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‘Lean
Maintenance’ and increasing competition require innovative solutions to
optimize resource allocation, and to effect high quality maintenance
practices. M&B Engineered Solutions has developed a unique and highly
effective Maintenance Prioritization & Optimization (MPOSM)
methodology that guarantees an optimized maintenance process, greater
reliability, and reduced costs.
Our MPO program is a
multi-tiered process incorporating:
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Maintenance History
Analysis
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Preventive & Predictive
Program Assessments
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Maintenance Procedures
Review
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Asset
Criticality Evaluation
Precision maintenance
concepts are applied at each process tier to:
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Identify Areas
of Best Return On Investment
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Identify
and Eliminate Zero Value PM Tasks
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Extrapolate and Identify
Repetitive Component Failure Modes
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Build
a Solid Foundation For An Optimized Maintenance Program.
Through optimization, PM, PdM and corrective activities are
integrated into a single coordinated effort. This allows us to design
and achieve more effective , high-quality maintenance with less time and
cost.
MPOs performed to
date have reduced plant-wide PM tasks by 40-60% without detriment. This
allows skilled labor to focus on high quality maintenance and to expand
condition monitoring practices, which directly results in greater asset
reliability.
By integrating
Preventive and Predictive Maintenance into one Proactive process tailored
for specific applications, resources are best utilized, maintenance costs
are reduced, and asset reliability is tangibly increased. For example,
studies and experience have shown one of the single most accurate failure
detection modes in large gear reducers is periodic lube oil analysis. As
such, intrusive periodic maintenance should only be used when lubricant
condition requires validation or indicates mechanical degradation. Periodic
lube oil changes would also be driven by oil analysis results, not arbitrary
time-based intervals. The flowchart on the next page shows the process as
applied to the gear reducer.
Minimal PM resources are
therefore required, and significant savings can result. For example,
NORIA reports that, on
average, lube oil changes cost a facility $1,000 per gallon when
all related costs are full considered. Thus, avoiding a single unwarranted
oil change can save your company several thousand dollars!!
 One
lesser realized upside of this process is that skilled resources, who may be
working day-to-day extinguishing fires, are able to perform corrective tasks
with greater precision as more time is available to do so. Executing a
machine alignment is common practice and one that rarely receives the
attention that it should receive. The short and long term
effects of misalignment can range from increased operating costs due to
excess power requirements to sudden catastrophic failure. Extensive studies
performed by NASA to quantify the effects of degrees of angular misalignment
revealed notable results. As can be seen in the graph at right, only 5
minutes angular misalignment (~0.07” across a 10” coupling) can reduce
roller bearing service life by nearly 50%. Conclusion? More
accurate alignment results in greater service life and reduced energy
consumption.
M&B can apply MPO
concepts to single assets, systems
or entire facilities depending on your needs. Our proven
techniques will result in a comprehensive, integrated and streamlined
maintenance program tailored to your facility and maintenance philosophy.
And we will reduce your maintenance costs while also increasing reliability.
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