Services Portfolio I-care

SERVICES PORTFOLIO

Improve your maintenance thanks to I-care:

Make sure that you comply with international standards (FDA, ISO, WANO etc.)Reduce non-scheduled shut-downs/Optimise scheduled shut-downsDecrease your environmental and safety risksReduce your maintenance costs

I-care works every day in partnership with all types of industries:

Process: pharmaceutical, chemical, petrochemical and foodEnergy: nuclear, cogeneration, wind powerExtraction: cement and quarryingOEM: machine manufacturers...

What are the guarantees of success with I-care?

European Leader with a presence in 7 countries, more than 60 engineers and 70 partners guaranteeing you local implementation of global maintenance.Sharing of experience and references with more than 100 satisfied customers Technical excellence gained over more than 10 years of industrial successMeasurement and taking account of your returns on investment

In short, I-care means proven industrial results!

Excellence in reliabilitySupportStock optimisationEnergy EfficiencyTPM & improvement in OEEReliability engineeringLong-term operationExcellent lubricationCMMS/EAMTraining

Equipment in serviceCorrective actionsCommissioningExpert ReportsSupportTrainingProducts

I-care Headquarters

Rue R. Descartes 187000 Mons - Belgium

T. +32 (0)65 45 72 [email protected]

1. EQUIPMENT IN SERVICE...........................................................................................6Periodic vibration measurements...............................................................................................7Thermographic Controls - Qualitative measurements..............................................8Leak Detection...........................................................................................................................................9Remote analysis - Route Measurement...............................................................................10Remote analysis – Online measurement..............................................................................11Oil Analysis......................................................................................................................................................12

2. CORRECTIVE ACTIONS...............................................................................................14Balancing ........................................................................................................................................................15

Laser Alignment .......................................................................................................................................16

3. COMMISSIONING.......................................................................................................18Before start-up...........................................................................................................................................19During start-up...........................................................................................................................................20Checks on systems under vacuum or under pressure...........................................21

4. EXPERT REPORTS......................................................................................................22Identifying the root causes of failure ....................................................................................23

5. PRODUCTS ...................................................................................................................24

6. TRAINING .......................................................................................................................25

PART 1: CONDITION MONITORING

1. RELIABILITY EXCELLENCE .....................................................................................28Reliability Excellence...............................................................................................................................29Reliability audit...........................................................................................................................................30Project Management for reliability............................................................................................31Creation/optimisation of maintenance plan.....................................................................32Criticality analysis.....................................................................................................................................33Integrating predictive maintenance...........................................................................................34Planning and workload.........................................................................................................................35

2. SUPPORT.........................................................................................................................36Planner, scheduler ...................................................................................................................................37

3. INVENTORY OPTIMISATION..................................................................................38Inventory audit ..........................................................................................................................................39Inventory definition and optimisation ...................................................................................40

4. ENERGY EFFICIENCY ................................................................................................42Energy audit & mapping.....................................................................................................................43Studying improvements ....................................................................................................................44

5. TPM AND IMPROVING OEE .................................................................................46OEE.......................................................................................................................................................................47

6. RELIABILITY ENGINEERING ....................................................................................48ROMSI ..............................................................................................................................................................49FMECA...............................................................................................................................................................50

7. LONG TERM OPERATION........................................................................................52Long term operation..............................................................................................................................53

8. LUBRICATION EXCELLENCE...................................................................................54Lubrication audit.......................................................................................................................................55Setting up a lubrication plan..........................................................................................................56

9. CMMS/EAM ................................................................................................................58CMMS Audit.................................................................................................................................................59

10. TRAINING........................................................................................................................60

PART 2: RELIABILITY

Do it for you

Do it with you

Drive youto do it

We guide and advise you in the application of methods and techniques

We train you to implement them in the most appropriate manner

We help you at all operational and strategic levels

We support you on an ad hoc or continuous basis

We are a day-to-day partner within your teams

We adapt day-to-day to your environment

We apply our or your methods with you

We transfer techniques and methods to you naturally

We take on full responsibility for all actions

We are self-sufficient in all our techniques and methods

We communicate regularly on actions and results

We work in compliance with quality standards and in complete safety

3APPROACHESWhatever the technology, or the type of project chosen, our entire team of engineers is here for you.

Expe

rt Re

ports

Commiss

ioning

Supp

ort

Train

ing

Prod

ucts

Thermographic controls

Leak detection

Steam trap operation analysis

Remote analysis/On-line

Oil Analysis

Electrical measurements

Combustion engine measurements

Balancing

Laser alignment

Checks on systems under vacuum or under pressure

Fault diagnosis

Search for root causes of failure

Modal Analysis/ODS

Vibration Analysis

2. Commissioning

3. Routine

4. Ageing

1. Design

Main Category

CONDITIONMONITORING

Equip

men

t in service

Corre

ctive

action

s

PART 1

Prod

ucts

EQUIPMENT IN SERVICE

PERIODIC VIBRATION MEASUREMENTSTHERMOGRAPHIC CONTROLS - QUALITATIVE MEASUREMENTS

LEAK DETECTIONREMOTE ANALYSIS - ROUTE MEASUREMENT

REMOTE ANALYSIS - ONLINE MEASUREMENT

OIL ANALYSIS

Condition Monitoring

CONTEXT

OUR METHOD

DELIVERABLES

Detection of failures before they occur

Avoids unscheduled shutdowns

Ensures equipment reliability

Identification of a problem and location on the equipment

Priority definition for each default

A detailed report is submitted to the client with identification of each instance of vibration on the equipment

A summary table is provided showing in order of priority each fault detected on an item of equipment together with the action to be taken in each case

Periodic vibration measurements

Use of expert equipment with customised configuration optimised for each facility

Continuous professional training of our engineers

Use of PeakVue™ patented technology enabling detection of a fault 6 months before a failure occurs

Periodic on-site measurements at least quarterly

7

CONTEXT

OUR METHOD

DELIVERABLES

Identify all instances of heat released within a process

Leak detection in a steam circuit

Damage to a bearing

Electrical fault

Operation of a steam trap

Measurements of the heat emitted by any item of equipment using a thermographic camera

Identification and location of occurrences

Comparison of the equipment components to assess the seriousness

A detailed report with infrared and visible images of the occurrences is submitted with a description of the default, its location and level of importance

A summary table of the faults is also provided showing the order of priority and the action to be taken in each case

Thermographic controlsQualitative measurements

8

CONTEXT

OUR METHOD

DELIVERABLES

Detection of gas leaks

Quantification of the volume leaking

Determination of the annual financial loss

Survey of the leak-tightness of circuits under pressure in service using ultrasound detection

Survey of the leak-tightness of a system under vacuum using an ultrasound generator and detection system

A detailed report is submitted to the client in order to ensure correct operating conditions or, if applicable, to suggest improvements in order to maximise the service life of the equipment

Identification on a data sheet of the sensitive points in the circuit

Financial study in order to quantify the financial loss associated with the leaks

Leak detection

9

CONTEXT

OUR METHOD

DELIVERABLES

Provide an analysis with a high level of expertise and optimum responsiveness

Help you when a peak load on your team occurs in the field

Provide analysis support

Systematic analysis

Use of analysis software linked to your monitoring system (any brand)

Remote spectrum analysis

Precise fault diagnosis

Priority definition for each faults depending on seriousness

Use of a portal accessible to all and simple, efficient read-out of indicators and conclusions

Diagnosis within 24 hours

Supply of effective, simplified indicators

Summary table of the main faults and action to be taken in each case

Supply of a detailed diagnosis illustrated with the main graphs for each item of equipment

Remote analysis - Route measurement

10

CONTEXT

OUR METHOD

DELIVERABLES

Ensure the monitoring of your critical equipment at any moment

Provide an analysis with a high level of expertise and optimum reactivity

Provide remote support to your maintenance teams

Use of analysis software linked to your monitoring system (any brand)

Supply, installation, configuration and implementation of a customised online solution

Remote spectrum analysis

Precise fault diagnosis

Use of a portal accessible to all at any time

Use of trends to provide simplified monitoring in the control room

Periodic measurements conducted on request

Monitoring of trends

Diagnosis of the fault when an alert level or alarm is triggered

Diagnosis within 24 hours

Supply of effective, simplified indicators

Summary table of the main faults and action to be taken in respect of each machine


Remote analysis – Online measurement

11

CONTEXT

OUR METHOD

DELIVERABLES

Identification of anomalies appearing inside machines (wear and damage)

Detection of contamination in the lubricant

Definition of the chemical condition of your lubricant

Plan the maintenance interventionwork as soon as possible

Analysis and monitoring of the chemical properties of the lubricant (viscosity, dielectric, water, additives, type of oil, ...)

Analysis and monitoring of the wear particles (number, size and type of wear particles)

Analysis and monitoring of the external contaminants

Supply of a report with a table summarising the actions depending on the priorities

Summary table of the main faults and action to be taken for each machine


Oil Analysis

12

CORRECTIVE ACTIONS

BALANCINGLASER ALIGNMENT


CONTEXT

OUR METHOD

DELIVERABLES

Reduce the vibrations due to a problem of imbalance on the equipment

Increase the lifetime of the equipment

Reduce in the electricity consumption

Preliminary vibration measurement on the equipment

Balancing of the machine using weights screwed on, welded on, etc. (depending on the features of the equipment)

Acceptance measurement in order to verify the balancing

A detailed report is submitted to the client in order to ensure a reduction of the vibrations

Service provided on site without moving the equipment

Balancing

15

CONTEXT

OUR METHOD

DELIVERABLES

Reduce the vibrations and internal forces created by misalignment

Prevent premature wear on the bearings and all mechanical components in the equipment

Reduce energy consumption

Prior vibration measurement on the equipment if possible

High precision laser alignment of the equipment, whatever the configuration of the machine

Elimination of angular and parallel misalignment using shims

A detailed report is submitted to the client in order to ensure elimination of the misalignment

Energy savings and improved service life of the equipment

Laser alignment

16

COMMISSIONING

BEFORE START-UPDURING START-UP

CHECKS ON SYSTEMS UNDER VACUUM OR UNDER PRESSURE


CONTEXT

OUR METHOD

DELIVERABLES

Ensure that the start-up conditions are correct and that the equipment will therefore work properly

Check the equipment and register the guarantee of the equipment with the supplier or manufacturer

Check the alignment of the moving parts

Check the levelness and overall geometry of the equipment

Check the balancing of the machine


Before start-up

19

CONTEXT

OUR METHOD

DELIVERABLES



Vibration Analysis performed at start-up in order to ensure there is no prior fault

Temporary continuous monitoring in order to ensure that the run-in curves are properly

followed

Thermographic monitoring to ensure that the equipment temperature rises correctly

Check that the mechanical tolerances are complied with in operation

During start-up


20

CONTEXT

OUR METHOD

DELIVERABLES



Check the leak-tightness of the equipment

Survey of the leak-tightness of circuits under pressure in service using ultrasound detection

Survey of the leak-tightness of a system under vacuum using an ultrasound generator and detection system


Identification on a data sheet of the sensitive points in the circuit

Financial study in order to quantify the financial loss associated with the leaks

Checks on systems under vacuum or under pressure

21

EXPERT REPORTS

IDENTIFYING THE PRIMARY CAUSES OF FAILURE


CONTEXT

OUR METHOD

DELIVERABLES

Identify the root cause of a fault causing a shut-down of the equipment

Propose technical solutions in order to prevent new occurence of this fault

Use of advanced mechanical diagnosis methods

Visual analysis of the components

Analysis of the occurrence and recurrence of the failures in the past

Discussion with the various parties involved (users of the equipment, manufacturer, ...)

Study of the loads and various parameters applied to the equipment

A detailed report is submitted to the client with identification of each fault and determination of the primary causes of this fault

Clear and effective advice on preventing recurrence of the fault is provided in the report

Identifying the root causes of failure

23


PRODUCTS

As l-care is above all a service company, we think it is important to give you the necessary tools to be able to optimise the use of the different predictive maintenance tools.

For this reason, l-care is linked to the major manufacturers of equipment in these various fields in order to offer you the best, customised solution for each situation.

Our company has a department dedicated to the supply of equipment and identification of the best technical solution depending on the specifics of each company and acting indepen-dently of the supplier.

For further information, please consult our dedicated brochure, which is also available on our website. We also have a web platform dedicated to the supply of equipment where you will find all the information you require: www.conditionmonitoringtools.com.

If you have a specific question or require a quotation, please contact us on +32 (0)65.45.72.14 or at the following email address: [email protected].

24


TRAINING

In order to provide you with the tools and weapons necessary to confront the different problems associated with predictive maintenance and the optimisation of reliability, I-care has developed its own technical training programme. These training courses focus on different topics associated with such problems, with the aim of enabling you to become independent in one or more fields.

For this reason, the training courses are delivered by l-care employees specialising in each field and working in it on a daily basis. Thanks to this approach the tools and advice provided are not simply theoretical, but also close to the reality on the ground in every type of industry.

The courses are also suitable for any audience at all levels in the company. We can also provide you with a certificate of the completion of the course and an exam allowing you to be ISO certified in the case of some courses.

Finally we can offer the course on your site, at your premises or at our premises if necessary.

For further information please consult our training course brochure which contains details of all courses.

Please also visit our dedicated website: www.reliabilityschool..eu or email us at [email protected].

25

Reliab

ility Ex

cellenc

e

Supp

ort

Energy

Ef cie

ncy

Stoc

k op

timisa

tion

TPM and

improvem

ent in OE

E

Reliability

eng

ineering

Long

-term

ope

ratio

n

Excellent lu

brica

tion

CMMS/

EAM

TRAINING

CMMS audit

Reliability audit

Creation/optimisation ofmaintenance plan

Criticality analysis

Integrating predictive maintenance

Planning and workload

Process operator, Scheduler

Stock Audit

Stock definition and optimisation

Energy audit & mapping

Study of energy improvements

OEE

SMED

FOMSI

FMECA

Long-term operation

Lubrication audit

Lubrication plan

Project Management for reliability

2. Commissioning

3. Routine

4. Ageing

1. Design

Short-term Medium-term Long-term Adaptable Main Category

RELIABILITYPART 2

CMMS/

EAM

TRAINING

RELIABILITY EXCELLENCE

RELIABILITY EXCELLENCERELIABILITY AUDIT

PROJECT MANAGEMENT FOR RELIABILITYCREATION/OPTIMISATION OF MAINTENANCE PLAN

CRITICALITY ANALYSISINTEGRATING PREDICTIVE MAINTENANCE

PLANNING AND WORK LOAD

Reliability

CONTEXT

Maintenance costs too high, not controlled

Non-optimised maintenance strategy (too curative and/or too preventive)

Very restrictive regulation (environment, GMP)

Limited resources and a strongly anchored emergency culture

Maintenance far from reality on the ground, few referenced parts

Complex organisation (flow), multiple roles

Reduction in technical knowledge of your facilities

Difficulty in perpetuating the culture of continuous improvement

OUR METHOD

DELIVERABLES

EVALUATION OF RELIABILITY

CRITICALITY ANALYSIS

BREAKDOWN RECURRENCE

STUDY

FMECA

OPTIMISED AND RATIONAL MAINTENANCE PLAN

UP-TO-DATE PARTS LIST

INTEGRATING PREDICTIVE

OPTIMISED SCHEDULING ACCORDING TO YOUR RESOURCES

REDUCTION IN COSTS/WORKLOAD

+

+

+

+

++++

=Criticality analysis

Fault analysis

Definition/Revision of maintenance strategy

Maintenance Plan that is consistent with

the reality on the ground and high-performance

Standardised maintenance procedures

Rational integration of predictive maintenance

Training/raising awareness of those involved

Identification of sources of waste/loss

Dynamic vision of maintenance performance (KPI)

Planning of tasks and evaluation of the workload

Analysis of costs and benefits of solutions put in place and potential investments

Reliability excellence

29

30

OBJECTIVES

OUR METHOD

DELIVERABLES

To establish the current reliability of the company

Set goals that meet your reality

Propose improvements that are easy to implement, with visible impact aimed at motivating staff to enter into a positive logic of change

Target areas for improvements while remaining faithful to the context of the company

Interview of the key players for reliability in your business

Field Visits

"How do I care?" questionnaire

Flow Analysis

Reliability audit

Summary report in the form of: star graph and axis scoring

Presentation of results

Complete Report including the definition of your goals and action plan

31

Assessment and definition of the framework of the project

Constant knowledge of exact progress in terms of budget, time and quality

Easy identification of progress and delay factors for the relevant actions

Vision that is both global and specific for each task

Standard on-line monitoring tool developed specifically for reliability improvement projects

Simple and relevant KPI

Action follow-up and report sheets, project logbook, time and coding sheets of hours worked

Structured, rapid and effective follow-up meetings for all levels of decision-making: start-up, weekly, monthly, closure

Simple and clear meeting minutes

Project Management for reliability

OBJECTIVES

OUR METHOD

DELIVERABLES

To control all maintenance activities in their entirety or in one part of the plant in terms of keeping to schedule, skills and quality

To best manage the work load and quality control of internal operations and contractors

To ensure optimal machine availability rates

To have an understanding of the means for obtaining good reliability and maintainability of my assets

To control all spare parts and tools used for predictive and preventive maintenance

To ensure consistency in preventive and predictive activities

A complete list of preventive and predictive actions configured for each machine which warrants this (up to around forty parameters available)

A database suitable for an introduction to the CMMS used

A database suitable for calculating the workload, the creation of geo-round, etc.

Standardised maintenance procedures

Involvement of all key players in the industry with suitable communication (Time To Care !)

Functionnalanalysis

Strategicchoice for

MPWalkthrough

MP Strategyadaptation

Sort regardingoperation constraint

Functionnalanalysis

CMMS/tree structure

Technical analysis

Existing documents (maintenance plan)

Logbook of failures

Manufacturer maintenance manual

Administrative and logistic constraints

BOM

Necessary Inputs

Plant

Input


Methods/Tools

Skills/Expertise

Tasks ListsJob ListsCustomer standard library

Occurence- Recurrence analysis

Optimisation

Creation/optimisation of maintenance plan

OBJECTIVES

OUR METHOD

DELIVERABLES

32

What maintenance strategy should be applied to the assets and why?

How can we get all those involved in the industry (safety, quality, production and maintenance) to adhere to the fundamental principles of maintenance operations?

How do you define "the right maintenance" and avoid over- or under-maintenance?

How can budgets/maintenance investment be justified technically?

Mapping of all assets or families of assets through their intrinsic and/or operational criticality

Well thought-through and objective study providing the argumentsneeded to support maintenance and investment strategies

Proposal for definition thresholds of different maintenance strategies

Controlling workload in light of increased risks in relation to threshold slippage

Scope(boundaries)definition

Raw eqptlist

Definedscope

Assets List/Study Level validation

No

Yes

Establishment of the assets

List/study level

Yes Yes

No No

Parameters/scale definition

Parameters/scale validation

MatrixCreation/Filling

ResultsReview/formatting (Graph)

Resultspresentation

Criticality mapping of the plant/line/Building

PARAMETERS: Safety Environment Quality Production Maintenance Business


OBJECTIVES

OUR METHOD

DELIVERABLES

33

OBJECTIVES

OUR METHOD

DELIVERABLES

CriticalityAnalysis

Raw eqptlist

Existence of a criticality analysis?

Establishmentof the equipment list?

Equipmenttechnology

matrix

ROIsimulation

Optimazed &predictive maintenance

plan

PDMIntegration

Economicalfaisabilitystudy

Technicalfaisabilitystudy

CriticalityAnalysis

No

Yes

What set of assets is eligible for the integration of predictive maintenance?

How can the best monitoring techniques/methods be selected?

What about technical feasibility?

How much will it cost? How much is this likely to yield? Is it profitable? How can the impact of short- and long-term integration of these new measures be measured?

What are the flows necessary for using the data and the sustainability of the project?

Controlling costs related to set-up in order to support the approach on an economic basis (CBA/ROI)

A method for determining the application framework for predictive maintenance techniques on a technical basis (criticality, recurrence/occurrence of faults, FMECA)

A complete structure of predictive actions configured for each machine which warrants this (equipment/technology matrix + flow of predictive maintenance integrated into the existing maintenance plan)

A database suitable for an introduction to the relevant CMMS

Involvement of all those involved in the industry with suitable communication

Integrating predictive maintenance

34

To quantify and organise your preventative and corrective maintenance interventions, major shut-downs, ...

Plan your monthly, quarterly, yearly, etc

Coordinate your maintenances with regard to production and other constraints

Smooth out your workload per person, team, area, etc

Data validationAnalysisMethod definitionCustomer’s needs identification

TranspositionScheduling optimization

Validation meetingImplementation

Schedule overhaul Smoothed organisation of your work load

Planning and work load

Carefully designed micro- and macro-schedules

A discussion medium for agreement between maintenance and production

A visual tool that is flexible according to changes in technical and human constraints

OBJECTIVES

OUR METHOD

DELIVERABLES

35

SUPPORT

PLANNER, SCHEDULER

Reliability

OBJECTIVES

OUR METHOD

DELIVERABLES

Managing daily maintenance activities

Planning and preparation for periodic shut-downs

Integration into your team of process operators/schedulers and your methods

Autonomous replacement of your or your process operator(s)

Adapting to your needs with input from our expertise, our external view, our precision and sense of priorities

Use and mastery of tools for monitoring projects and the main CMMS

Receipt and prioritisation of work requests

Creation and modification of work requests in the CMMS

Processing of requests in order of work with allocation and planning of the task

Analysis of the team's workload and monitoring of KPIs

Creation and modification of the maintenance plan in the CMMS

Managing how interventions run in collaboration with production

Managing tooling and PPE, reserving and preparing parts

Proposal requests and encoding of articles in the CMMS

Orders and follow-up of parts and equipment

Managing sub-contracting

Carrying out site meetings, including the safety aspect

Drawing up work permits

Planner, Scheduler

37

INVENTORY OPTIMISATION

INVENTORY MANAGEMENTINVENTORY DEFINITION AND OPTIMISATION

Reliability

OBJECTIVES

OUR METHOD

DELIVERABLES

Establish the current level of inventory management of your business

Identify opportunities for improvement in the management of inventories over different periods of time depending on your expectations:

Short-term Medium-term Long-term

TrainingOrganisation of the

spare parts database

Adaptation or carrying out facilities'

maintenance plans

Organisation of the storeStandardisation of spare part

names

Producing equipment

spare parts lists

Setting up

procedures and KPIs

Definition of stock levels based

on the current situation and on

an historical basis

Definition of stock levels based on

the actual use of the

equipment (criticality, predictive,

preventive and curative maintenance,

etc.)

Set realistic improvement goals in relation to your needs and your resources

Interview based on quick questionnaires of the key players in the management of inventory in your company

Field visit to your facilities and your storage areas

Detailed analysis of stock management set up on a representative sample of your facilities

Summary report in the form of star diagrams and axis scoring


Complete Report including the definition of your goals

Proposal for an action plan including "Quick Wins" and specific actions

Inventory management

39

OBJECTIVES

OUR METHOD

DELIVERABLE

Highlighting storage costs Rationalisation of the quantities put into stock

Reduction in storage costs Reduction in the risk of stock shortages

Improving store ergonomics Improvement in picking time

Organisation of the store Management of the database Managing restocking

Staff awareness-raising

Structuring the store tailored to needs

Improvement in ergonomics for the staff

Establishment of a system forcontinuous monitoring of articles

Setting up procedures suitable for the operation of the store

Establishing KPI

Updating the database of articles (cost, deadlines)

Standardisation of labels for existing articles

Highlighting duplicates

Setting up a robust process for article creation

Supplier rationalisation

Optimisation of the quantities in stock according to the action needs of the company (existing maintenance plans, l ists of spare parts for faci l ities, criticality, etc.)

Anticipating consumption by studying previous consumption

Database M

anagem

ent

Warehouse Organization

Inventory Optimization

Resu

pply M

anag

ement

Inventory definition and optimisation

40

ENERGY EFFICIENCY

ENERGY AUDIT & MAPPINGSTUDY OF IMPROVEMENTS

Reliability

OBJECTIVES

OUR METHOD

DELIVERABLES

To highlight the efforts needed to achieve a sufficient level of energy efficiency

To highlight the distribution of energy consumption by energy vector and by equipment

Energy performance questionnaire

Detailed listing of the different energy vectors

Quantification of consumption by vector

Comparison of energy systems in relation to a benchmark threshold

Audit and energy mapping

Energy Audit

How:• From customer info (invoices,

old readings)• From readings on site or ad

hoc measurements

Energy Mapping

How:• Monitoring from meters• Analysis of consumption graphs

OUR

STUDIE

43

Vector EquipmentCosts (€/

year)

Steam Steam Generator 43,800

Compressed Air Compressor ...

Electricity Engine ....

Building lamps 560.64

Cold Chiller ....

Compressed Air

Electricity

Steam

Heat

Cold

OBJECTIVES

OUR METHOD

DELIVERABLES

Select, quantify and implement energy improvements

Pre-requisite: audit results

Identification of Quick Wins and long-term gains

Feasibility Study

Estimate of cost savings

Estimate of investments

Calculation of the return on investment

Overview of Quick Wins and long-term gains identified

Costed returns on investment

Technical monitoring of project implementation

Improvement Equipment Economy Investment RSI

Replace engine Compressor, engine x €/year X’ € X’’ Months

Regulation Compressor, regulation Y €/year Y’ € Y" Month

Insulate pipes Pipes Z €/year Z’ € Z" Month

Repair leaks Leaks ZZ €/year ZZ’ € ZZ" Month

Study of improvements

44

TPM & IMPROVEMENT IN OEE

OEE

Reliability

CONTEXT

OUR METHOD

DELIVERABLES

Production line displaying:

Micro-shutdowns or recurrent faults

Too much scrap or products of lesser quality

Repair service calls that are too long

Little maintenance or monitoring

Changes in size/production that are too long

Unsuitable maintenance planning

OUR CONTRIBUTION:

Analysis of OEE

Choosing and setting up methods & tools

Drawing up and submitting appropriate deliverables

YOUR REALITY:

Your goals:

Availability

Performance

Quality

Modification of working methods

Process control

Increase in output

Initial Situation:Determination/

Evaluation

Final situation:Revision/

Improvement

Con

tinu

ous

Impr

ovem

ent

SMED: Reduction in the time to change over

FMECA: Analysis of failure modes, their effects and their criticality

5S: Safety marking, labelling, organisation

Maintenance Strategy: Predictive, preventive, scheduling, metering, etc

Inventory Management: parts available in sufficient quantity

Study linked to reliability: Machine Improvements

OEE

Batch1

Batch 2

Batch 3

Batch 4

Batch 5

Batch 1

Batch 2

Batch 3

Batch 4

Batch 5

Batch 6

Batch 7

Batch 8

47

RELIABILITY ENGINEERING

ROMSIFMECA

Reliability

OBJECTIVES

OUR METHOD

DELIVERABLES

Obtaining operational equipment right from commissioning

Optimising availability (optimising time for service interventions & minimising faults)

Risk reduction

Improvement of organisation (Inspection & maintenance)

Identifying weak points and strengths of the equipment

Recommendations for control of maintenance

Techno-economic analysis by recommendation

Prioritisation

ROMSI Evaluation Matrix

Research & Engineering department/maintenance communication channel

Anticipating maintenance in the specifications

Integration of RAMS concepts (Safety and Availability through Reliability and Maintainability)

ROMSI Evaluation Grid

ReliableRobustness/Quality

OperableFunctionality

MaintainableErgonomics/Accessibility

SureControl of risks

Integration of safety systems

InspectableReadability

ROMSI

Start-up Period

OverallEquipment

Output

Number of faults

OverallEquipment

Output

Inst

allation

Objective

OverallEquipment

Output

Number of faults

OverallEquipment

Output

Inst

allation

Objective

Reduction in the period forramp-up

Reliability in design

ROMSI

49

OBJECTIVES

OUR METHOD

DELIVERABLES

Creation or improvement of a tailored maintenance plan

Adapt existing preventive and predictive maintenance tasks depending on the criticality of the failure modes

New equipment or existing equipment

Appropriate maintenance plan and adjustment of preventive and predictive

maintenance tasks

Functional breakdown of equipment

Definition of the effects of failures

Establishment of failure modes

Determination of fault detection modes

Definition of the criticality of failures

Criti

calit

y

Det

ectio

nm

ode

Effe

cts

Failu

re

mod

e

Better knowledge of failure modes, of their effect(s) and their criticality

Tailored maintenance

Improvement in maintenance time management

Eradicating over-maintenance without incurring risks

ANALYSIS

OF

FAULT

FMECA

50

LONG TERM OPERATION

LONG TERM OPERATION

Reliability

OBJECTIVES

OUR METHOD

DELIVERABLES

Short term

Identification of wear mechanisms

Optimisation of reliability

Medium/Long term

Extending the useful life of your facilities

Increase in availability

Optimising use (capacity factor)

Action plan: Changes to the equipment

Update the maintenance plan

Study of costs: ROI

Definition of priorities according to business, quality, SSE and reliability criteria

• Technical records/Readings on site

• Technology monitoring

• Supplier contacts

• Current use

• Potential for increase of use

• OEE

• Occurrence/Recurrence of faults

• Change History

• Statutory Inspections

Analysis of

obsolescence

Analysis ofCapacity

Analysis ofaging

Long term operation

OUR METHOD

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LUBRICATION EXCELLENCE

LUBRICATION AUDITSETTING UP A LUBRICATION PLAN

Reliability

OBJECTIVES

DELIVERABLES

OUR METHOD

To establish the initial situation by measuring your ability with respect to good practiceregarding the lubrication of machines

To target areas for improvement while remaining faithful to the context of the company

To set goals that meet your reality

To propose improvements that are easy to implement, with visible impacts aimed atmotivating staff to enter into a positive logic of change

Report CBA Action plan

Measurement of the initial situation

SWOT study

Definition of objectives through areas for improvement

List of actions


Summary available in sheet form

Study of the costs and benefits of the imple-mentation of the actions proposed in the report

Definition of priorities

Proposal for an action plan including "Quick Wins" and specific actions

Field Visits

Interview of the key players for reliability in your business

"How do I care?" questionnaire in order to achieve a representative and reproducible assessment of your lubrication practices

Flow Analysis

Lubrication audit

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OBJECTIVES

DELIVERABLES

OUR METHOD

Increase the reliability and the lifetime of your machines

Reduce costs by streamlining types of lubricants and their suppliers, and by controlling consumption

Control the quality of food and non-food lubricants

Oil Store Routes & schedules for Inspection Procedures

• List of lubricants suitable for your needs

• Tailored to your consumption

• Equipped to cope with daily service interventions

• Designed to respect the environment including a lubricant recycling plan

• Inspection rounds• Schedule of

inspections/lubrications

• Procedures for lubrication• Procedures for the

management of the store (cleanliness, handling, etc.) and the oils

• KPIs and continuous improvement

process

• Lubrication procedures• Procedures for the

management of the store (cleanliness, handling, etc.) and the oils

• KPIs and continuous improvement process

Staff Training

Setting up a lubrication plan

PHASE 0

Audit

PHASE 1

Summary

PHASE 2

Setting up the plan

PHASE 3

Storage of

lubricants

PHASE 4

Continuous Improvement and Training

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CMMS/EAM

CMMS AUDIT

Reliability

OBJECTIVES

DELIVERABLES

OUR METHOD

Establish the initial situation by rebuilding your tools and maintenance management processes

Identify the existing tools and processes which are computer-assisted

Targeting areas for improvement to be followed in the creation of tools and processes and/or in the implementation of the existing tools and processes in the system

Know the extent of the possibilities of your CMMS tool and optimise its use

Set realistic improvement goals in relation to your needs and your resources

Inspection of your facilities

Interview based on quick questionnaires of the key players in your technical department and specifically data, encoding and documentation managers

Detailed analysis of your processes and the use made of them in your CMMS tool according to 13 major work areas

Summary report in the form of spider graphs and area grading in two views: existing processes and computer management

Proposal for optimal use of your CMMS, regardless of its brand


Complete report including the definition of your goals and action plan

CMMS Audit

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Reliability

TRAINING

In order to provide you with the tools and weapons necessary to confront the different problems associated with predictive maintenance and the optimisation of reliability, I-care has developed its own technical training programme. These training courses focus on different topics associated with such problems, with the aim of enabling you to become independent in one or more fields.

For this reason, the training courses are delivered by l-care employees specialising in each field and working in it on a daily basis. Thanks to this approach the tools and advice provided are not simply theoretical, but also close to the reality on the ground in every type of industry.

The courses are also suitable for any audience at all levels in the company. We can also provide you with a certificate of the completion of the course and an exam allowing you to be ISO certified in the case of some courses.

Finally we can offer the course on your site, at your premises or at our premises if necessary.

For further information please consult our training course brochure which contains details of all courses.

Please also visit our dedicated website: www.reliabilityschool..eu or email us at [email protected].

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EN-V

1.3

Services Portfolio I-care

Documents

Transcript of Services Portfolio I-care