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May 2017
Reliability Consulting
 
In This Issue
Emerson Exchange 2017
Reliability Tip
SMRP Approved Provider
Public Training Classes
New Webinar – Not Your Granddad’s Machinery Protection System
Upcoming Events
  White Paper – How Reliability Impacts Shareholder Value

As reliability professionals, we understand the obvious benefits of lower manufacturing costs and higher uptime in embarking on a reliability improvement initiative. However, many organizations that are well down this path find that there are many additional benefits that are seen, many of which were completely unexpected. In other words, the payback of reliability greatly exceeds the planned benefit that the original business case was based upon. Some of these additional benefits are tangible and measureable; others are intangible but no less real or important. This paper will explore some of the reasons behind these unexpected benefits and may provide some assistance in determining a business case for your own reliability initiative.

There are four general areas of value generation due to a reliability initiative

  • Revenue Growth
  • Cost Effectiveness
  • Asset Efficiency
  • Market Expectations

To read the white paper, click here.

 
 
 
 
EMERSON EXCHANGE 2017
October 2-6 in Minneapolis, MN


You could be the Next Reliability Program of the Year
Emerson and the University of Tennessee are looking for the companies with the best application of integrated maintenance best practices and the most effective use of reliability technologies as part of a “best in class” reliability program, with measurable results on the operation’s performance and savings. A thorough evaluation of these practices will lead us to find the facility that will take the honors for 2017.

“Reliability is not a goal. It's a way to be, to think, to act.”
— Frédéric Thivierge, operations manager at Ethanol Greenfield 2016 Program of the Year

If you would like your company to be considered for this year’s recognition and share your great results, please contact Bruce Hawkins (Bruce.Hawkins@Emerson.com).

Click here for additional information
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Reliability Tip:

Permanently Installed Condition Monitoring Instruments

The advent of wireless condition monitoring instrumentation has resulted in the ability to justify installation of permanent sensors in places where it was previously cost-prohibitive. This can replace the need to use a route-based strategy to take readings, and in some cases, increase the effectiveness of the condition monitoring program. Although relatively inexpensive to apply, installation should still be supported by a sound business case. So, what are some of the advantages and challenges of employing this strategy?

Advantages of permanent installations include:

  • Safety – Machinery that is in a hazardous location are ideal candidates for permanent sensors. This eliminates the need to routinely send a technician into these areas for readings.
  • Frequency – Readings can be taken at much more frequent intervals when needed. Machines whose condition changes with varying loads or speeds can be more effectively monitored. When a potential defect is discovered, the measurement frequency can be increased to get a better prognosis of the remaining life.
  • Accessibility – Instruments can be installed on equipment that would be impossible or impractical to access, allowing more equipment to be under surveillance.
  • Flexibility – Equipment that operates intermittently or on campaigns can be monitored more effectively because readings can be taken at any time, resulting in fewer “missed readings”.
  • Labor efficiency – Less manpower is required to collect the data; technicians spend less time traveling to and from the job site and more time on analysis, where the value is truly added.
  • Integration – The data can be automatically interfaced to existing enterprise systems, such as the data historian, DCS, PLC, etc. where condition readings can be compared to operational readings. This can provide a more complete picture of asset health.

Some of the challenges include:

  • Initial cost – The first installation must support the installation of the infrastructure such as the wireless gateway and user interface (if one doesn’t already exist in the facility). However, since a gateway can support several dozen instruments, the cost per point monitored after the initial installation is significantly lower.
  • Maintenance – Batteries will need to be changed periodically. Battery life is dependent on measurement frequency, so more frequent readings will mean more frequent battery changes. However, some companies are overcoming this disadvantage by installing “energy harvesters” that make use of nearby energy sources (thermal, solar, or kinetic energy) to maintain battery charge. Line power sources can also be used to provide continuous power if available.
  • Remote – No one physically visits the machine to do a visual check or situational observation. In addition, the types of tests are defined on initial setup; additional ad-hoc troubleshooting tests to check for issues such a resonance or soft foot can’t be run.

The advantages clearly outweigh the challenges, so enhance your condition monitoring program by considering permanently installed sensors!

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Emerson’s Reliability Consulting training is recognized by the Society for Maintenance and Reliability Professionals (SMRP) as an approved provider of continuing education and training aligned with key subject areas related to reliability and physical asset management.

Emerson’s Reliability Consulting is a Tier 5 Approved Provider for the following courses:

  • Introduction to Planning and Scheduling Principles
  • Advanced Maintenance Planning
  • Introduction to Developing Reliability-Based Maintenance Strategies
  • Maintenance Management 101/201
  • Materials Management Strategies
  • Understanding and Successfully Managing the Process of Change
  • Reliability Centered Maintenance (RCM) Principles
  • Reliability Awareness Featuring the Reliability Game®
  • Foundational Awareness for Maintenance and Reliability Professionals
  • The Reliability Game®

Get more details about available on-site and remote training options here.

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Public Training Classes

Materials Management Strategies - REL006 - This introductory 2-day course is designed to provide participants instructions about how to manage, organize, and control inventory risk through strategic MRO inventory management.

Date October 11-12, 2017
Location - Round Rock, TX

The Reliability Game - REL001 - The Reliability Game focuses on participants' attention on the maintenance function at a facility. This 1-day workshop is a simulation that clearly demonstrates the value of proactive reliability practices and the positive effects it has on the bottom line. The simulation is both fun and educational. The simulation also provides a mechanism to help the participants create a common understanding of basic reliability business goals.

Dates – October 10, 2017
Location – Round Rock, TX

Additional Training Information

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New Webinar – Not Your Granddad’s Machinery Protection System

Machinery protection systems are generally thought of as a necessity that acts as an “earthquake switch” for your critical machinery. Often, these systems are stranded in hard-to-reach areas and are not connected to the plant’s data processes. They are typically hard to configure and require many spare parts to deal with the different types of signals. New technologies are emerging to deliver valuable predictive data from the protection system, making it a contributor to improving plant and asset reliability.

Topic to be discussed include:

  • Traditional protection systems are evolving to provide more value.
  • Mobile applications are making interaction with these systems more efficient.
  • Flexible I/O is reducing spare-parts inventory and allowing late configuration changes.

To register, follow this link.

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UPCOMING EVENTS
SMRP Symposium
June 7-8, 2017

Workshop - Essential to Top Quartile Performance – Stan Moore

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Your Local Connection

Learn more about local reliability community activities and local access to Emerson’s expertise and accelerators. Click here to connect.

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