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OUTSOURCING MAINTENANCE - Latest

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9 views

OUTSOURCING MAINTENANCE - Latest

Uploaded by

MOJALEFA JACOB MOLEFI
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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OUTSOURCING MAINTENANCE

OUTSOURCING MAINTENANCE: Another preference to increase the level of maintenance


productivity is to outsourcing for maintenance partners. Associating with professional
maintenance people give a company the advantage to address these issues with those experts
who face and meet these challenges on a daily basis. In addition, outsourcing also enable a
company to gain greater control over maintenance results.
However, it is important to note that the following key elements have to be highlighted to
achieve the optimum benefit from this outsourcing activities: 8
1. Performance measurements are developed and clearly communicated
2. Planned maintenance is established as the focus of the operation
3. Maintenance becomes a competitive advantage
4. Both manufacturer and maintenance contractor desire a mutually beneficial relationship
5. Maintenance best practice are established and tracked.
In the maintenance partnership scenario, performance guarantees and continuous improvement
goals provide greater control over maintenance results and assure production goals are being
achieved.
CONDITION MONITORING
In this day and age, predictive maintenance and condition monitoring are necessities for any company that
has machinery which is critical in achieving production goals.

Oil analysis is a condition monitoring technique that has been in use for more than 50 years and has
proved to be a highly effective management tool for monitoring the health of lubricated machinery and
the lubricants themselves. However, oil analysis is not the only condition monitoring technique available
to today's maintenance professional. Other techniques such as vibration monitoring, thermography and
ultra-sonic analysis can also be used.

This section will look at the evolution of condition monitoring philosophies, the goals of a condition
monitoring programme and how a combination of different analytical practices can be used to achieve
these goals.

Definition: Condition monitoring is the process of monitoring a parameter of condition in machinery


(vibration, temperature etc.), in order to identify a significant change which is indicative of a developing
failure.

Condition monitoring is a major component of predictive maintenance. The use of conditional monitoring
allows:
1. Maintenance to be scheduled
2. Actions to be taken to prevent failure
3. Avoid catastrophic failure consequences
4. Benefit lifespan of machine
OUTSOURCING MAINTENANCE
5. Control maintenance cost
6. Have effective planed stops
7. Ensuring correct ordering of spares
8. Effective utilization of staff and machinery
9. Ensure accurate safety precautions before each task
10. Avoids unexpected catastrophic breakdowns with expensive or dangerous consequences.
11. Reduces the number of overhauls on machines to a minimum, thereby reducing maintenance costs.
12. Eliminates unnecessary interventions with the consequent risk of introducing faults on smoothly
operating machines.
13. Allows spare parts to be ordered in time and thus eliminates costly inventories.
14. Reduces the intervention time, thereby minimizing production loss. Because the fault to be repaired is
known in advance, overhauls can be scheduled when most convenient.
Condition monitoring techniques are normally used on rotating equipment and other machinery (pumps,
electric motors, engines etc.) while periodic inspection using non-destructive testing techniques are used
for stationary plant equipment such as steam boilers, piping and heat exchangers.
Condition monitoring can go a long way to reducing failures so that most will fall in the proactive or
predictive categories.

There are also various levels of condition monitoring:


1. Detection: Is there a problem? What is the criticality of the situation?
2. Diagnosis: What is the problem? What condition monitoring techniques need to be used?
3. Prognosis: How serious is the problem? What does experience tell the maintenance professional?
In a plant some machines will be more critical than others and this will determine the level of
maintenance on them. By using the correct condition monitoring technique, the important questions can
usually be answered. Some machines will need more than one technique to positively identify a problem.
When taking a critical machine out of production, the maintenance manager wants to be absolutely sure:
1. What needs to be fixed?
2. That the right spares and personnel are available,
3.How long it will take?
A wide range of condition monitoring techniques is available. Some of the more common ones are listed
below, followed by a brief description of how they work.
OUTSOURCING MAINTENANCE
1. Oil analysis - This technique involves the removal of a small sample of oil from an operating piece of
machinery. The oil is subjected to a number of physical and chemical tests that determine the health of the
machine, the health of the oil and the level of contaminants in the oil.
2. Vibration monitoring - This involves the measurement of oscillation of a body, machine or part of a
machine around a fixed point; vibration is due to an excitation force that causes motion. These readings
are subject to a wide variety of mathematical analyses in order to detect such problems as mass
unbalance, bent shafts, misalignment, mechanical looseness, belt drive problems, journal bearing wear,
gear wear and AC induction motor problems.
3. Thermography - This technique entails the use of infrared thermography whereby temperatures of a
wide variety of targets can be measured remotely and without contact. This is accomplished by measuring
the infrared energy radiating from the surface of the target and converting the measurement to an
equivalent surface temperature. Thermography is used to monitor wherever excess heat can be generated
when a component is defective, for example a bearing.
4. Ultra sonic - Acoustic emission or transmission and reflection of ultra-high frequency sonic waves are
used to detect and locate material defects. This technique can be used to detect bearing wear and is
particularly useful for finding leaks.
5. Dye penetration - Cracks and surface irregularities can be easily picked up using a dye penetrant. A
fluorescent dye is sprayed onto the surface to be examined, a developer or fixer is added and the
component is examined under visible or ultra violet light to highlight the presence of any surface flaws.
Eddy currents. Surface defects can also be detected by eddy currents, which occur as a result of
electromagnetic induction.
6. Radiography - Radiography uses X-rays in very much the same way that a medical X-ray would
reveal a broken bone, to determine if any internal flaw or weakness exists within a mechanical
component.

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