Reliability Centered Maintenance (RCM) and Total Productive Maintenance (TPM) are two important processes that can be used to maintain asset integrity. This session will provide an over view of some of the things that Power Partners has implemented to reduce total down time in the facility by over 50% in 5 years.
Power Partners is a leading manufacturer of overhead distribution transformers, serving utility, industrial and commercial customers in North America, Central America, Mexico, the Caribbean and other markets. Working with Suppliers, we provide value to our customers, associates and community by responsibly producing reliable, energy-efficient distribution and cooling solutions.
Our facility is 677,400 square feet under the roof and we employee 415 associates. Our facility has produced over 8 million transformers since 1958. We produce single phase, three phase and submersibles transformers as well as absorption chillers.
Our Vision is “Transforming the world through innovative manufacturing.” Our mission is “Partnering with suppliers, PPI provides value to our customers, associates and community by responsibly producing reliable, energy-efficient distribution and cooling solutions. Our Values include: Safety, Quality, Delivery and Cost; Thrill the customer; Rise to the Challenge; enthusiastically improve everything you can; Pride and Passion in all we do; Encourage and serve daily; Think like an owner, control your own destiny.
Maintenance also has a vision and mission statement: The vision statement for maintenance is, “The maintenance Department is a respected, strong, eager bunch of well-trained & educated associates committed to safety & excellence in work performed, so that less downtime, and “always being ready to run,” will help to achieve continuous flow and ultimately greater profitability. Our mission is to proactively apply our expertise and resources to sustain the condition and functionality of all assets in the safest manner possible. Do you have a maintenance vision and mission?
A Case for Asset Integrity Change:
The primary case for change is the desire to improve the bottom line. Equipment downtime is very expensive to any organization.
Power Partners has had a reduction in overall downtime of over 50% in a period of 5 years.
The road map for achieving this improvement to move from reactive to proactive is through 7S, MRO, RCM, Lube Excellence, Maintenance excellence, and TPM.
Lean as it applies to maintenance starts with 7S. The seven S’s are Safety, Security, Sort, Straighten, Shine, Standardize, and Sustain.
Storeroom management is anther key element of world class maintenance.
Reliability Centered Maintenance is the third key element of our success. Our reliability engineer implemented lubrication excellence in our facility and brought vibration analysis in house to enhance our reliability efforts. Optimizing PMs was a huge focus as well making sure we were performing PM to a standard and catching problems before they happen.
The result of RCM is lower cost, less waste and a huge reduction in hydraulic related failures.
The cost savings in oil alone was over $45,000 annually by moving to condition based maintenance. More than enough to cover cost of filtering equipment.
Case Study #1
On our core annealing furnace we used babbit bearings. This application created a lot of stress on the bearings and good lubrication could not be achieved. The bearings were also located in an area that required a ladder to access. The bearings would typically fail after 6 months of service.
New roller bearings were installed with an automatic lubricator. Since the change has been made the bearings are still operational after 4 years.
A second enhancement on this annealing furnace is using graphite bearing technology to replace the water cooled grease bearings. Graphite works well in high temperature slow RPM applications like this one and saved a huge amount of labor, grease, and heating load on our cooling tower.
Case Study #2
The second project we tackled was our oil degas equipment. In this application we spent capital to replace the equipment. The equipment had so many leaks and too many problems to cost effectively reduce the oil consumption. The newer equipment uses no water for cooling and has no leaks and the level of dryness for our oil is much better than specification
Case Study #3
The last case study to share is our power unit consolidation process. We had an application that used 3 power units for 6 presses. However, the operators never utilized over one press at a time. We purchased one new power unit to replace the 3 and used a header to supply each machine with a valve. The result is less oil in our overall inventory and huge energy savings removing 2 15 HP motors from the plant load.
Total productive maintenance is a lean approach to world class maintenance. We will explore the 5 major components of TPM and how to utilize them in turning your reactive maintenance to proactive and achieving asset integrity.
The 5 areas are maintenance excellence, autonomous care, equipment improvement teams, early equipment care, and training. Maintenance excellence is all about process and procedures for how maintenance is performed. Autonomous maintenance develops the operator standards and self care. The kinds of things we would shift to an operator are things like cleaning and inspection. Sometimes lubrication if the proper training is performed. I will share our story on how we implemented on our seam welder machine and show metrics of improvement.
This article was previously published in the Reliable Plant 2013 Conference Proceedings.
By Ken Hughes, Power Partners
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