Reliability Based Maintenance
Practical Applications at
DuPont Teijin Films
Hopewell Site
Dave Van Aken
Reliability Manager
Maintenance’s Role
� Preserve the physical plant assets
� Ensure they are available to perform as good
or better than required
� Using the most cost effective means
available
Maintenance Business Impact
� Maintenance is largest controllable cost
� Potential Cost Savings
� Avoiding breakdowns (lost production)
� Avoiding costs associated with failures
�Materials
� Labor
� Avoiding cost of inconsistent quality
Regressive
Reactive
Planned
Defect
Elimination
Asset
Optimization
Don’t Fix It,
Delay The Fix
Fix it After
It Breaks
Fix It Before
It Breaks
Don’t Just Fix It,
Improve It
Don’t Just Improve It,
Optimize It
Cost
Focus
Productivity
Focus
Value Focus Optimization
Focus
The Journey to World Class Manufacturing
Behavior: Careless Responding Org. Discipline Org. Learning Inventing
World Class Manufacturing Continuum
Staged
Decay
Reliability Based Maintenance
� Three Main Components:
� Preventive
� Time based maintenance
� Predictive
�Condition based maintenance (technology based)
� Proactive
� Investigative analysis to extend machine life
Preventive Maintenance
� Time-based maintenance activities
� Inspections
� Calibrations
� Lubrication
� Changing filters (oil or air)
� Cleaning
Preventive Maintenance Concerns
� PMs can be intrusive
� Introduce failure mechanisms
� Conflicting priorities may delay
PMs
� Full production schedule
� Cost control
“Pay me now, or pay me later”
Predictive Maintenance
� Technology to detect faults
� Vibration analysis
� Thermographic analysis
� Oil condition monitoring
� Ultrasonic analysis
� Electric motor current
analysis
Proactive Maintenance
� Applying advanced techniques & technologies to
extend machinery life
� Root Cause Failure Analysis (RCFA)
� Precision Alignment & Balancing
� Reliability Engineering (design/modification)
� Purchasing specifications for equipment/parts
� Reliability Centered Maintenance (RCM)
Predictive / Proactive Maintenance Barriers
� Existing Plant Culture
� “We’ve always done it this way.”
� Need a Champion/Sponsor
� Involve Stakeholders early
� Cost
� Investment in people and equipment
� In-house or Contract
Tribology - Lube Oil Analysis
� Lubrication is part of our Maintenance foundation
� Changing the oil in your cars
� Our program:
� Equipment needing lubrication is identified.
�What types of grease / oil will be used.
�Grease compatabilities
�Who will do the lubrication?
� Top grade mechanic?
� Gearbox oil condition monitoring
Tribology - Lube Oil Analysis
Wear
Contamination Chemistry
Extreme
Alarm
Alert
High Normal
Normal
Trivector
Sampling and changing the oil in our gearboxes prolongs their life and
reduces our costs.
Report Recommendations:
The particle count results are much higher than desired. Iron and
tin content are elevated indicating wear occurring in this
system. Check for sources of abrasives/dust entry. The silicon
result indicates contamination with dust/dirt/abrasives. All other
results are within expected ranges or are consistent with established
history. Continue sampling at scheduled intervals to establish
trends.
Thermography
� Diagnostic technique
�Measures the thermal difference between various
components and their environment.
� Electrical Distribution survey
� Began in 1976
� Identify “hot spots” - loose or corrosion
� 2100 pieces of electrical distribution equipment
� “No surprises” in our distribution equipment
Thermography Examples
Motor Starter - 2 phases on line side of starter
• >125 F (#2) and >150 F (#3)
• Inspect, clean, tighten/replace connections
• Repair immediately
Thermography
� Augment vibration analysis program
� Helps to fine tune predictive “call”
� Energy Savings
� Steam trap surveys
� Piping or Building insulation problems
� Process Troubleshooting
� Heat transfer in process rolls or ovens
Troubleshooting Process Problems
� Roll had suspected heat
transfer problem
� Film sample between rolls,
showing thermal artifacts
of the spiral cooling
channels in the main roll.
� Roll confirmed to have
heat transfer problems and
was acid cleaned.
IR00227.ISI
Vibration Analysis
� Premise - All operating machines vibrate.
� Increase in vibration = deterioration in machine
� Vibration analysis is used to determine the cause of
the vibration.
� Each fault generates a specific vibration pattern
� Frequency of vibration is dependent on Machine
geometry & speed
� Collect 3,000+ data points on plant equipment
Vibration Analysis
L44C - EXTRUDER MOTORMT 51100 -M2H MOTOR INBOARD HOR. 22-C1
Route Waveform22-Aug-02 07:21:18
RMS = .8270LOAD = 100.0RPM = 613. RPS = 10.22
PK(+) = 2.32PK(-) = 2.36CRESTF= 2.85
0 50 100 150 200
-3
-2
-1
0
1
2
3
Time in mSecs
Acceleration in G-s
CF ALARM
CF ALARM
PK ALARM
PK ALARM
Fault diagnosed and plans made to repair motor.
Vibration Analysis
L44C - EXTRUDER MOTORMT 51100 -M2H MOTOR INBOARD HOR. 22-C1
Route Waveform26-Sep-02 09:00:28
RMS = .1572LOAD = 100.0RPM = 1061.RPS = 17.68
PK(+) = .5138PK(-) = .8079CRESTF= 5.14
0 50 100 150 200
-2.0
-1.5
-1.0
-0.5
0
0.5
1.0
1.5
2.0
Time in mSecs
Acceleration in G-s
CF ALARM
CF ALARM
PK ALARM
PK ALARM
Normal operation - same location. This is what it’s supposed to look like!
Precision Alignment
Others (10%)
Misalignment
(50-70%)
Imbalance
(30-40%)
� Misalignment causes excessive vibration
� Leading cause of machine malfunction and
maintenance downtime.
� But often not identified as a root cause
Precision Alignment
� An alignment program results in:
� Increased bearing life (8X)
�Reduced vibration
�Reduced operating temperatures (longer lasting
lubricants)
� Increased seal life
� Reduced energy consumption (~11% reduction in
motor power requirements)
IncreasedIncreased $$$$$$
Web Transport Alignment
� Misalignment in web handling portions of
machines can cause quality faults
� Creases, wrinkles, etc.
� Alignment can be performed in house or through
a contract organization.
� At least every three (3) years on our transport
and winding equipment.
Root Cause Failure Analysis (RCFA)
� Common problem-solving tool
� “The 5 Whys”
� Defect elimination in our:
� Processes
�Machinery
� Performance
� Drive to the systemic factors
� The true root
Root Cause Failure Analysis
� Catastrophic Failures
�Management driven to know WHY
� Significant immediate impact
� Chronic Failures
� Smaller in nature but reoccurring
� Safety Incident investigations
Summary - Turning the Profit Lever
� Maintenance produces Plant Capacity
� Maintenance is a Process & can be Improved
� Our Improvement
� (1989) Total maintenance downtime = 9.3%
� Average of 815 hours per film line (8)
� Improvement to 4.4% for all film lines
� >50% improvement in availability