on OEE software.

OEE


@

Together, we can ensure that fluid contamination doesn’t compromise your maintenance programme.

Parker’s IcountPD represents the most up-to-date

technology in solid particle detection; delivering countless

advantages to maintenance engineers worldwide.

The design dynamics, attention to detail, and small size

of the permanently mounted, on-line particle detector

combine to deliver a truly innovative product. The laser

based, leading-edge technology means the IcountPD

is a cost-effective market solution to fluid management

and contamination control.

Identifying particulate contamination is key to predictive maintenance.

ADVERTISEMENT FEATURE

To learn more about IcountPD and other Parker fluid contamination monitoring products email [email protected].

Particle contamination in hydraulic oils and lubricants

can have a significant impact on system efficiency,

safety and operating costs. This is especially true

in modern high performance systems, where tolerances

are becoming ever tighter, and where equipment is used

in critical industrial, mobile and process applications.

Recognising this fact, Parker Hannifin has developed

innovative contamination monitoring technology that

measures both the size and concentration of particles

in oils and lubricants. The latest IcountPD particle

detector is based on the company’s 20 years experience

of particle analysis, and of working with customers

in building predictive maintenance programmes.

IcountPD is designed as a simple to fit and operate

instrument, that provides plant and maintenance

engineers with an extremely accurate, reliable and cost

effective method of particle detection.

IcountPD can be permanently fitted on-line to any

hydraulics or lubrication system and features proven

laser detection technology for precise and repeatable

particle detection. The instrument provides a continuous

indication of the quality of oils or lubricants, with an easy

to read digital status display, backed by appropriate

alarms, to confirm that operating conditions are within

safe parameters or are changing due to fluctuations

in contamination levels.

With the ability to be used at flow rates from 6 to 380

l/min and at line pressures from 2 to 420bar, a choice

of output signals, including 4-20mA, 0-5V, CANBUS,

J1939 and RS232, plus an optional moisture sensor,

IcountPD is ideal for a wide range of industrial,

process and mobile applications.


CMMS

Monster’ without bringing theperformance results hoped for.So how does one decide howmuch effort to put into a RCMproject, in order to achieve theset goals?

New trends (or hypes?),derived from World ClassManufacturing or LeanManufacturing, surprisinglydon’t give the full answereither. Of course it soundschallenging to aim for theWorld Class Maintenance(WCM, or World ClassReliability, WCR) level, but thislevel has not yet been definedproperly anywhere. In themajority of cases, qualitativestatements are used like: aWCM organisation deliversconsistent uptime week toweek, minimises impact onproduction, delivers it work asplanned, has ‘spot on’budgeting, etc... Although it isvery positive that this willstimulate a much moreprofessional attitude towardsthe maintenance process, westill don’t know how far we arefrom this level and when it willever be reached. What is thebusiness (economic) impact ofa consistent, but 3% too lowequipment uptime? How muchcheaper would ourmaintenance be if we accept a90% weekly schedulecompliance instead of aiming

for 100%? Even a highlyrewarded quantitative methodlike Six Sigma hasn’t broughtbreakthrough results in theMaintenance arena, mainlybecause maintenance data istoo poor to apply these kind ofstatistical techniques. Whatabout Lean Maintenance,which has been getting a lot ofpublicity lately due to somegood results of LeanManufacturing? Well, it mustbe all about eliminating waste,so distinguishing betweenvalue adding and non-valueadding maintenance activities.But in contradiction to thedetailed description in LeanManufacturing of how toeliminate non-value addingproduction activities, in LeanMaintenance there is nodefinition yet which activitiesto eliminate and which not.


If you are unclear of yourdestination, don’t be surprisedif you fail to reach it!

Most people will state thatthey have to achieve maximumequipment availability atminimum cost. However thisstrategy isn’t very S.M.A.R.T(Specific, Measurable,Achievable, Realistic/Relevant,Time framed). Plants within agroup of companies often gettop down targets based on theperformance of the best plant.However, if there are bigdifferences in the product mixor technology, it isn’t alwayswise to go after the assumed‘best in class pace setter’.

Some of the well knownmaintenance methodologiesalso fail to provide the rightguidance. Total ProductiveMaintenance (TPM) proved tobe successful in the automotiveeconomy of the 60’s and 70’s,when every car built could besold immediately. Butnowadays there is significantovercapacity in the marketplace. Zero defects is notalways the best goal to aim foranymore. Reliability-CenteredMaintenance (RCM) showedthe world how to engineer agood preventive maintenanceprogram covering all possiblerisks. But if not applied in apractical way, it can easilybecome a ‘Resource Consuming

FINALLY,grip on your maintenance performance

After implementing an EAM or CMMS1 system, many companies are disappointed to discover that the system provides hardly any useful management information. However, if you ask the same companies what information or performance indicators they exactly need to fulfil and track their maintenance strategy, many of them cannot provide a clear answer.

But the answer indeed is inexploring the (added) valuepotential. To be honest, the wordvalue has been misused often inmaintenance literatures lately.That shouldn’t be the case,because the value (potential) ofmaintenance has been clearlydescribed in Value DrivenMaintenance® (VDM), see figure 1.VDM is the first, and so far only,methodology that shows amaintenance organization how toreveal its value potential, set clearand realistic improvement targets,give focus and embed continuousvalue creation (or continuousimprovement) in the organization.It focuses on dynamic measuringof value creation opportunities,selection of the most appropriatesteps/techniques to go after the potential instead ofadvocating one best technique for all situations.

Figure 1: VDM Value Drivers and Value Calculation


This simple web-based system is designed to monitor and control safety within your company by centralising core risk areas.

��Risk Assessment

��Permit to Work

��Contractor Management

��Skills & Training

��Accident Reporting

One system allows you analyse, educate and inform all areas, reducing your exposure to risk and ensuring business continuity.

PMI SOFTWARE, HAINAULT HOUSE, THE SQUARE, TALLAGHT, DUBLIN 24. PH + 353 1 4040 000. FAX +353 1 4599 794. WWW.PMISOFTWARE.COM

THE MISSING PIECE IN RISK ASSESSMENT SOFTWARE

KEY BENEFITS

� Compliance with Health & Safety, Financial or Legal Obligations is achievable.

� Risks are identified and managed.

� High risk activities and equipment are recognised.

� Remedial action is assigned, monitored and controlled.

� Skills and training requirements are linked to the business need.

� Contractors are managed in a systematic way.

� Incidents can be managed systematically.

� Information gathered in one department is available to all.

FOR MORE INFORMATION CLICK ON

www.pemac.co.uk


CMMS


Being able to show theactual added value ofmaintenance in a businessperspective has helped to putthe topic of Maintenance onthe agenda of the Board. ButVDM is more than just a set offinancial (Net Present Value)formulas or a new language to‘impress’ the Board. It givesthe modern MaintenanceManager a practical ‘Planning& Control’ framework (Plan –Do – Check – Act), the ability toprioritise betweenbreakthrough measures andnice to have initiatives and anintuitive selection of relevantbest (or just better) practices.Based on what has beenachieved before in the sameindustry, based on validatedbenchmark information. SoVDM makes your maintenancestrategy definitely SMART.

The basics of the VDM valuecalculations have been describedin-depth in the book ‘VDM, newfaith in maintenance’. In short,VDM shows that there are 4relevant value drivers inmaintenance, the value potentialof each driver will bedetermined by the marketdynamics and the performancegap (current performancecompared to industry peers). Forthis, the VDM benchmarkingservice has been available formain industries since 2004 andthe use of maintenancebenchmarking information willonly be accelerated by currentEFNMS Benchmarking initiatives.Once you know where thebiggest value potential is,attention shifts to how to realizeit in an effective and efficientway.

Probably the mostimportant model in VDM, theVDM Competence Model (seefigure 2), provides a coherentcontrol framework formaintenance decision making.This model has been translated(without modifications) tomany languages and industriesalready, but in all cases provedto be an excellent means tocommunicate the current stateof affairs, the biggestbottlenecks and challenges, thedesired future state and thelogical highlights of theimprovement agenda to getthere. Especially because theVDM Competence Modelcombines the qualitative waysof working and thequantitative metrics in oneframework. This alone makes ita more powerful steeringmodel than for example theBalance Scorecard. With theentrance to reliablemaintenance benchmark dataand priority setting based oneconomic cash flows, VDM alsosupports meaningful multi-yeartarget setting.

Therefore, the planning &control framework to finally getgrip on your maintenanceperformance is here. So are thetools! Leading EAM/CMMSsoftware suppliers like ‘IBMMRO Software’ (Maximo), ‘Infor’ (Datastream7i) and ‘SAP’ (SAPEAM) have already adopted theVDM framework into theirmanagement reportingmodules. Users of these VDMreporting modules are able tosee at a glance which indicatorsare in control and which onesare not and start an analysisfrom there to drill down to the

actual (set of) EAM/CMMS workorder(s) that caused thedeviation. That’s trueManagement by Exception.

But the real benefit of aVDM implementation is not justa state of the art IT solution. Itprovides guidance for themaintenance organisation onwhy they need to improve,where they need to improveand how to improve. Notideological, but in a way thatcreates tangible cash flows forthe company. Not based on aten year journey, but withrealistic milestones year afteryear, achieving a truecontinuous improvementmindset. And above all: focus,focus, focus. There are noshortages of good ideas outthere, but very few of thecompanies understand thevalue of having a structuredimplementation.

VDM will provide you thenecessary insight to work on theright improvement measures inthe right sequence, at the rightpace. Should, for example, theVDM Audit reveal that themaintenance organisation cancreate the most value byfocusing on the value driver CostControl, this overall focus shouldbe translated into specific targetsfor the pilot projects. Say, 10%cost reduction withoutjeopardizing current performanceon Asset Utilisation and SHEQCompliance. A dedicated teamcould undertake a focused APMCanalysis on the top-3 cost killing

equipments within a few weekslead time, proving the potentialbeing actually there. One couldrefer to this technique as ‘valuedriven RCM’. Instead of focusingon all possible risks and allpossible failure modes, youdefine which failure mode effects(in terms of impact on VDMvalue drivers and thus cashflows) you want to ‘attack’ withwhich level of detail. The APMCtool then will present only thenon-acceptable failure modes towork on. With the simulationfeature of the APMC tool theteam can monitor whether thenew preventive maintenanceplan will deliver the targeted10% cost reduction. Usually, theteam establishes that 80% of thepotential benefits can be realizedin 20% of the time needed froma classical RCM approach.

With the analysis done, it is relatively easy to thentransfer the new plan into anAsset Based Budget. This isalso the ideal starting point toreview stock policy for thespare parts of this (pilot)equipment, because now thereal criticality of the equipmentcomponent function, that youwould need the spare part for,is documented.

And if the company shouldnot focus on Cost Control butAsset Utilisation instead, thegoals may be different but thetoolset and techniques are thesame. With proper training andcoaching it is possible, even ina busy and hectic maintenance

Figure 2: VDM Competence Model and VDM KPIs

Figure 3: VDM Control Panel and drill down analysis

High Performance Adhesive Technology

StructuralAdhesives

Cyanoacrylates(instant adhesives)

UV Curing Adhesivesfor bonding acrylic,

glass and metals

ElectricallyConductive Adhesives

ThermallyConductive Adhesives

ConformalCoatings

Glob Tops ThreadlockerUltra High

Temperature Ceramic Adhesives

Bonham Drive, Eurolink Industrial Estate, Sittingbourne, Kent ME10 3RY

UK Distributors of Reinhardt-Technik Metering Mixing Dispensing Systems

www.eurobond-adhesives.co.uksales@ eurobond-adhesives.co.ukT 01795 427888 F 01795 479685


CMMS


environments, to roll out thepilot approach and results toother critical equipments in theplant, making continuousimprovement not only anideology but also a provencapability of the organisation.More and more companies arestarting to discover that thisimprovement function, oftenreferred to as ReliabilityEngineering, is the trueaccelerator of any maintenanceperformance improvement.

The revised, or optimisedpreventive maintenance plan,must be implemented in theEAM/CMMS system. Westrongly encourage tooldevelopments like SAP-RCMO,making it possible to do anddocument the FMECA/RCM-analysis ‘almost’ inside the SAPEAM system, establishing atransparent link between failuremodes and actual PM tasks inthe system. Using the same

Failure Mode codes (as derivedfrom the FMEA analysis) inEAM/CMMS breakdownreporting gives vital feedbackon the MTBF estimates used inthe FMEA analysis. This actuallyis a big step in transferringknowledge from the heads ofour people (only) into avalidated knowledgebase.

Implementing a VDM basedmaintenance strategy oftenmeans closing the improvementloops (Plan, Do, Check, Act). TheVDM Control Panel monitors theactual progress of yourimprovement activities andidentifies new opportunities. Themost problematic equipment, ifproperly ‘attacked’, willeventually fall from the top-Nlist but, as always in real-life,new problem equipments willshow up. One of the powerfulanalysis features of the VDMControl Panel is to correlatebunches of relevant data into a

logical action strategy. Forexample, figure 6 shows acorrelation between number offailures and number ofinspections per (mainequipment). It shows at aglance the effectiveness of thecurrent inspection policy. Forexample, the matrix quadrant‘frequent inspection, hardly anyrepair from inspection ofbreakdown’ indicates it is worthto analyze to lower theinspection frequency oreliminate the inspection task infull. The quadrant ‘frequentbreakdowns, no inspections’obviously indicates a newequipment failure mode thathasn’t been tackled in the PMplan before. The VDM ControlPanel is an excellent startingpoint for any focused problemsolving and decision making(techniques like root causeanalysis, 5 Why’s, etc).

So, how much value can amaintenance improvementinitiative actually generate? Hereare some typical examples: -� DSM realised a sustainable

30% cost reduction byimplementing gatekeeping,no change mentality, assetbased budgeting,standardized work processes

� DAF Trucks realized anuptime improvement of27%, meaning 14.000 extraproduced trucks yearly, bysystematically reducing thelead-time of the weeklyscheduled cleaning stop

� IFF Tilburg managed todeliver the productionvolumes of originally 3plants into only 2, byimproved line availabilityof the remaining two

� Smurfit Kappa PackagingNieuweschans improvedequipment output with a 8 OEE percentage points,resulting in lowerstoppages and defects,reducing maintenance costsby 25%. The cash flowresult of more output atlower costs equals to a15% improvement of thecompanies EBITDA.

� Cement Australia appliedan MRO segmentationstrategy to optimise thestock levels throughouttheir production plants andreduced the inventoryvalue by 40%.

ConclusionsValue Driven Maintenanceis a start to finish approach.It is a platform to collect,describe and exchangeinternal and external bestpractices. It delivers a fullmaintenance planning &control framework supportedby modern tools like theEAM/CMMS VDM ControlPanel. Welcome to the nextgeneration in maintenancemanagement...

� www.mainnovation.com


Figure 4: VDM Effect Categories in FMEA analysis

Figure 5: Cost Control Improvement Loop Figure 6: VDM CP Detailed Graph & action categories

DUST CONTROL


Fibreglass has many unique qualities and isused in an increasing number of industriessuch as automotive, marine, aviation andwind turbine. The increased use offibreglass has resulted in problems forpersonnel as well as production itself.

Significant health risksFibreglass dust makes you itch just bylooking at it – but the problem is muchgreater than that. Fibreglass dust has a lowweight and stays airborne for a long time.It penetrates into the trachea and lungsand stays there causing allergies, asthmaand even cancer. OSHA and the EuropeanUnion mandate have imposed limits onhow much airborne dust is permittedwithin the operators breathing zone. TheWorld Health Organization has classifiedceramic fibres and other special fibres aspossible contributors to cancer.

Faults in electronics increase costsIn addition to the negative consequences ofhealth, the fibreglass dust causes faults incomputers and other productionequipment. Visibility for the operators isdecreased in many working situations andin most companies the cost for cleaninghas increased.

Fortunately there are efficient solutionsto the problemWith 35 years of experience, Dustcontroloffers a unique know-how about on-toolextraction that draws away, filters andremoves the dangerous particles. With on-tool extraction, the dust iscollected where it is created. The resultis a cleaner working environment and inmany cases, increased product quality because of less contaminationduring production.

The right extraction system contributesto health and economy� Improved health through less fibreglass

dust and other particles in the air.� Safer work and increased productivity

since there is no dust decreasing theoperator’s visibility.

� Increased productivity due to fewerdisturbances in surrounding areas.

� Eliminates need for dedicated grindingroom.

� Longer life time for tools and electronicequipment.

� Reduced time and costs for cleaning.� Less faults due to dust in computers

and electronics.� Extraction system can also be incorporated

into FOD prevention scheme.Strict environmental requirements

combined with advanced technicalsolutions encouraged the manufacturer ofAirbus to choose solutions from Dustcontrolfor their German installation inMühlenberger Loch, outside Hamburg. Thesuction systems are designed forcontinuous operation. The deliveriescovered complete installation of pneumatic,mechanical and control systems. Specialemphasis was put upon EX protectedinstallations. Three of the four installationshave been purpose-built for dust explosionrisks, complying with a k value of 180 barm/sec. In addition to offering a dustlessenvironment for such tasks as drilling,milling and grinding, the suction systemsare used for general vacuum cleaning tasksand extraction of residue materials duringriveting and gluing works. Also sealantmaterials and chrome residual products areinvolved. The materials which arecommonly extracted are aluminium, GLARE(GLAss-REinforced” Fibre Metal Laminate),carbon fibre, fibreglass, epoxy, polyester,aluminium alloys and titanium.

� www.dustcontrol.co.uk


Dustcontrol UK Ltd discuss the problems associated with dust pollution in modern

fibreglass production facilities and how an integrated high vac system can provide

the competitive advantage you may be wondering how to achieve

DUST, PRODUCT QUALITY,health & workplace efficiency

On tool extraction from sanders during aircraftpreparation. Note the operative working onanother job unhindered in the same area

ATEX

most information on these new rules Companies need to use suppliers and

repairers that correctly certify machines ifthey are to avoid liability shouldsomething go wrong.

Commenting, Dave Hawley, GeneralManager of the Deritend Wolverhamptonmotor repair and rewind workshops: 'thereare many companies that are now subjectto ATEX regulations for the first time, dueto the inclusion of dust laden atmospheres.

They may be aware that explosions

and fires caused by dust can be equally asdevastating as those caused by explosivegases and vapours, but not whatconstitutes a risk and how to address it.

Compliance as far as dust and electricmotors are concerned is actually relativelysimple and the motor parameters requiredare not extreme, but there is a genuineneed to know within industry'.

� www.deritend.co.uk



Deritend is one of the few UK companies qualified to repair, certify, install and

commission electric motors for use in ATEX zoned environments

Repairing motors for use in ATEX DUST ZONESWhile traditional industries such aspetrochemical processing facilities are usedto working in conformity with the ATEXRegulations, Deritend is warning that manyfirms are now likely to be using motorswithout the correct certification in thenewly defined ATEX zone 20 to 22hazardous dust conditions Industries such aspaper, processing, food preparation, textiles,woodworking and companies supplyingmachines into these sectors, are likely to beincluded for the first time and require the

Dust and fume extraction hoses from Masterflex

� Temperature range -260°C to +1100°C

� Size range 38 mm to 900 mm

� Very flexible, small bend radius

� Long service life, low operating costs

� Suitable installation and connecting systems

Masterflex Technical Hoses Ltd

GB-Oldham OL1 4ER

Tel: 0161 626 8066

www.masterflex-uk.com

TUBE PROTECTIONPU / FABRIC HOSES CONNECTIONS


VISITwww.engineeringmaintenance.info

for the latest � Jobs� News� Interviews� Online Seminars� Events� Training� Products� White Papers� Case Studies� Forum


COMPRESSORS/COMPRESSED AIR


As a result of increased demand in thesteel market, the production capacity forstructural steel had expanded in theworks. This also involved an increaseddemand for high quality processedcompressed air. Measuring devices areused in the production process whichneeds such compressed air. Besides therequired compressed-air quality, greatimportance was attached to an absolutelyreliable plant control and datatransmission, as the system operatescontinuously and without supervision.

The dryer is controlled by a PLC(programmable logic controller). Allprocess data is indicated at the controlcabinet and transmitted to the primarycontrol unit via "Ethernet". The electricalcontrol was designed in close cooperationwith the plant operator, in accordance withthe in-house standard of the facility.

There were no issues at all after one year, on the occasion of thepreventive maintenance. All thecustomer’s requirements were met orexceeded, and the required compressed-air quality supplied.

"The hopes we placed on EverAir, acompany of the Beko group were entirelyfulfilled", commented the customer. "Weactivated the plant and, afterwards, wecould forget about it, so to speak."

The dryer supplies a volume of 5,500 Nm3/h with a pressure dew point of -40°C. Compressed air which is not required for the application is fed into the general operational network for the shop air.

� www.bekotechnologies.com


During last year, a heat-regenerated adsorption dryer of the BEKO Everdry®

FRP 5500 C type was installed in a large steel mill in Lower Saxony, Germany,

for the application-based processing of compressed air

BEKO prove their steel

For details of the positions below email us at [email protected] orto view more superb vacancies please visit www.mslrecruitment.com


DRAFTSMAN/DESIGNER (M/F) The Draftsman/Designer is responsible for designing and drawing of machinery and parts ofmachinery. The Draftsman/Designer is the contact person for the departments Production andProject Management for the drawings which he/she produced. Duties: • Calculate and designing of machinery

• Drawing of parts of machinery in detail • Entering of material bills in the ERP-system • Maintenance of contacts with for instance the departments Production and

Project Management • Follow up for instance the following duties as Product Specialist:

- keeping the logbooks up-to-date - checking up the drawings - keeping the standard machinery up-to-date

Job requirements: • Technical College-level mechanical engineering, or equal experience • Experience as a Designer of machinery • Experience with the food sector is an advantage • Managerial capacities • Pro-active attitude to work • Great moderation of self-reliance• Knowledge of CAD systems, with preference Inventor

CONSTRUCTIONAL FITTER-WELDER (M/F) The constructional fitter-welder is partly responsible for constructing stainless steel machineryfor the food industry in a team as well as independently. The constructional fitter-welder isalso partly responsible for the correct procedure of constructing these machines, taking intoaccount the current quality and safety standards. Job requirements: • Professional training level of mechanical or metal engineering.

• Experience in processing stainless steel would be an advantage.• Experience in constructing machines for the food processing industry.• Having mastered the TIG- and pulse-MIG/MAG-welding process

(level 2 minimum)• Being able to work independently as well as in a team• Critical yet positive craftsman• Willing to work and being able to work under pressure

PLANNER/OUTSOURCING MANAGER (M/F) The Planner/Outsourcing Manager is responsible for the planning of the Drawing Office andthe Production. He/she is co-responsible for outsourcing-projects which are being made bythe department Bedrijfbureau and program the laser cutting block. Duties: • Organize a planning for the Drawing Office and the Production

• Issue delivery periods for the various projects, and keep watch on these delivery periods

• Co-responsible for outsourcing-projects which are being made by the department Bedrijfsbureau

• Co-responsible for programming the laser cutting block • Closely consult with Head Logistics & Production, Head Drawing Office

and Head Production Job requirements: • Education and/or experience on Higher Vocational Education level

• Great moderation of self-reliance• Pro-active attitude to work

DRAFTSMAN (M/F) The Draftsman is responsible for drawing of machinery and parts of machinery and the contact person for the departments Production and Project Management for thedrawings which he/she produced. Duties: • Drawing of machinery

• Drawing of parts of machinery in detail • Entering of material bills in the ERP-system • Maintenance of contacts with for instance the departments Production

and Project Management Job requirements: • Intermediate Technical School/Technical College-level mechanical

engineering, or equal experience • Experience as a Draftsman of machinery is an preference • Experience with the food sector is an advantage • Knowledge of CAD systems, with preference Inventor

www.kiremko.com

MECHANIC (OR A STUDENT MECHANIC) (M/F)The mechanic will assist with installing, maintenance and modification duties on machineryand systems of Kiremko B.V.’s customers. These duties will be carried out on site in theNetherlands as well as abroad. A job with options for future development. Duties: • Installing machinery and systems on site

• Modification and revision of machinery and systems• Maintenance of machinery

Job requirements: • Experience in several welding techniques like Mig-, Tig-, backinggas- and electrode-welding and experience in processing stainless steel would be an advantage.

• Being prepared to work irregular hours and at weekends. Also being prepared to work away from home for longer periods.

• Performing at the professional training level of mechanical engineering.• Some working experience would be an advantage

SALES ENGINEER (M/F) The Sales Engineer works closely together with, and assist the Area Sales Managers, Agents,Account Managers en Project Managers. De Sales Engineer takes care of offers and budgetproposals and will follow them up if necessarily. The Sales Engineer will also take care of theadministrative handling of order confirmations. Duties: • Being a good assistant of the Area Sales Managers, Agents, Account

Managers en Project Managers • Take care of commercial descriptions for products/product groups • Self-employed preparing of offers en budget proposals in case of

standard machinery • Prepare offers and budget proposals together with Product

Managers in case of specials Job requirements: • Education and/or experience on Higher Vocational Education level,

respectively the working field • Commercial and communication skills • Organizing skills • Dynamic en consisting working attitude • Good control of Microsoft Office • Good command of the languages Dutch, English and German,

verbal and in writing

APPLICATION MANAGER (M/F) The Application Manager is responsible for the optimal functioning of the ERP-software. For this purpose, he/she consults with the key-users of Kiremko and the supplier of the ERP-software. Duties: • Maintenance, testing and organizing of the ERP-software

• Consult with the key-users of Kiremko and the supplier of the ERP-software

• Manage the several Crystal-repports • Act as stand-in co-worker Planning Engineer

Job requirements: • Higher Vocational Education working-/meditate level • Great moderation of self-reliance• Pro-active attitude to work

TO ADVERTISE YOUR LISTING IN OUR BUYER’S GUIDE PLEASE PHONE 0207 9933355ANNUAL BUYER’S GUIDE

Company Website Email Contact Telephone Number ACCESS EQUIPMENT

Planet Platforms www.planetplatforms.co.uk [email protected] 0800 0854161ASSET MANAGEMENT

Rockwell Automation www.rockwellautomation.co.uk [email protected] 0870 2425004

BOILERSByworth Boilers www.byworth.co.uk [email protected] 01535 665225Certuss Steam Generators www.certuss.co.uk [email protected] 0121 3275362Wellman Robey www.wellman-thermal.com [email protected] 0121 543 0000

BOILER HIREWellman Robey www.wellman-thermal.com [email protected] 0121 543 0000

BOLT SECURING SYSTEMSNordlock Ltd www.nord-lock.co.uk [email protected] +44 (0)1980 847129

CMMSCayman Venture www.cayman.co.uk [email protected] 0191 2963816Productivity Europe www.productivityeurope.org [email protected] 01234 215867Idhammar Systems Ltd www.idhammarsystems.com [email protected] 0117 9309300Shire Systems www.shiresystems.co.uk [email protected] 44(0) 23 80224111Softsols Group Ltd www.getagility.com [email protected] 44(0)1924 200344

COMPRESSED AIRAirchannel Ltd www.airchannel.co.uk [email protected] 0800 526581Atlas Copco Compressors www.atlascopco.co.uk [email protected] 0800 181085Gardner Denver www.gardnerdenver.com [email protected] 01452 338116

COMPRESSED HIRESpeedy Compressors www.speedyhire.co.uk/compressors [email protected] 0845 307 0777

CONDITION MONITORINGAlpine Components www.alpine-components.co.uk mike@alpine-components .co.uk 01424 437000Artesis www.artesis.com [email protected] 0845 634 3854Elcomponent Ltd www.elcomponent.co.uk [email protected] 01279 503173Holroyd Instruments www.holroyd-instruments.com [email protected] 01629 822060Proviso Systems www.proviso-systems.co.uk [email protected] 01777 817536Monitran www.monitran.co.uk [email protected] 01494 816569Schaeffler www.schaeffler.co.uk [email protected] 0121 351 3833SPM Instrument UK ltd www.spminstrument.co.uk [email protected] 01706 835331

CONDITION MONITORING EQUIPMENT/SERVICESRockwell Automation www.rockwellautomation.co.uk [email protected] 0870 2425004

DATA ACQUISITIONMetrum www.metrum.co.uk [email protected] 0118 973 3000

HEALTH & SAFETYIntegrity&Compliance Management www.icm-uk.com [email protected] 01779 474748

HEALTH & SAFETY PRODUCTSRockwell Automation www.rockwellautomation.co.uk [email protected] 0870 2425004

INDUSTRIAL COOLINGTPC(Total Process CoolingLtd) www.totalprocesscooling.co.uk [email protected] 44(0)121 711 4014

INDUSTRIAL DOOR SERVICESBID Group www.bidgroup.co.uk [email protected] 0870 607 5050

INDUSTRIAL FLOORINGCG Flooring Systems Ltd www.cg-flooring.com [email protected] 01484 600085

LUBRICATIONATS Electro-lube (UK) ltd www.ats-electro-lube.co.uk [email protected] 0191 491 4212

PLANNED MAINTENANCET Cards Direct www.tcardsdirect.com [email protected] 01732 871417

THERMOGRAPHYExpress Instrument Hire www.expresshire.net [email protected] 01772 815600Flir www.flir.com [email protected] 01732 221245Fluke www.fluke.co.uk [email protected] 020 7942 0700Hawk-IR www.hawk-ir.com [email protected] 01642 497000Testo Ltd www.testo.co.uk/testo880 – 01420 544 433

THERMOGRAPHY TRAININGThe Institute of Infrared Thermography www.infraredinstitute.co.uk [email protected] 44 (0)151 424 4060

TRAININGNational Fluid Power Centre www.nfpc.co.uk [email protected] 01909 504700

VIBRATION ANALYSISHansford Sensors www.hansfordsensors.com [email protected] 0845 6801957

FOR FURTHER COMPANY INFORMATION PLEASE VISIT www.engineeringmaintenance.info


EENNQQUUIIRRYY??F R E E P R O D U C T I N F O R M A T I O N S E R V I C ECCOOMMPPLLEETTEE AANNDD FFAAXX TTHHIISS PPAAGGEE BBAACCKK TTOO 00220088 77111133115533

enquiry no. enquiry no. enquiry no. enquiry no. enquiry no. enquiry no.

enquiry no. enquiry no. enquiry no. enquiry no. enquiry no. enquiry no.

Please fill in your details if you (a) wish

to continue to receive a free copy of EMS

or, (b) wish to be included in the

magazine’s circulation list for the first

time. (Please use capitals and please

sign and date as indicated). Fax Back on:

00220088 77111133115533Please send me FREE information on:

(Delete as appropriate)(Mr, Mrs, Miss, Ms) First Name Surname

Job Title

Company

Post Code

Tel Fax

E-mail

Signed Date / /

PLANT MANAGEMENT

❏ Artificial Intelligence/Expert Sys

❏ Asset Management

❏ Bearings

❏ Calibration

❏ Coding Systems

❏ Computerised Maintenance Management

❏ Condition Monitoring Consult

❏ Condition Monitoring

❏ Consultancy – unspecified

❏ Contract Maintenance

❏ Corrosion Prevention

❏ Couplings

❏ Data Analysers/Loggers

❏ Degreasers

❏ Descaling

❏ Drives

❏ Electric Motors

❏ Electrical Maintenance

❏ Equipment Rental

❏ Filters

❏ Flexible Hose

❏ Flexible Ducting

❏ Flow Meters

❏ Food Safety Lubricants

❏ Gaskets

❏ General Engineering Services

❏ Handling Equipment

❏ Hose & Cable Reels

❏ Hydraulics/Pneumatics

❏ Internet Services to Maintenance

❏ Labelling and/or Barcoding

❏ Laser Alignment

❏ Leak Detection Equipment

❏ Lubrication/Oil Analysis

❏ Maintenance Consultancy

❏ Maintenance Materials

❏ Measurement Instrumentation

❏ NDT Equipment or Services

❏ Pipe Freezing

❏ Pumps, Valves and Process Equipment

❏ RCM Consultancy

❏ Remote Monitoring

❏ Seals

❏ Sensors or Probes

❏ Specialist Maintenance Services/Products

❏ Surface Treatment and Coating

❏ Temperature Measurement

❏ Thermographic Services/Equipment

❏ Tools & Workshop Equipment

❏ TPM Consultancy

❏ Vibration

❏ Visual Planning

❏ Welding and Joining

TRAINING

❏ Institutes and Professional Bodies

❏ Recruitment

❏ Training Aids and Services

BUILDING MAINTENANCE

❏ Access Equipment

❏ Building Maintenance Consultancy

❏ Chemicals/Paints/Finishes

❏ Cleaning Components

❏ Cleaning Machines/Equipment

❏ Computer Aided Facilities Management (CAFM)

❏ Cranes/Hoists

❏ Doors/Curtains

❏ Flooring

❏ Lifts/Escalators

❏ Lighting

❏ Property Maintenance and Management

❏ Roofing

❏ Security and Fire Prevention

❏ Storage Systems

❏ Tank Linings & Bundings

ENVIRONMENTAL

❏ Dust/Fume Extraction

❏ Environmental Health/Testing/Equipment

❏ Noise Control

❏ Pollution Control Equipment

❏ Water Treatment

HEALTH & SAFETY

❏ Communication

❏ Health & Safety Products

❏ Legislation & Compliance

❏ Machine Guards

❏ Safety Showers & Eye Baths

❏ Workwear

ENERGY MANAGEMENT

❏ Boilers

❏ Burners

❏ Climate Change Levy

❏ Combined Heat & Power

❏ Compressed Air Equipment and Ancillaries

❏ Energy

❏ Energy Control Systems

❏ Energy Metering/Monitoring Systems

❏ Generators

❏ Heating, Ventilating and Air Conditioning

❏ Industrial Controls

❏ Power Quality

❏ Steam Traps

JJUUSSTT FFAAXX TTHHIISS CCOOMMPPLLEETTEEDD FFOORRMM BBAACCKK OONN 00220088 77111133115533

THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

ISSUE 6

JULY/AUG 2008

BUYERS GUIDE

RECRUITMENT

VIBRATIONANALYSIS

w w w . e n g i n e e r i n g m a i n t e n a n c e . i n f o

INDUSTRY NEWS

PLANT MANAGEMENT

CMMS

COMPRESSED AIR

– the antidoteto recession?

MAINTENANCE

July/August 2008

RREEGGIISSTTEERR NNOOWWttoo ccoonnttiinnuuee ttoo rreecceeiivveeyyoouurr FFRREEEE ccooppyy ooff EEMMSS

�� For more information quote EMS Enquiry No. 127 on IBC

Date post:	10-Mar-2016
Category:	Documents
Upload:	michael-dominguez
View:	221 times
Download:	0 times

ems july/august 2008

Documents