Maintenance and Reliability Technology Summit 2009 - Sessions
Afternoon Sessions - Tuesday April 15 | Morning Sessions - Wednesday April 16 Afternoon Sessions - Wednesday April 16
Tuesday, 8:00-9:00 a.m.
Keynote Session: How Reliability Increases Profits
Bob Williamson, Strategic Work Systems, Inc.
Internationally respected maintenance consultant and author Bob Williamson tackles the ultimate question of relating profits—leven corporate survival—to reliability and maintenance in this keynote presentation that informs and inspires. We must find ways to transform
our top-level decision makers' thinking by continually showing the compelling business case for good, sound plant operations and maintenance methods, Williamson says. Join him to learn how your leadership can make a difference in your plant and company.
Tuesday, 9:00-10:00 a.m.
Break – Exhibition Open
Tuesday, 10:00-10:45 a.m.
5S Implementation Within Maintenance
Dave Thompson, Alcoa
The 5S process is a lean tool that supports proactive maintenance and improved equipment reliability, both of which reduce costs. Instilling understanding, acceptance, and the associated cultural change of implementing 5S on the shop floor is not intuitive or easy, but well worth the journey. Concepts addressed in this session include: Cascading 5S to improve housekeeping and safety, and sustaining the efforts; developing standard operating procedures around 5S; conducting value added audits using standardized checklists; incentives that work, yet are simple
Tuesday, 10:00-10:45 a.m.
Designing for Reliability & Maintainability
TBD
One of the best ways for ensuring equipment reliability is to begin at the design stage of a machine or process. Doing so requires a joint commitment from all of the groups involved—maintenance, operations, engineering, and purchasing.
Tuesday, 10:00-10:45 a.m.
Look Beyond General-Purpose Motors for Increased Reliability and Additional Energy Savings – Part 1
John Malinowski, Baldor
Since the passage of the Energy Policy Act (EPAct) of 1992, which applied only to general-purpose motors, there have been many advancements for electric motors with increased efficiency and reliability. In this two-session presentation, you'll learn about many of these advances and the wide variety of improved motors now available.
Tuesday, 10:00-10:45 a.m.
Lubricant Program Management
Ken Bannister, Eng Tech Industries, Inc.
Drawing on a career as a lubrication specialist, Ken Bannister reviews the many facets of lubrication program management and offers advice on how to prioritize your activities for effectiveness and efficiency.
Tuesday, 10:50-11:35 a.m.
Identifying & Managing Risks in Capital Projects
Mike McGee and Dave Schrader, Fluor
Identifying, evaluating, and mitigating risk is essential to protecting an owner's investment in capital improvements. The presentation provides a methodology to assist participants in identifying and quantifying the risks associated with a capital project. The difference between a successful project and an unsuccessful
project is often the failure to establish a comprehensive list of project risk factors. Once the risks are identified, mitigation strategies can be developed to reduce the total risk profile. This session will answer such questions as: How to identify risks, how to determine the severity of the various risks, what is the probability of occurrence, and what can be done to mitigate the risk? The presentation will then address managing risk throughout the life of the project.
Tuesday, 10:50-11:35 a.m.
Infrared Thermography: What's Hot in PdM
Jim Seffrin, Infraspection Institute
Once an obscure technology, thermography has matured to enjoy worldwide use for a broad range of applications. Thermography is now used routinely for PPM, PdM, and Condition Monitoring for electrical and mechanical systems, buildings and roofs, boilers and steam systems, and process equipment. This presentation will discuss the benefits of thermography, current applications and how to initiate and maintain an infrared inspection program.
Tuesday, 10:50-11:35 a.m.
Look Beyond General-Purpose Motors for Increased Reliability and Additional Energy Savings – Part 2
John Malinowski, Baldor
Since the passage of the Energy Policy Act (EPAct) of 1992, which applied only to general-purpose motors, there have been many advancements for electric motors with increased efficiency and reliability. In this two-session presentation, you'll learn about many of these advances and the wide variety of improved motors now available.
Tuesday, 10:50-11:35 a.m.
Hydraulic Fluid Condition Monitoring
Bryan Chaka, Parker Hannifin Corp., Hydraulic Filter Div.
Today's hydraulic components and systems require that specific fluid cleanliness levels be maintained in order to function within their design parameters. Failure to comply typically results in unscheduled downtime, high component replacement costs, high fluid replacement and disposal, and increased maintenance costs. The key is to know the condition of your hydraulic fluid so that the necessary adjustments can be made to the filtration system. You must have some point of reference that can be monitored to reflect both positive and negative changes to condition of the hydraulic fluid. On-site fluid condition monitoring equipment is available for this purpose. The types and capabilities of this equipment will be explored.
Tuesday, 11:40 a.m.-12:25 p.m.
Driving Performance Beyond Wrench Time
Ed Stanek, LAI Reliability Systems, Inc.
True capacity is not defined by available head count but rather the technician's effectiveness within the system. Maintenance effectiveness goes way beyond the elusive "holy grail" of wrench time into a dynamic, real-time dashboard of the maintenance process. Although the plant focus remains optimizing the product flow, what most have not understood is "when the product value stream stops, the maintenance process takes over." This principle reveals that we all play different roles in throughput and thus need to share the same metrics. Technician effectiveness is the OEE for maintenance. By measuring technician effectiveness, you improve throughput by identifying the non-value-added activities that limit optimum return. Elevating MTE is the next step: This session takes a new look at conventional methods and how, by focusing on the constraint, you can yield tremendous improvements
of 50-90%.
Tuesday, 11:40 a.m.-12:25 p.m.
How To Make Reliability Improvements Stick
Jerry Dover, Give & Go Prepared Foods
Tuesday, 11:40 a.m.-12:25 p.m.
Centrifugal Pump Troubleshooting Tools for Extending Service Life and Reliability
Colleen Reeves, Dubric
Even with the integration of state of the art monitoring equipment,
vibration analysis, and PdM programs, basic centrifugal pump troubleshooting skills applied on a day-to-day basis will positively impact the service life and reliability of centrifugal pumps. A general understanding of how a pump operates, its design, and its application will provide a foundation of knowledge to be used to troubleshoot pump and pumping system issues. Furthermore, an understanding of typical failure indicators associated
with pumps will provide the tools used to correct problems prior to catastrophic failures.
TOP
Tuesday, 12:25-1:30 p.m.
Lunch – Exhibition Open
Tuesday, 1:30-2:15 p.m.
The Partnership Organization - Part 1
Christer Idhammar, Idcon
In the best manufacturing organizations, maintenance, operations, and engineering work in a close partnership. In poorly performing plants, it is typical that production, maintenance, and engineering organizations work in silos without much cooperation. In this series of three sessions, you'll learn how to foster the kind of partnership organization that improves equipment and process reliability while lowering total life cycle costs.
Tuesday, 1:30-2:15 p.m.
Bridging the Gap: Communicating Motor Reliability to Management
Noah Bethel, PdMA Corp.
"It's not the Motor!" just doesn't cut it anymore in today's highly advanced maintenance and reliability world. Convincing management
to spend money on reliability for a motor that is running just fine requires a higher degree of communication than merely pointing fingers. From reliability technicians and engineers to reliability supervisors and management, a common communication protocol can increase the understanding of a reliability situation and make these expensive decisions easier. By focusing on the six fault zone approach, this paper will "bridge the gap," providing insight into one of the largest problems faced in analyzing electrical equipment: Accurately identifying where the true problem exists. Once identified, it is imperative that these issues are communicated to management efficiently and effectively.
Tuesday, 1:30-2:15 p.m.
Soft Foot Issues
Dieter Seidenthal, Ludeca
Tuesday, 1:30-2:15 p.m.
Creating Precision Machinery Lubrication Practices - Part 1
Mike Johnson, AMMRI
Oil is oil and grease is grease—right? Fortunately, the answer is a resounding NO! There was a time when companies left the health of the machine lubrication practices to the local brand licensee, but with the growth in awareness of the benefit of precision maintenance practices, companies have markedly improved foundational requirements for a variety of routine activities, including that of machine lubrication. Perhaps it is time for your organization to tune up and document your effective practices. This half-day seminar can help you understand how to define, detail, and document comprehensive machine lubrication practices.
Tuesday, 2:20-3:05 p.m.
The Partnership Organization - Part 2
Christer Idhammar, Idcon
In the best manufacturing organizations, maintenance, operations, and engineering work in a close partnership. In poorly performing plants, it is typical that production, maintenance, and engineering organizations work in silos without much cooperation. In this series of three sessions, you'll learn how to foster the kind of partnership organization that improves equipment and process reliability while lowering total life cycle costs.
Tuesday, 2:20-3:05 p.m.
The Maintenance Control Cycle
Robert Kertis, Fluor
The maintenance control cycle provides a feedback system to improve the maintenance organization by establishing and following simple procedures and guidelines. It can be applied no matter the level of complexity of software systems used. Feedback is provided on all phases of work, including: Work request, estimating, planning, execution, performance reporting, analysis, and history.
Tuesday, 2:20-3:05 p.m.
Arc Flash Hazard Risk Assessment
Richard Shirer, Baxter Healthcare
This session reviews the process of conducting an arc flash hazard risk assessment to meet the requirements of NFPA 70E Standard for Electrical Safety. Included is guidance on identifying arc flash hazards, data collection, and corrective actions to meet requirements.
Tuesday, 2:20-3:05 p.m.
Creating Precision Machinery Lubrication Practices - Part 2
Mike Johnson, AMMRI
Oil is oil and grease is grease—right? Fortunately, the answer is a resounding NO! There was a time when companies left the health of the machine lubrication practices to the local brand licensee, but with the growth in awareness of the benefit of precision maintenance practices, companies have markedly improved foundational requirements for a variety of routine activities, including that of machine lubrication. Perhaps it is time for your organization to tune up and document your effective practices. This half-day seminar can help you understand how to define, detail, and document comprehensive machine lubrication practices.
Tuesday, 3:10-3:55 p.m.
Break – Exhibition Open
Tuesday, 4:00-4:45 p.m.
The Partnership Organization - Part 3
Christer Idhammar, Idcon
In the best manufacturing organizations, maintenance, operations, and engineering work in a close partnership. In poorly performing plants, it is typical that production, maintenance, and engineering organizations work in silos without much cooperation. In this series of three sessions, you'll learn how to foster the kind of partnership organization that improves equipment and process reliability while lowering total life cycle costs.
Tuesday, 4:00-4:45 p.m.
Digital Imaging
Clint Del Valle, Honeywell
Using only a basic digital video camera setup, some inexpensive software, and a little imagination, reliability engineers at Honeywell have opened a whole new world of analysis and problem solving.
Tuesday, 4:00-4:45 p.m.
Professional Certification and You
Jack Nicholas
Learn about the value of professional certification, programs available, and what you need to do to become certified.
Tuesday, 4:00-4:45 p.m.
Creating Precision Machinery Lubrication Practices - Part 3
Mike Johnson, AMMRI
There was a time when companies left the health of the machine lubrication practices to the local brand licensee, but with the growth in awareness of the benefit of precision maintenance practices, companies have markedly improved foundational requirements for a variety of routine activities, including that of machine lubrication. Perhaps it is time for your organization to tune up and document your effective practices. This half-day seminar can help you understand how to define, detail, and document comprehensive machine lubrication practices.
Tuesday, 4:45-6:30 p.m.
Reception – Exhibition Open
TOP
Wednesday, 8:00-9:00 a.m.
Keynote Session: Making the Business Case for Reliability
Peter Martin, Invensys
Exercising your influence often means learning to think and communicating
differently—in the language of management. You won't want to miss this special keynote session to learn about how you can sell your ideas to management, get approval for your projects, and further your reliability objectives.
Wednesday, 9:00-10:00 a.m.
Break – Exhibition Open
Wednesday, 10:00-10:45 a.m.
Mismanaging Complex Change
Scott Franklin, Life Cycle Engineering
All too often, corporate initiatives designed to change the way we do business lose focus and energy and are remembered as a brief flurry of excitement and activity that started strong and fizzled just as quickly. For most initiatives, there is no worry of success because complex change is, well, complex, and the initiative will find one or more of the usual roadblocks naturally. In critical cases where success may be a possibility, it is important to understand how to shove defeat into the jaws of victory! In this humorous presentation on perfecting the "program of the month," you will learn the secrets of how to kill off intrusive corporate initiatives with stunning speed and (most importantly) with no direct connection to you!
Wednesday, 10:00-10:45 a.m.
Introduction to Cause Mapping
Mark Galley, ThinkReliability
Cause mapping is a visual-thinking system for identifying cause-and-effect relationships for solving complex problems. This session introduces the concepts involved and the basic methodology. A full-day workshop on cause mapping on Thursday will teach the techniques for putting it into practice.
Wednesday, 10:00-10:45 a.m.
Financial Impact of Improving Equipment Reliability - Part 1
James Netzel, JPN Consultants
Improving mean time between repair of equipment can lead to substantial
savings for the user. This presentation will focus on identifying causes for failure and the use of the latest sealing technology to improve performance of pumping equipment. Case studies of savings through increased reliability and reduced cost of ownership are presented.
Wednesday, 10:00-10:45 a.m.
Role of the Overhaul Coordinator
Laren Huntsman, PacifiCorp
Plan, execute, measure, and correct—these are the four phases of every overhaul. Certain activities and objectives need to be accomplished during each phase. The overhaul coordinator must effectively communicate
expectations associated with each phase and require accountability for the successful completion of activities and objectives. In addition to fundamental project management skills, the overhaul coordinator needs to be proficient in change management. Excellent interpersonal skills help influence members of the overhaul team toward achieving success in their overall objectives. Another imperative function of the overhaul coordinator is having a clear focus of the entire overhaul scope. This perspective is crucial for coordination of various department activities and in identifying areas that need additional consideration.
Wednesday, 10:50-11:35 a.m.
PM Optimization: Understanding the Costs of a Preventive Maintenance Program
Kenny Myers, ISP Chemicals, Inc.
At ISP, our ultimate goal is to arrive at a place where our predictive (condition based) maintenance techniques are the determining factor in scheduling maintenance activity and reliability is the focus of the production organization. This session describes how we went about changing our reliability culture and the lessons we learned along the way.
Wednesday, 10:50-11:35 a.m.
World-Class Equipment Reliability
Ed Ray, Dofasco
Developing a state of world-class equipment reliability in Dofasco is an effort involving the restructuring of all manufacturing business units and redefining roles and responsibilities for about 2000 maintenance and technology personnel. This session presents the business drivers, strategy, management structure, and other aspects of this ongoing project.
Wednesday, 10:50-11:35 a.m.
Financial Impact of Improving Equipment Reliability - Part 2
James Netzel, JPN Consultants
Improving mean time between repair of equipment can lead to substantial savings to the user. This presentation will focus on identifying causes for failure and the use of the latest sealing technology to improve performance of pumping equipment. Case studies of savings through increased reliability and reduced cost of ownership are presented
Wednesday, 10:50-11:35 a.m.
Getting the Most from Root Cause Failure Analysis
Steve Fox, Aera Energy
RCFA is a powerful tool that often falls short of its promise. Learn how Aera Energy, a North American Maintenance Excellence Award winner, applies RCFA to tackle equipment failures and process upsets.
Wednesday, 11:40 a.m.-12:25 p.m.
Operator and Mechanic Leveraged Training
Karen Simmons, Dupont
Prior to 2004, Dupont plants were using over 8000 different, but overlapping, training courses to train its operators and mechanics. Skill levels were declining, and the need to hire and train a substantial turnover of the workforce was looming. Learn how the company developed a program to build and deploy a single, optimized training curriculum and the results achieved so far.
Wednesday, 11:40 a.m.-12:25 p.m.
When, How, and Why To Go Wireless
Jeff Kleban, Syclo
It's easier and less expensive than ever to implement wireless technologies for a variety of purposes in industrial plants. This session
will focus on the do's and don'ts of building a mobile strategy as well as explain the different flavors available in networks, devices, and mobile application platforms.
TOP
Wednesday, 12:25-1:30 p.m.
Lunch – Exhibition Open
Wednesday, 1:30-2:15 p.m.
Best Practices in Continuous Improvement
ARC Advisory Group
A new research study reveals many of the factors that contribute to the success or failure of a continuous improvement culture. If you want to foster CI in your organization, you'll benefit from these findings.
Wednesday, 1:30-2:15 p.m.
On-Line Condition Monitoring: Using Real-time Data To Predict and Prevent Failures
Craig MacKenzie, Matrikon
Wednesday, 1:30-2:15 p.m.
Infrared Technologies: New Developments in Infrared Cameras and Infrared Viewing Ports
Charles Rolek, Sun Infrared Technologies
This presentation reviews the options available with new, cutting-edge infrared camera technology and discusses what resolution may be the correct choice for your application. Temperature spot sizes with different camera resolutions will be demonstrated. Session includes discussions and demonstrations of the options available for infrared windows and infrared ports when performing surveys on high- and medium-voltage electrical switchgear.
Wednesday, 2:20-3:05 p.m.
Baby Steps Lead to Giant Strides in Implementing a Reliability Program
James Amendola, BE&K
No reliability program can be successful if the maintenance staff refuses to buy in. This presentation suggests a number of practical methods that have worked to convince project staff that changes are valuable for them as well as for their employer. These opening steps are small, but by winning the support of the maintenance staff, they permit the major improvements of a reliability-based program to make great strides.
Wednesday, 2:20-3:05 p.m.
HazCom and Flammable Liquid Storage
Robert Ernst, J.J. Keller & Associates, Inc.
What OSHA rules affect maintenance operations? Are you allowed to store gasoline in plastic containers? What does OSHA say about labeling of products you can buy at the local hardware store? Learn about these topics, and more, during a presentation by a trainer who specializes in OSHA's hazard communication standard and hazardous materials.
Wednesday, 3:05-4:00 p.m.
Break – Exhibition Open
Wednesday, 4:00-4:45 p.m.
Panel: Award-Winning Practices
Wrap up your conference experience with an inspiring discussion on the kinds of practices that make award-winning maintenance organizations stand above the rest. Ask your questions about best practices—or whatever else comes to mind. You'll find our experts enlightening.
