Tips & Tricks

Maintenance ideas that help save time, money, and aggravation.

08/01/2006


Involve key staff in CMMS training



When implementing a CMMS, it is critical that the work order system is accurate in parts used, cause codes, work types, fault codes, and man hours. This cannot be achieved efficiently without the direct involvement of the maintenance personnel. The solution involves representing the department in the training process and code establishment. It is critical to train someone on each shift to lead the ongoing training required to implement the process. Do not give the training process any less than your best personnel. This will set the tone for the entire improvement process, and the historical information that you can gather in two years will also allow you to understand your MRO stores accurately.

Roger Harris CMRP CPMM, NYPRO Kentucky, Louisville KY

Anchoring machines to concrete:


In a company that’s staying competitive these days, machines come and go or get moved around quite a bit. The way we try to handle anchoring is to drill through the floor with a hammer drill. Our floors are 4 to 6 inches thick, so the drill bit must be long enough. I use a round brush to scrub the hole clean, then blow it out, either with compressed air, or with a short length of soft 1/4 inch tubing, around 3 feet long, using your lungs. A heavy mallet with a plastic face works best for driving the anchor home. When the anchor is no longer needed, it can be driven down into the hole, flush with the surface of the floor

Tom Lynn, TopFlite Golf Co., Chicopee, MA

Check internal assembly clearance:


Internal clearances between parts may be tricky to measure directly, but a little modeling clay help. Stick a ball of clay in a critical area, oil the clay in the area of likely contact, make a trial assembly, then pull it back apart. The clay thickness records the clearance.

Craig Cox, Project Engineer, Twin Disc, Inc., Racine, WI

Vacuum, don’t blow through transformers:


Vacuum, don’t blow transformers and switches. Part of any normal electrical preventative maintenance is the opening and cleaning of distribution switches and transformers. In many instances it is very tempting to take a compressed air hose and just blow off any dust or dirt that clings to the windings and switches. Especially the medium voltage [600v - 33kv] windings and switches since nobody wants arcing or discharge. Using a compressed air blow-off tends to drive dust and dirt into the windings, and any grit present in a high pressure air stream could embed in or scratch the primary [high voltage] windings which are normally on the outside of the secondary [low voltage] windings. In the worst case this can damage insulation and cause local corona discharge which can further damage insulation. Use an industrial vacuum to pull the dirt and grit off the windings and switchgear conductors. If there are areas that are really inaccessible, use the low pressure air from a vacuum or an inducer nozzle to avoid any insulation damage.

Gary Snead, Honeywell ACS

A smoother, more comfortable wire pull:


When pulling wire, rather than use commercial wire lubes, shaving cream works even better, and smells nice too! The foaming action coats the wire more uniformly, and it evaporates without residue.

Kevin L. Larkowski, Maintenance Supervisor, Omaha Standard, Council Bluffs, IA

 

 

 

 

 





Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2017 Top Plant.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
February 2018
2017 Product of the Year winners, retrofitting a press, IMTS and Hannover Messe preview, natural refrigerants, testing steam traps
March 2018
SCCR, 2018 Maintenance study, and VFDs in a washdown environment.
Jan/Feb 2018
Welding ergonomics, 2017 Salary Survey, and surge protection
April 2018
ROVs, rigs, and the real time; wellsite valve manifolds; AI on a chip; analytics use for pipelines
February 2018
Focus on power systems, process safety, electrical and power systems, edge computing in the oil & gas industry
December 2017
Product of the Year winners, Pattern recognition, Engineering analytics, Revitalize older pump installations
April 2018
Implementing a DCS, stepper motors, intelligent motion control, remote monitoring of irrigation systems
February 2018
Setting internal automation standards
December 2017
PID controllers, Solar-powered SCADA, Using 80 GHz radar sensors

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

The Maintenance and Reliability Coach's blog
Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
One Voice for Manufacturing
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Maintenance and Reliability Professionals Blog
The Society for Maintenance and Reliability Professionals an organization devoted...
Machine Safety
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
Research Analyst Blog
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Marshall on Maintenance
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
Lachance on CMMS
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
Maintenance & Safety
The maintenance journey has been a long, slow trek for most manufacturers and has gone from preventive maintenance to predictive maintenance.
Industrial Analytics
This digital report explains how plant engineers and subject matter experts (SME) need support for time series data and its many challenges.
IIoT: Operations & IT
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
Randy Steele
Maintenance Manager; California Oils Corp.
Matthew J. Woo, PE, RCDD, LEED AP BD+C
Associate, Electrical Engineering; Wood Harbinger
Randy Oliver
Control Systems Engineer; Robert Bosch Corp.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me