Don’t miss insightful case studies and mini-workshops from industry leaders…
Maintenance Planning & Scheduling
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Michael Macsisak – PdM Tech, Nestle Purina
April 25, 2:30 pm – 3:20 pm. Room: A122-123
This case-study presentation will describe how Nestle Purina was able to successfully implement predictive maintenance (PdM) at its plant in Allentown, Pennsylvania. Find out how the organization developed its PdM program and kept it moving forward, which PdM tools were the most effective, and how PdM helped the plant add to its bottom line. Attendees will learn how to track their PdM successes, how to keep PdM from going into failure mode and how to move from PdM to greater reliability.
Ted Melencheck – Maintenance Reliability Supervisor, Cargill; Cheryl Huff – Sales and Marketing Coordinator, R&G Laboratories
April 25, 11:00 am – 11:50 am. Room: A122-123
Establishing open lines of communication with suppliers is key to an effective maintenance program. Indeed, working with companies that can help troubleshoot and offer different ideas or approaches can be an invaluable asset. This presentation will show the advances that can be made by working directly with vendors and suppliers at such a close level. Examples will be given to illustrate how these partnerships can increase the chance of success for plant initiatives. Attendees will walk away with important information that can be applied in various situations for better results in any industry or organization.
J.R. Nield – Maintenance Planner, J.R. Simplot Co.
April 27, 8:00 am – 8:50 am. Room: A120-121
Can you really prevent accidents from happening in your workplace? This presentation will open your eyes to accepted shortcuts in your working environment that need to change, as well as describe how to prevent bad habits from forming, such as failing to fix issues in a timely manner. J.R. Simplot’s J.R. Nield will help you look into the future for a more proactive approach to maintenance safety issues and explain why being safe should not be an excuse for uncompleted tasks.
Michael Mazur – Maintenance Trainer/Technician, Schwan’s Global Supply Chain
April 26, 4:30 pm – 5:20 pm. Room: A120-121
When it comes to plant maintenance, too often new employees are dropped onto the shop floor to sink or swim. Orientation covers so little compared to the vast number of machines and their interactions with each other. Lacking knowledge of your plant’s operations and how everything works, these new technicians can cause miscommunication, unintentional damage and downtime. This session will break down a complex plant into systematic and functional areas for individual training. Join Michael Mazur as he describes how a viable training standard with plant-specific needs can be achieved and implemented, as well as how this training guide can be used to enhance and track a technician’s progress.
Saul Cizek – Senior Maintenance Planner, Upper Occoquan Service Authority
April 26, 2:30 pm – 3:20 pm. Room: A122-123
The Upper Occoquan Service Authority’s maintenance program needed a serious overhaul to address its lubrication, PM task effectiveness and procedural instructions. This case-study presentation will reveal how the plant’s team of maintenance planners improved equipment reliability by identifying and replacing ineffective PM tasks. Senior maintenance planner Saul Cizek will explain how the water reclamation plant was able to move toward more condition-based maintenance and employ root cause analysis. See the changes that were implemented, the processes used for improvement and the discoveries made along the way to achieve significant results.
Kevin Grayson – Assistant Director of Advanced Technology, NCSU-IES
April 26, 2:30 pm – 3:20 pm. Room: A112
In most manufacturing environments, maintenance programs are the leading problem solvers, yet their efforts frequently fail to apply fundamental tools that could lead to even greater productivity. This presentation will show how many quality tools often associated with Six Sigma can easily and effectively be employed for maintenance. Several examples and takeaways will be provided that attendees can use to boost the productivity at their facility, including how to utilize failure mode and effects analysis (FMEA) for maintenance problems.
Brad Halterman – Maintenance Manufacturing Engineer, Orbital ATK
April 26, 4:30 pm – 5:20 pm. Room: A122-123
This case-study presentation will detail how aerospace manufacturer Orbital ATK was able to create a new culture on the plant floor that is empowering and enabling greater contribution from its people for significant reliability improvements. Brad Halterman will highlight several common challenges experienced by maintenance professionals and show how greater transparency and real-time visibility can align teams in driving continuous improvement and overcoming obstacles. Find out how data can be aggregated to identify a plant’s most important problems, how historical information can be made easily accessible to technicians while on task, and how to make audit and compliance success part of everyday operations.
Kevin Grider – Predictive Analyst, General Motors; Scott Venable – Energy Conservation Engineer, DTE
April 25, 1:30 pm – 2:20 pm. Room: A120-121
In this case-study presentation, General Motors’ Kevin Grider and Scott Venable will discuss utilizing predictive technologies to identify and mitigate energy waste, especially as it relates to compressed air and steam heat. Attendees will see how the General Motors Marion Metal Center developed a process for reporting, verifying, quantifying and compiling results, as well as the communication with the utility company that has resulted in incentives. You will learn what waste is, what it costs, what you can do about it and which technologies to use to detect it.
Colby Hammock – Maintenance Manager, Independence Tube Corp.
April 27, 9:20 am – 10:10 am. Room: A120-121
Machine setups are a necessary evil when a company manufactures different products using the same equipment. When machinery is idle during a setup, it produces neither products nor profits. Decreasing the amount of time that machines are inactive during the setup period will greatly increase production and profits. This session will explain how to reduce the time involved in making tooling changes or machine setups by evaluating and improving the process. Join Colby Hammock as he details how Independence Tube Corp. was able to lessen its machine setup times by 40 percent in a 12-month period.
Luke Sanders – Senior Predictive Maintenance Technician, Muscatine Power & Water; Donald McCullough – Predictive Maintenance Technician, MPW
April 27, 8:00 am – 8:50 am. Room: A122-123
Many manufacturing professionals work in aging facilities with foundations made of concrete. Over time, this concrete breaks down and becomes brittle, creating vibration problems. Other facilities have flimsy foundations built with hollow bases and no substance to handle the rotational forces generated by equipment. This session will describe how stiffening, bracing or rebuilding the base plate with a solid foundation can greatly decrease or eliminate vibration problems. Luke Sanders and Donald McCullough will share how the Muscatine Power and Water generating station reduced vibration by 85 percent and at a very low cost. Vibration spectrums and detailed before and after pictures will be shown.
Alan Wood – Mechanical Integrity Coordinator, M3Midstream; Matt Guinn – Regional Manager, Wickes and Associates
April 26, 4:30 pm – 5:20 pm. Room: A124-125
Mechanical integrity is a crucial component for safe and reliable industrial facilities. There have been numerous incidents in which plants have had fires or explosions because they didn’t implement a sound mechanical integrity program. This presentation will describe how the best programs go beyond just the required inspections and incorporate an action system to address the findings from these inspections. Attendees will walk away with a better understanding of the basic components for a mechanical integrity program and how to integrate them into their maintenance and reliability programs.
Dale Constantine – Reliability Specialist, STEP Energy Services
April 25, 11:00 am – 11:50 am. Room: A115
In this increasingly difficult economic environment, organizations need a new type of maintenance professional who will eagerly apply best practices. Gone are the days of parts changers, mechanics and reactionary wrench turners. Today, it’s essential to have individuals who understand how to execute maintenance plans, monitor the results and affect positive outcomes. Enter the maintenance caregiver. This session will explain how to develop these company makers and breakers by changing the minds of maintenance personnel and implementing action items that work. Attendees will hear how a major oil and gas service supplier has become financially stable and successful by employing maintenance caregivers.
Abdul Alami – Maintenance Supervisor, Alberta Infrastructure
April 27, 10:20 am – 11:10 am. Room: A122-123
Tactical leadership can be a driving force that motivates maintenance personnel to attain greater productivity. But how can effective maintenance leadership be sustained in an organization? This presentation will focus on strategic maintenance leadership principles and how they relate to reliability. You will learn about the importance of leadership in achieving goals, the different types of leadership, the essential elements of maintenance management and organization, as well as examples of good maintenance leadership.
Terry Harris – President, Reliable Process Solutions
April 25, 11:00 am – 11:50 am. Room: A124-125
For an organization to be successful, it must take full advantage of its people. Many companies struggle to use their employee resources effectively. This session will explain how important people are to the success of a company and examine the various personalities, attitudes and backgrounds of employees. You will learn how to conduct a skills audit, the importance of training programs and new ways to engage the forces to add efficiency to the bottom line.
Mike Waltrip – Vice President of Industrial Parts Services, Advanced Technology Services
April 26, 11:00 am – 11:50 am. Room: A115
There comes a time when every maintenance organization must decide whether to rebuild or buy new equipment. Most companies don’t understand all the variables involved and tend to make poor choices. This presentation will describe a systematic approach that can be employed for better decision-making. A lot of downtime and money will be on the line when making this decision, so be sure not to miss this session. Mike Waltrip will help you understand the value of proper maintenance, options outside of the “sucker’s choice” and tools to aid in the decision-making process.
Kent Knight – Vice President of Reliability & Training Services, Fluid Life
April 27, 8:00 am – 8:50 am. Room: A124-125
When laying the groundwork for asset management, there are six key factors that must be considered. Missing any of these factors can prevent you from achieving effective asset management. This session will review each of the six elements and explain what steps can be taken to move closer to world-class asset management. Find out how to determine whether reliability initiatives are taking root in your organization, identify common inefficiencies in your asset management program, and manage projects for success and continuous improvement.
George Krauter – Vice President, Synovos; Scott West – Senior Vice President, Synovos
April 25, 2:30 pm – 3:20 pm. Room: A114
Many organizations do not recognize the value of spare parts supply in a reliability program. Others realize its importance but are not sure how to correct the situation or do not have the time or authority to affect change. This presentation will reference multiple case studies to outline steps for turning a profit-draining maintenance, repair and operations (MRO) “storm” room into a profit-earning reliable plant asset. If your storeroom is not reliable, if you keep substocks for insurance and/or recognize that value can be released by improving your MRO stores operations, this session is for you.
Joel Leonard – Workforce Developer, SkillTV.net
April 26, 8:00 am – 8:50 am. Room: A113
Several major factors are causing the current maintenance crisis: baby boomers are retiring, younger workers are not interested in manufacturing jobs, and U.S. companies are keeping operations stateside, increasing the need for skilled workers. As these factors become more pronounced, organizations must develop a good strategy for adapting to tough circumstances in order to stay competitive. This session will examine how companies can build pipelines of new talent, obtain top leadership support for maintenance, and enlist the help of schools and communities in generating greater interest in manufacturing careers.
Doc Palmer – Managing Partner, Richard Palmer & Associates
April 26, 2:30 pm – 3:20 pm. Room: A114
Several simple but essential key performance indicators (KPIs) can help you assess and guide proper maintenance planning and scheduling practices. This session will explain how planning provides the productivity piece of maintenance and can increase your workforce without hiring. Doc Palmer will show you how to know if planning is working and how to guide its proper deployment. Attendees will also gain a better understanding of tricky KPIs, such as mean time between failures (MTBF) and planned vs. actual time estimates.
Sergio Rossi – Principal, RP4M
April 26, 9:00 am – 9:50 am. Room: A115
In most organizations, predictive maintenance (PdM) and total productive maintenance (TPM) are introduced separately. As a result, the possible benefits that could be produced from these powerful improvement tools are not maximized. This session will detail a proven process for synchronizing TPM and PdM that can generate a significant return on investment in just 30 days. While TPM and PdM are popular, their implementation success long term is challenging to sustain. Attendees will be shown how to solve this common problem.
Lanny Smith – President, Arrival 3D
April 27, 8:00 am – 8:50 am. Room: A115
This session will describe how the predictive maintenance (PdM) program at an Oklahoma power company involved thousands of assets, various testing technologies, multiple plants and many technicians. Testing results came in a variety of formats, which made it difficult to get an overview of asset conditions at any given time and to share results with upper management. Attendees will hear how the company was able to create a virtual collaborative environment to make PdM easier to manage. With the 3-D virtual environment, an overview of asset conditions can be surmised at a glance, personnel in remote locations can become familiar with the equipment, and management can now see the value in the company’s PdM program.
Jeremy Wright – Director of Product Management, Advanced Technology Services
April 25, 11:00 am – 11:50 am. Room: A112
Manufacturing will need to fill 3.4 million jobs over the next decade. Current statistics show that 60 percent of these jobs will go unfilled. How can your company overcome these odds? This session will provide business strategies that can help lessen the effects of the skills gap. Ideas such as developing mentoring programs, outsourcing non-essentials and improving employee retention will be discussed. Come hear Jeremy Wright explain the practical solutions to help position your company for success in the future.
Chris Jackson – Principal Engineer, Luminant Power Optimization Center
April 26, 8:00 am – 8:50 am. Room: A112
Utilizing machine learning applications can improve the availability, efficiency and profitability of your manufacturing plant. This session will explore industrial machine learning applications, their use in the manufacturing industry, the resources required and examples of where these applications have saved millions of dollars in the power generation industry. Attendees will gain a basic understanding of machine learning applications and how they can be applied in a manufacturing environment to increase machine availability and a facility’s overall profitability.
Sue Benes – Product Marketing Manager, FS-Elliott
April 26, 1:30 pm – 2:20 pm. Room: A120-121
When considering plant maintenance and repair costs, air compressors are often an afterthought. Most organizations focus on reducing utilities but frequently discount any benefits they may enjoy by addressing the compressor room. This session will take you through a real-world situation in which an air compressor room is investigated in detail. Maintenance professionals will walk away with a thorough understanding of how they can improve their compressor rooms, which in turn will allow them more time to dedicate to other areas of their plant.
Kevin Price – Senior Product Director, Infor; Kevin Williams – Senior Business Analyst, Ring Container Technologies
April 26, 9:00 am – 9:50 am. Room: A113
As organizations grow and expand operations, more and more assets are often added into the mix. These assets need to be properly managed in order to achieve the most efficient operations possible. This presentation will describe the process Ring Container Technologies used to select and implement an enterprise asset management (EAM) solution. See how the company was able to update and transform its operations while improving workflows and efficiency. Attendees will hear implementation strategies that helped make the transition as seamless as possible, as well as how the system has been functioning and improving operations since the implementation.
Joe Anderson – Senior Reliability Manager, Schwan’s Food Co.
April 26, 8:00 am – 8:50 am. Room: A120-121
One of the largest knowledge gaps in organizations around the world is the lack of business understanding of what maintenance and reliability departments do. This presentation will address how reliability and maintenance contribute to an organization’s bottom line, thereby providing the needed big-picture perspective to sell their value. Schwan’s Joe Anderson will help attendees understand how each area in maintenance and reliability relates to organizational objectives, how to show others in the organization the value of what they do and how their roles affect company profits.
John Sexton – Reliability Engineer, BASF; Douglas Bowker – Senior Reliability Engineer, BASF
April 25, 1:30 pm – 2:20 pm. Room: A112
How can you determine the right key performance indicators (KPIs) for your reliability program? This presentation will discuss how to choose value-added KPIs and how to adjust as the business needs or other factors change. BASF’s John Sexton and Douglas Bowker will bring a real-world example of a reliability dashboard used in their plant and take you step by step through each part to explain how it was developed, how it is used and what value it adds. This will enable you to build your own reliability dashboard for managing and developing a reliability program.
Tony Dotson – Division Reliability Manager, WestRock
April 26, 1:30 pm – 2:20 pm. A114
All companies are faced with the challenge of improving performance to stay competitive in their respective markets. Frequently, the person responsible for implementing change does not have the background or experience to define the vision and action plan that will yield the desired outcome. This case-study presentation will describe the strategic and tactical approach WestRock has put into motion to drive improvement across the company by leveraging reliability best practices to change the culture, engage employees and yield performance improvements. Join Tony Dotson as he shares tactics for “breaking the ice” at the facility level to begin the transformation process and for championing an initiative across a large organization.
Jeff Shiver – Founder/CEO, People and Processes
April 25, 1:30 pm – 2:20 pm. Room: A114
When it comes to asset reliability, many organizations struggle with a high level of reactive uncertainty. This uncertainty affects equipment availability, which can result in increased human and monetary costs. In this presentation, Jeff Shiver will share the eight steps necessary to build and sustain an effective work execution management foundation to drive improved equipment reliability. Attendees will learn the roles different partners should have in work execution management and how to structure a preventive maintenance program from a failure modes perspective to add value and eliminate wasted efforts.
Mike Greenholtz – Vice President of Reliability Solutions, GenesisSolutions
April 26, 1:30 pm – 2:20 pm. Room: A112
Maintenance organizations are responsible for maintaining a wide array of assets to support manufacturing and operations. While safeguards are typically assigned, such as operator care, spare parts and PM programs, understanding both the inherent and residual risks associated with critical assets is key for achieving reliability. This session will explain an effective risk management methodology that can be readily applied to improve reliability programs, including a case study on the practical application of this approach. Attendees will gain the tools and techniques to better manage risk so they can move toward operational excellence.
Paul Dufresne – Reliability Improvement Specialist, DCS
April 27, 10:20 am – 11:10 am. Room: A120-121
This case-study presentation will outline the steps one company took to realign the values, beliefs and behaviors of its culture. See how the organization was able to change from a reactive mode of operations to a proactive mode for improved reliability. Attendees will learn how to achieve the awareness of the need for a culture change, the desire to support and participate in the change, the knowledge of how to change, the ability to implement the required skills and behaviors, and the reinforcement to sustain the change.
Root Cause Analysis
Gordon Van Dusen – Global Maintenance Strategist, Ford Motor Co.; William Harmych – Global Maintenance Operating Strategist, Ford Motor Co.
April 25, 2:30 pm – 3:20 pm. Room: A120-121
This case-study presentation will describe how the Ford Motor Co. performs root cause analysis for its equipment failures using a team approach. Gordon Van Dusen and William Harmych will share the step-by-step process of conducting a root cause analysis and the importance of communicating your findings. Attendees will learn how to select the right team for performing the analysis, how to identify the root cause rather than the symptom and the advantages of integrating the analysis into your maintenance data system.
Jeffrey Ng – Engineering Group Leader, Kimberly-Clark
April 26, 9:00 am – 9:50 am. Room: A122-123
Many organizations remain somewhere between reactive and predictive maintenance. How can you break through to the next stage? This session will address the process of going beyond simply fixing equipment defects to eliminating them. Join Kimberly-Clark’s Jeffrey Ng as he describes a process for documenting root cause failure analysis and communicating defect elimination to prevent similar failures. Attendees will also learn how to create a learning organization where knowledge is disseminated as well as capture tribal knowledge before it leaves their company.
Gary Helmink – Reliability Engineer, West-ward Pharmaceuticals
April 25, 2:30 pm – 3:20 pm. Room: A112
Root cause analysis has a bad reputation for being difficult and time-consuming. In this session, Gary Helmink will describe how to use the define, measure, analyze, improve and control (DMAIC) process as a step-by-step method to perform root cause analysis. Real-world problems that were solved using the DMAIC process will be included. Discover how to use root cause analysis to move from a reactive organization to a world-class organization and how you can be confident the solution you’ve enacted truly solved the problem.
Thomas Brown – Principal Engineer, Reliability Solutions; Pamela Brown – Business and Course Development Specialist, Reliability Solutions
April 26, 11:00 am – 11:50 am. Room: A114
Lightly loaded rolling-element bearings should run indefinitely. Unfortunately, many do not. This session will enable you to recognize the causes of premature bearing failure as well as help you identify what can be done to reduce or eliminate future failures. Attendees will learn how to calculate the proper lubricant viscosity for rolling-element bearings, establish if a bearing is lightly loaded, distinguish the physical failure modes, and determine the influence of speed and lubrication on bearing failures.
Michael Johnson – Vice President, Gorman Co.
April 25, 2:30 pm – 3:20 pm. Room: A113
It is estimated that 80 percent of hydraulic system failures are oil related. Traditionally, the elevator industry has treated the symptoms of oil-related problems instead of the root causes. This session will reveal common flaws in system designs and explain how these defects can often be the source of maintenance issues. Attendees will gain the knowledge to address the cause of these problems, instead of just treating the symptoms, so they can reduce their labor costs and increase customer satisfaction.
Denise Pigula – Quality Assurance Manager, Stauff Corp.
April 26, 4:30 pm – 5:20 pm. Room: A113
Today’s organizations do not have the time, manpower or resources required to solve the same problems over and over again. Yet safety, quality, reliability and environmental incidents need to be resolved more quickly and effectively than in the past. This session will describe the “5 Why” analysis approach to incident investigation, including its advantages and how to implement it. Attendees will gain insight into how to hone their problem-solving skills prior to the onslaught of a real incident.
Lubrication Program Management
Mark Beatty – Lubrication Champion, Nissan North America
April 25, 11:00 am – 11:50 am. Room: A120-121
This case-study presentation will explain how the Nissan North America plant in Smyrna, Tennessee, continued its journey to lubrication excellence after winning the John R. Battle Award from the International Council for Machinery Lubrication (ICML). Attendees will find out how the plant was able to sustain its lubrication program, obtain management and employee buy-in, reduce downtime and save money, as well as how these same steps can be used to achieve results in any organization.
Christopher Brokopp – Senior Lubrication Technician, Weyerhaeuser
April 26, 11:00 am – 11:50 am. Room: A120-121
It is a common misconception that bearings should be lubricated like bushings. Many people are also under the impression that if a little lube is good, a lot must be better. This session will address proper lubrication fundamentals and how important the right lubricant quantities are to the longevity of your equipment. Join Weyerhaeuser’s Christopher Brokopp as he explains how overlubing a bearing can cause the same or more catastrophic problems as underlubing bearings. Formulas for calculating lubricant quantities and intervals will be presented along with advice for utilizing technologies such as ultrasound and vibration.
Dave Tiffany – Mechanic, C&W Services
April 26, 11:00 am – 11:50 am. Room: A122-123
This case-study presentation will describe how the city of Fort Collins, Colorado, was able to employ best practices in machinery lubrication and oil analysis to produce equipment reliability and extended mean time between failure for more than 22 years. C&W Services’ Dave Tiffany will explain the importance of your maintenance staff’s knowledge, skill set and attitude in using the proper lubricant for the application as well as in ensuring fluid cleanliness, contamination control and representative lubricant sampling. Real-world examples will be shown of relatively inexpensive practices and equipment modifications that have produced significant results and that can be utilized by most any facility.
Loren Green – Senior Technical Consultant, Noria Corporation
April 26, 8:00 am – 8:50 am. Room: A111
While most people understand the need for proper lubrication in maintaining a bearing, this workshop will show what that means and how to establish precision lubrication for a rolling-element bearing. Attendees will learn how to calculate greasing amounts and frequencies as well as how to determine a lubricant’s base oil viscosity.
Terry Harris – President, Reliable Process Solutions
April 26, 9:00 am – 9:50 am. Room: A112
Poor storage practices have the potential to render lubricants totally useless or even harmful to machines and technicians. This presentation will outline key considerations for developing your lubricant storage, including safety, capacity, the environment, etc. Attendees will learn what they need to know to redesign or create new lubricant storage at their facility. They will understand how moisture, temperature, contaminants and other issues can affect machines, as well as how to avoid preventable storage mistakes.
Rich Wurzbach – President, MRG Labs
April 26, 4:30 pm – 5:20 pm. Room: A111
All greases are not the same. Before switching to a different grease, it is critical to consider all the compatibility issues involved between the new grease and the current grease in use. This workshop will show how to determine if two greases are compatible and offer examples of grease compatibility testing.
Keith Smith – Vibration Analyst/ Reliability Specialist, Shermco Industries
April 25, 11:00 am – 11:50 am. Room: A114
Overpacking and overgreasing bearings account for more electric motor failures than any other factor. This session will outline a basic program for properly lubricating electric motors, including how to replace time-based lubrication practices with condition-based lubrication. Attendees will learn how to prevent overlubrication and underlubrication, the advantages of condition-based lubrication, how to standardize the type of grease used in your motors and why you must record the grease type for each motor.
Gerardo Trujillo – Director, Noria Latin America
April 26, 11:00 am – 11:50 am. Room: A112
Most maintenance programs have repetitive problems that must be dealt with every day. These issues are often caused by root causes that have not been detected or eliminated. Many of these root causes are related to poor lubrication practices. This session will show how to use reliability-centered maintenance (RCM) principles to eliminate these root causes. Join Gerardo Trujillo to discover how lubrication excellence can optimize your preventive maintenance tasks to reduce the overall number of tasks as well as the time required to perform each task.
Bill Correll – Director of Business Development, Generation Systems
April 26, 8:00 am – 8:50 am. Room: A114
Studies show poor or inadequate lubrication accounts for more than half of all equipment failures, with the global cost to industry in unplanned downtime, reactive maintenance and lost productivity estimated to be more than trillion a year. Being aware of this opportunity and focusing on lubrication allows organizations to proactively decrease their reactive maintenance and downtime. This presentation will provide valuable insights into lubrication-related machine wear and failure, their primary causes, and what measures can reduce their occurrence. Attendees will learn key steps their organization can take to establish a best-practice lubrication program along with the substantial savings such a program can deliver.
Mark Latunski – Lab Manager, American Chemical Technologies; James Kovanda – Vice President, American Chemical Technologies
April 26, 8:00 am – 8:50 am. Room: A124-125
Since mandates from the Environmental Protection Agency forced oil companies to remove impurities and carcinogenic material in crude oil, base oils have had more of a propensity to produce varnish and less solvency to hold varnish in solution. As a result, end users are contending with reliability issues that are crippling the productivity of their assets. This session will discuss the thermal degradation mechanisms causing varnish formation and the mitigation techniques currently available. Attendees will learn how certain lubricants can have an impact on these varnish issues and which types of lubricants are the best choice for critical equipment.
Anoop Kumar – Director of R&D/Business Development, Royal Mfg.
April 27, 8:00 am – 8:50 am. Room: A113
The color of grease is a major issue in the current marketplace that can influence which lubricant is chosen for a particular application. Grease manufacturers often use color to identify the type of lubricant and to make it more appealing to consumers. This session will help you better understand grease color so you can make the best selection for your application. You will also learn guidelines for grease testing as well as when you should choose a high-performance grease.
Loren Green – Senior Technical Consultant, Noria Corporation
April 25, 11:00 am – 11:50 am. Room: A111
There is much more to keeping a lubricant clean, cool and dry than just outfitting a machine. There are many avenues for contaminants to enter your systems. This workshop will show you what a properly equipped system looks like and the protection each item provides.
Josef Barreto-Pohlen – Global Product Manager Greases, Quaker Chemical Corp.
April 27, 9:20 am – 10:10 am. Room: A114
Most industrial plants make every possible effort to lower the risk of fire in their facility. This is especially true regarding hydraulic fluids, but what about lubricating greases? This presentation will describe a test method developed by the steel industry to predict the fire hazards of grease. A number of case studies will show the potential of fire-resistant greases in terms of reducing fire hazards as well as their function as lubricants under various conditions. Discover how these greases can help to create a safer workplace and generate cost savings due to the decreased number of fires.
Greg Livingstone – Executive Vice President, Fluitec
April 27, 8:00 am – 8:50 am. Room: A114
When you have extremely sophisticated, precise metal pieces rotating at more than 3,000 revolutions per minute on a film of oil a fraction of the thickness of a strand of hair, it’s important to ensure you are using the correct lubricant. This session will explore how to go about selecting the right turbine oil and other critical lubricants. Learn how turbine oils are formulated, which tests are most useful in differentiating various oil formulations and how you can make the wisest investment for your oil purchases. Attendees will walk away with a better understanding of why it’s important to collect independent data when selecting turbine oils as well as how to determine which oil provides the greatest value for your organization.
Alex Puentes – Senior Manager of Asset Reliability & Utilization, Ingredion; Javier Navarro – Senior Manager of Process Engineering, Ingredion
April 26, 2:30 pm – 3:20 pm. Room: A120-121
Implementing an effective lubrication program is a process. It requires decision-making and involvement from top management as well as a commitment on the plant floor. This case-study presentation will describe the process used by Ingredion, a leading global ingredient solutions provider, to implement a new lube program. From the identification of problems associated with lubrication to the formal engineered implementation, discover what the organization has gone through over the years, including the successes, failures and obstacles along its journey to lubrication excellence.
Greg Romer – Lubrication Specialist, Newcrest Mining
April 26, 11:00 am – 11:50 am. Room: A124-125
Managing a lubrication program can be challenging. Where should you spend your time and energy? Where can you save money? How can you sustain your program’s momentum? This session will answer those questions as well as explain how to avoid many of the common pitfalls. Join Newcrest Mining’s Greg Romer as he details an award-winning approach for lubrication program management, including key targets and goals, the benefits of lubrication training, and using oil analysis metrics. Real-life examples will be offered for how dedicated personnel with enthusiasm and support can achieve where others have failed.
Tim Newman – Maintenance Manager, Simmons Feed Ingredients; Seth Schroeder – Account Executive, Noria Corporation
April 26, 4:30 pm – 5:20 pm. Room: A112
This case-study presentation will explain how the Simmons Feed Ingredients plant in Southwest City, Missouri, was able to reduce equipment breakdowns by more than 50 percent and achieve an annual cost savings of nearly million once the organization decided to put more of an emphasis on lubrication. Attendees not only will hear how the plant made a complete transformation in its lubricant storage and handling practices but also see how it changed its culture through employee training and certification, allowing the company to focus on predictive and proactive maintenance rather than just reactive work.
Wes Cash – Director of Technical Services, Noria Corporation
April 26, 1:30 pm – 2:20 pm. Room: A111
Few field tests can pack the power that a patch test does. For such a simple test, it can provide valuable information on contamination and machine health. This workshop will show you the steps to perform an effective patch test as well as how to diagnose problems based upon the results.
K.N.V. Subrahmanyam – Chief Technical Officer, Lube Expert PVT
April 27, 10:20 am – 11:10 am. Room: A115
Wear debris analysis is an important tool for identifying critical component wear at an early stage to increase equipment availability and reduce maintenance expenses. This session will explore advanced wear monitoring techniques and how they can be used to understand abnormal wear in its early stages. Attend this presentation to learn which wear debris analysis methods are appropriate for different types of critical machinery and how a combination of spectroscopy and ferrography techniques can be employed to recognize machine faults.
Evan Zabawski – Senior Technical Advisor, TestOil
April 26, 8:00 am – 8:50 am. Room: A115
Oil analysis users are often heavily dependent on alarm limits. However, most of these limits are not set properly, and even those that are can miss serious issues. This presentation will highlight the drawbacks of limits while describing the advantages of supplementing with dynamic trending. This information will enable oil analysis users to get more out of their data without incurring extra costs while identifying only relevant problems and not missing sub-alarm issues or creating a cry-wolf effect through overalarming.
Bennett Fitch – Senior Technical Consultant, Noria Corporation
April 25, 2:30 pm – 3:20 pm. Room: A111
Taking an oil sample may seem straightforward on the surface, but putting the concepts and procedures into action can quickly bring to light many questions about the appropriate method. A successful oil analysis program can hinge entirely on the approach taken to obtain the sample. This workshop will show you the best methods for taking a representative sample so you can be confident in the oil analysis results.
Arthur Ward – R&D Manager, MOA Instrumentation; Marshall Borlaug – President, MOA Instrumentation
April 27, 9:20 am – 10:10 am. Room: A112
When performing oil analysis using ASTM methods for rotating disk electrode (RDE) emission spectroscopy, errors often occur. This session will offer alternative techniques to help overcome these problems so you can obtain an accurate analysis of your oil samples. Attendees will discover why they should verify oil analysis methods before using them, how to identify problems in analytical measurements, and how to improve the accuracy and reliability of their data.
Brett Minges – Vice President of Sales, Polaris Laboratories
April 26, 1:30 pm – 2:20 pm. Room: A124-125
Many organizations have trouble integrating oil analysis into their maintenance programs, which often results in them remaining reactive instead of practicing condition-based maintenance. This session will follow a company over a decade as it progresses from not using oil analysis to having a top-performing program that continually searches for ways to extend equipment life, increase uptime and reduce maintenance expenses. Attendees will see how this company faced challenges, setbacks and triumphs along the way with examples of the how and why behind the people, processes and technology that led to success.
Michael Holloway – Strategic Accounts & External Training, ALS Tribology
April 27, 9:20 am – 10:10 am. Room: A124-125
Although oil analysis has become a common practice for maintenance and reliability teams looking to improve equipment reliability and reduce operating costs, it is now being utilized by some organizations to direct when to sample for wear debris analysis. This session will explain how using data points in oil analysis allows a trigger for when to run direct and analytical ferrography. Find out how this advanced form of condition monitoring can help identify where debris is being generated and what contaminants are contributing to early failure modes so you can reduce downtime and parts replacement.
Bill Bars – Senior Application Scientist, Beckman Coulter; Joe Dabbs – Global Marketing Manager, Beckman Coulter
April 26, 2:30 pm – 3:20 pm. Room: A124-125
Improper sample collection and/or preparation can skew your oil analysis results dramatically. This session will walk you through the fundamental steps to properly collect an oil sample and avoid cross-contamination, from the appropriate collection vessels to the optimal sampling locations within the system. Attendees will learn how to prepare samples prior to measurement to guarantee accurate, repeatable and reproducible results, as well as how to analyze the results to make good business decisions.
Esteban Lantos – CEO, Dr. Lantos Laboratory; Gabriel Lucchiari – Director, Dr. Lantos Laboratory
April 27, 10:20 am – 11:10 am. Room: A124-125
Good oil health is essential to achieve transformer availability and reliability. This presentation will discuss a number of analytical techniques that can be used to monitor oil and transformer condition. These methods can be as simple as a blotter test to detect polar substances developing in the oil or as sophisticated as gas chromatography (GC) to assess gas evolution and internal electrical failure. Attendees will learn how to assess transformer health, the key tests to perform on transformer oils and how to detect anomalies in transformer behavior up to three years before an oil failure is noticeable or a transformer breaks down.
Bennett Fitch – Senior Technical Consultant, Noria Corporation
April 26, 11:00 am – 11:50 am. Room: A111
There is no reason to perform oil analysis if the reports obtained are not understood correctly. With so much information packed into just a few pages of data, the wealth of knowledge available is astounding. This workshop will show you how to make sense of the data provided and determine whether further action is required.
Giuseppe Adriani – President, Mecoil Diagnosi Meccaniche; Matteo Campatelli – R&D Manager, Mecoil Diagnosi Meccaniche
April 27, 9:20 am – 10:10 am. Room: A113
The goal of any oil analysis program is to collect the most accurate information possible from machine components while eliminating the potential for cross-contamination. This session will explore the technological advancements in sample bottle design that not only have eliminated the potential ingression of contaminants from the environment but also reduced the number of tools needed to collect an oil sample. Attendees will learn methods for pulling an oil sample that are fast, clean and virtually hands-free, even when collecting highly viscous lubricants in the field.
Dave Wooton – Consultant, Wooton-Consulting
April 26, 4:30 pm – 5:20 pm. Room: A114
As an oil reaches its end of life, the first objective of maintenance engineers is to determine which lubricant will be used as a replacement. With constantly changing formulations and improvements in performance, how can you determine whether the information being advertised by lubricant manufacturers is valid? This presentation will take an in-depth look into the industry-accepted tests for predicting fluid life as well as examine the test results for both mineral oil and synthetic-based formulations to explain how to achieve the optimal combination of additives and base oils. Attendees will see examples from new and in-service oil samples and learn the positive and negative aspects of these tests to assist in their decision-making process.
Tom Fitch – CEO, Luneta
April 27, 9:20 am – 10:10 am. Room: A122-123
When it comes to oil analysis, there are no scientific instruments, sensors, algorithms or computers that can outperform the eyes and mind of a human inspector. However, to get the most out of your sense of sight, you need to know what you are looking for. This presentation will explain how to identify the critical states of oil that can cause machine failure or reveal an active failure in progress. Attendees will learn routine visual inspections that enable earlier alerts without the use of tools, pulling oil samples or special instruction aids.
Randi Price – Senior Applications Chemist, Spectro Scientific
April 26, 9:00 am – 9:50 am. Room: A120-121
Many industrial plants send their oil samples to a commercial laboratory for measurement and interpretation of the results. However, it is possible to achieve lab-quality results onsite, especially if a chronic water problem is present. This session will detail a new method for measuring both dissolved and free water using infrared spectroscopy. Learn how this approach can make onsite water measurement easier than ever before and why oil samples collected and measured by an external lab may not be representative of what is pulled from the machine.
Paul Kimble – Vibration Analyst, General Motors/Marion Metal Center; Jeremy Jeffers – Machine Repairman/Vibration Analyst, General Motors
April 26, 8:00 am – 8:50 am. Room: A122-123
In this case-study presentation, General Motors’ Paul Kimble and Jeremy Jeffers will describe how their plant was able to develop an online vibration program for monitoring its stamping presses, which has resulted in detecting numerous anomalies and saving hundreds of hours of downtime. See how the plant went from trying to collect vibration data once a month with a handheld data collector to collecting data every hour, 24 hours a day, seven days a week and 365 days a year while monitoring more than 1,000 points. Attendees will learn the most important thing to keep in mind when collecting data, why spectral data doesn’t always show the real problem and why trending data is essential.
David O’Toole – Assistant Chief Engineer AFC, Washington Metropolitan Area Transit Authority
April 26, 9:00 am – 9:50 am. Room: A124-125
Industry is dependent on complex systems built from mechanical, electrical and software components. These components are frequently affected by reliability and asset management problems. In this presentation, improved methods of visualizing and documenting component relationships will be discussed to aid in systems management. Attendees will discover how to employ a comprehensive condition monitoring model to get alerts on developing threats before emergency remediation is required. This model can predict the future state of system availability, identifying future problems and providing the foresight to plan maintenance and component replacement.
Alan Ross – Vice President of Reliability, SD Myers; Jason Dennison – Production Manager Laboratory Analytical Services, SD Myers
April 25, 1:30 pm – 2:20 pm. Room: A124-125
A significant risk for unplanned outages and lost production has been on the increase over the past few years due to critical transformer failures. Both the insurance industry and monitoring equipment manufacturers are pointing to online dissolved gas analysis (DGA) and partial discharge (PD) monitors as the future. This session will examine the role DGA monitoring can play in reducing unplanned outages, the problems that come with the data influx from online monitors and the need for a robust oil testing program. Alan Ross and Jason Dennison will help you understand how trending DGA data can be more useful than single-point analysis and lead to better life-cycle planning.
Scott Shults – Product Specialist, Flowserve
April 27, 10:20 am – 11:10 am. Room: A114
This session will present a reliability assessment of a plant’s rotating equipment, detailing the problem encountered, the condition-based monitoring methodology applied, the root cause analysis performed and the implementation plan for the improvement recommendations. Attendees will hear about the benefits realized by the plant as a result of implementing these recommendations, which included improved safety and efficiency, increased reliability, decreased cost of ownership and reduced downtime.
Ed Kochanek – Regional Sales Director, FLIR Systems
April 27, 8:00 am – 8:50 am. Room: A112
Heat can be a sign of problems or damage in electrical and mechanical systems, but it’s difficult to detect in a routine inspection. Too often these issues go unnoticed until the system breaks down, leading to lost production and expensive repairs. This session will describe how thermal imaging can be an essential tool in predictive maintenance, allowing you to uncover faults and damage by visualizing heat as well as accurately measure temperatures for a better grasp of the problem. Attendees will gain a greater understanding of the science behind thermal imaging and discover the range of applications for this technology in the plant environment.
Andy Page – Principal Consultant, Allied Reliability
April 25, 1:30 pm – 2:20 pm. Room: A115
Many people apply both oil analysis and vibration analysis to the same machine components, but often the results are presented independently, with some details lost in the process. This session will explain how much can be gained from comparing the findings of both oil analysis and vibration analysis before maintenance recommendations are made. Attendees will gain a better understanding of how different technologies can corroborate each other as well as some of the most common mistakes made by lubricant analysts and vibration analysts when they do not compare notes.
Ron Kittle – Sales & Service Engineer, SPM Instrument
April 27, 9:20 am – 10:10 am. Room: A115
Vibration analysis has been stagnant for years, especially on complex machinery such as gearboxes and low-speed bearings. This session will describe how condition monitoring with high-definition (HD) technologies can provide longer warning times for planning maintenance and repairs. Real-world examples will be shown to illustrate how these technologies can help you take control of applications in your facility that were previously in unknown conditions. Discover how to optimize asset life, cut repair costs and minimize the consequences of unplanned downtime with these new tools.
T.J. Garten – Subject Matter Expert, Allied Reliability
April 26, 2:30 pm – 3:20 pm. Room: A115
There are a number of common misconceptions about infrared thermography and how it can be employed to inspect plant equipment. This presentation will discuss these misconceptions and the actual capabilities of the technology, including examples from real-world plant inspections. Attendees will gain a better understanding of how infrared thermography works from a foundational perspective, which in turn will help them understand what they can achieve through proper application of the technology.
Andy Page – Principal Consultant, Allied Reliability
April 26, 1:30 pm – 2:20 pm. Room: A115
Maintenance personnel often attempt to utilize ultrasound without understanding the appropriate application, methodology and device settings. This can result in misusing or misapplying the technology, sometimes without even knowing it. In this session, Andy Page will explain some of the common errors and traps people fall into when applying ultrasound or creating an ultrasound program as well as how to correct them. Attendees will walk away with the information they need to help turn around a failing ultrasound program and transform it into a powerful program that produces quality results.
Walter Barringer – Senior Reliability Professional, Allied Reliability
April 25, 2:30 pm – 3:20 pm. Room: A115
The source of many underlying machinery problems can be traced to structural issues. This presentation will reveal how to use vibration analysis to identify these issues. Discover how the cross-channel phase in a typical two-channel vibration analyzer can be employed to track down those hidden structural issues that cause machine degeneration and failure. Attendees will gain insight into the principles on which phase analysis works, the proper settings to use with a vibration analyzer for optimal results and how to interpret your readings.
Chris Dellinger – Hydraulic Consultant/Instructor, GPM Hydraulic Consulting
April 26, 2:30 pm – 3:20 pm. Room: A113
Unlike most tools, hydraulic troubleshooting tools can quite literally pay for themselves the very first time they are used. This session will describe the most essential troubleshooting tools, such as pressure gauges, quick disconnects, flow meters, infrared cameras, voltage meters and electrical test boxes. Find out why these tools are so helpful, how many companies and maintenance professionals rarely use them, and why most do not even know they exist.
Nnamdi Achebe – Lead Engineer & Country Manager, Petrosave Integrated Services
April 25, 1:30 pm – 2:20 pm. Room: A113
The most important component of a hydraulic unit is the oil. For this reason, keeping oil cool, dry and clean should be the central focus if maximum value is to be extracted from the machine. This session will share how a waste-paper recycling company was able to use comprehensive oil analysis and contamination control methods to double the expected life of its in-service hydraulic oil and save thousands of dollars in oil replacement and associated labor charges. Attendees will walk away understanding the correlation between oil cleanliness, oil life optimization and lower operating costs, as well as the importance of setting oil cleanliness targets.
Martin Migliori – Fluid Systems Engineering Manager, Airline Hydraulics; Joseph Lisowski – Senior Applications Engineer, Airline Hydraulics
April 26, 9:00 am – 9:50 am. Room: A114
With the widespread use of environmentally friendly hydraulic fluids, the opportunity for an electrostatic charge in hydraulic systems has become even greater. This presentation will describe how an electrostatic charge can build up in hydraulic filter elements and what can happen if it occurs. Martin Migliori will reveal ways this issue can be prevented in the design phase, corrective actions to take after the unit is in place, and how to determine if your system is prone to this phenomenon.
Tony Casassa – Application Engineer, Aggressive Hydraulics
April 26, 1:30 pm – 2:20 pm. Room: A113
When repairing or replacing hydraulic cylinders, it is critical to consider contamination and cleanliness. For some industrial facilities, this means implementing procedures to ensure cleanliness. For others, it means finding a cylinder company that has a cleanliness program already in place. In this presentation, follow the journey one manufacturer took to maintain cleanliness and provide clean hydraulic cylinders to its customers. Attendees will learn how ideas were generated and implemented, how results were communicated throughout the company, what the company’s current state of cleanliness is and what steps the company plans for improvement.
Brian Schmidt – Reliability Based Lubrication Manager, Chevron Lubricants; Jason Gerig – Business Development Manager, Chevron Lubricants
April 25, 11:00 am – 11:50 am. Room: A113
Meeting lubricant cleanliness requirements can be challenging. Many plants spend a lot of time and money designing systems to filter new lubricants but still do not achieve their objectives. This session will demonstrate how to set up a contamination control program that guarantees cleanliness every time. You will learn how to ensure new lubricants are clean upon arrival, implement air management and handling methods to sustain cleanliness, and perform in-service filtration. These strategies will help you attack the No. 1 cause of lubricant-related equipment failure – particle contamination.
Steffen Nyman – Corporate Trainer & Consultant, C.C. Jensen
April 26, 11:00 am – 11:50 am. Room: A113
A used oil sample carries a vast amount of information, but you must have the tools to translate the oil’s language. Likewise, a used oil filter holds a lot of evidence that can only be understood with the right tools and techniques. This session will discuss the difference between new tools such as automatic particle counters vs. old-school tools that can be used onsite. Find out how experience and the appropriate tools will allow you to understand oil cleanliness and verify filter efficiencies so you can reduce operation and maintenance costs associated with downtime, component wear and lubricant replacement.
Eric Krause – Technical Specialist, Pall Corp.
April 26, 4:30 pm – 5:20 pm. Room: A115
Although anyone who uses an oil filter on a regular basis should understand the difference between beta values and micron ratings, confusion often exists over what these numbers mean. This presentation will explain filter ratings and discuss why beta values truly matter. It will also provide important information on the applicable test methods and presentation of the results. Attendees will hear about the various filter rating methods and why higher beta ratings can equal better reliability.
Wojciech Majka – President and CEO, Ecol
April 27, 10:20 am – 11:10 am. Room: A113
Many turbines go down every year because of dirty oil systems. Unfortunately, there is no magic wand to restore the situation to normal, except for properly cleaning the system followed by appropriate oil flushing. This presentation will discuss the benefits of hydrodynamic cleaning with high-pressure water jets and subsequent high-velocity oil flushing of systems as a viable alternative to other methods. Find out how this cleaning and flushing technology can be an effective method of preparing new oil systems and restoring operated systems regardless of their size and complexity.
Roger Simonson – President, One Eye Industries
April 25, 2:30 pm – 3:20 pm. Room: A124-125
Premature wear of machine surfaces is a common problem caused by ferrous and non-ferrous contaminants. The most damaging of these contaminants are less than 10 microns in size and, in most cases, cannot be captured by traditional filtration methods. This presentation will describe the benefits of using magnetic filtration solutions to filter oil to sub-micron levels. Discover how the latest technological advancements in magnetic filtration can be used to improve fluid cleanliness, increase machine reliability and decrease maintenance costs.