Anatomy of an Effective PM Program at United Water Springfield
Transcript of Anatomy of an Effective PM Program at United Water Springfield
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Anatomy of an
Effective PM
Program at United
Water Springfield
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Presentation Highlights
¢ PM Basics
¢ Origin of the Springfield Program
¢ Developing the Program
¢ Conclusions
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Effective Preventative Maintenance
What is
Preventative Maintenance?
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Effective Preventative Maintenance
The care and servicing by personnel for the
purpose of maintaining equipment and
facilities in satisfactory operating condition by
providing for systematic inspection, detection,
and correction of incipient failures either
before they occur or before they develop into
major defects
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Effective Preventative Maintenance
Part 1
“care and servicing by personnel for the
purpose of maintaining equipment”
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Effective Preventative Maintenance
Part 2
“inspection, detection, and correction of
incipient failures either before they
occur or before they develop into major
defects”
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Effective Preventative Maintenance
RPM Work Order – A Repair Work Order
generated from the performance of a
Preventative Maintenance Work Order
An important metric to track and helps to
prevent Emergency Work Orders
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Effective Preventative Maintenance
wear on centrifuge discharge port
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Effective Preventative Maintenance
Preventative Maintenance
Program for facility centrifuges
and associated equipment
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Effective Preventative Maintenance
2 Centrifuges were installed in 2008
replacing 4 belt filter presses and
became operational in 2009 as part
of a sludge dewatering upgrade
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Effective Preventative Maintenance
2 Centrysis 21HC Centrifuges
1 Spare Rotating Assembly
Polymer Storage, Makeup, and Pumping
Systems
Conveying Systems – 5 Conveyors
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Effective Preventative Maintenance
Centrifuge Production
40,000 Wet Tons Per Year
@ 25% Solids
Polymer – 14 lbs Active Polymer / DT
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Effective Preventative Maintenance
A great opportunity to start a
PM program from scratch on
new equipment
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Effective Preventative Maintenance
Where do PM’s come from?
¢ Manufacturers Recommendations*
¢ Staff Recommendations
¢ Experience
* To avoid warranty issues
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Effective Preventative Maintenance
Example of Staff Recommendation/Experience:
¢ Metal greased bearings on shafted sludge
conveyors that required monthly maintenance
replaced with nylon bearings that only
required maintenance every six months
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Effective Preventative Maintenance
Example of Staff Recommendation/Experience:
¢ Combine multiple short PM’s into one larger
PM
¢ Shorten or lengthen the time between PM’s
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Effective Preventative Maintenance
Who does the PM?
The person that can add the
most value to the task
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Effective Preventative Maintenance
In general:
Assign 90-day or less PM tasks or
simple PM tasks to your Operators
and free up Mechanics for higher
level functions.
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Effective Preventative Maintenance
Today’s operators are smarter and more
capable than ever before, not only in terms of
formal academic achievement, but relative to
interest and desire to be part of the
maintenance solution.
Avoid the “I operate it, you fix it” mentality!
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Effective Preventative Maintenance
Components of a PM Task
• Accurate Task Instructions (SOPs)
• Job Safety Analysis
• Equipment Specific LO/TO Procedures
• CMMS – Computerized Maintenance
Management System
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Effective Preventative Maintenance Equipment Specific LO/TO Procedure
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Effective Preventative Maintenance
United Water Springfield Job Hazard Analysis
Job: Monthly Centrifuge Polymer Make Up Units PM
Job Description: Perform monthly PM on centrifuge polymer make up units, LO/TO and test equipment, remove flow sensor and clean tip, take apart polymer check valve and clean components
Job Hazards:
1. Ergonomic – bending, standing lifting, congested area 2. Falls – working on elevated platform 3. Stored Energy – process water line under pressure, equipment must be depressurized,
locked out, tagged, and tested 4. Slips and Trips – work area may be wet, polymer is extremely slippery
Hazard Controls:
1. Test LO/TO before starting work 2. PPE – hard hat, safety glasses, safety shoes, gloves 3. Check floor for polymer spills and clean if needed 4. Use proper lifting and bending technique 5. Clean jobsite after completion
Task Related Safety Information
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Effective Preventative Maintenance
Accurate Task Instructions
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Effective Preventative Maintenance
Grease fi(ng for bearing – grease un1l fresh grease comes out of plug hole on opposite side of sha9
Grease fi(ng for sha9 seal – three squirts
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Effective Preventative Maintenance CMMS Program
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Effective Preventative Maintenance
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Effective Preventative Maintenance PM Assignment Board
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Effective Preventative Maintenance
PM Assignment Board Value
• A visual tool that clearly establishes performance expectations
• Promotes accountability
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Effective Preventative Maintenance
11 PM’s Done by Operators 4 day – 1
7 day – 2 30 day – 3 90 day – 1
180 day – 2 365 day – 2 730 day – 2
~191 PM’s Per Year
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Effective Preventative Maintenance
Completion – Failure Rate 2012 to 2014
4 Day PM Conveyors
7 Day PM Centrifuges
30 Day PM Poly Units
30 Day PM Centrifuges
30 Day PM Conveyors
90 Day PM Poly Units
180 Day PM Centrifuges
180 Day PM Hydraulic Units (2)
365 Day PM Belt
Conveyor
730 Day PM Conveyors
730 Day PM Poly Pumps Total
2012 -‐ Completed 88 52 12 12 10 4 2 4 1 1 186 2012 -‐ Failure 3 2 5
2013 -‐ Completed 91 52 12 12 12 4 3 1 1 188 2013 -‐ Failure 2 1 3
2014 -‐ Completed 92 52 12 12 12 4 2 4 1 1 192 2014 -‐ Failure 0
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Effective Preventative Maintenance
Completion – Failure Rate 2012 to 2014
Total PM Work Orders 574 Total -‐ Completed 566 Total -‐ Failed 8 CompleMon Rate 98.6%
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Effective Preventative Maintenance
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Effective Preventative Maintenance
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Effective Preventative Maintenance
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Effective Preventative Maintenance
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Effective Preventative Maintenance
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Effective Preventative Maintenance
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Effective Preventative Maintenance
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Effective Preventative Maintenance
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Effective Preventative Maintenance
Major Centrifuge Maintenance In House – Every 5,000 Hours Back to Manufacturer – Every 15,000 Hours
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Effective Preventative Maintenance
0
10
20
30
40
50
2010 2011 2012 2013 2014
Cent 1 Y Avg
Cent 2 Y Avg
Cent 1 D Avg
Cent 2 D Avg
Shutdown
Alarm
Centrifuge Vibration Levels
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Effective Preventative Maintenance
Conclusions • CMMS System provides strategic value • Whiteboard provides tactical value • Our effective preventative maintenance
program is a very important part of our overall maintenance program
• Use metrics to measure the effectiveness of your program