MAINTENANCE

S UMMER ED I TI O N
Contents
3 — Why do factories still have ‘maintenance’ departments?
8 — Timken Power Systems Industrial Drivetrain Repair Services
9 — Pump Powertrain Project for a Wastewater Treatment Plant
13 — Six steps to design a preventive maintenance program
21 — Remote Monitoring of Solids and Liquids Inventory in Silos
21 — Use Automation to Monitor Inventory in Silos
31 — Five strategies to achieve world-class preventive maintenance
38 — STVM Washdown Station
39 — Wisconsin Cheese Group Increases Uptime with STVM®
Washdown Station
42 — How to write a maintenance task procedure
49 — Product Launch - The OnTrak SmartLube
50 — Ultrasound and the IIoT: the Future of Condition Monitoring
54 — How to develop an asset maintenance strategy

2
Contents
3 — Why do factories still have ‘maintenance’ departments?
8 — Timken Power Systems Industrial Drivetrain Repair Services
9 — Pump Powertrain Project for a Wastewater Treatment Plant
13 — Six steps to design a preventive maintenance program
20 — Remote Monitoring of Solids and Liquids Inventory in Silos
21 — Use Automation to Monitor Inventory in Silos
31 — Five strategies to achieve world-class preventive maintenance
38 — STVM Washdown Station
39 — Wisconsin Cheese Group Increases Uptime with STVM®
Washdown Station
42 — How to write a maintenance task procedure
49 — Product Launch - The OnTrak SmartLube
50 — Ultrasound and the IIoT: the Future of Condition Monitoring
54 — How to develop an asset maintenance strategy

2
Why do factories still have Why do factories still
‘maintenance’ departments? have ‘maintenance’
departments?
Timken Power Systems Industrial
Technology helps put the focus on continuous improvement rather than Drivetrain Repair Services
current state.
Pump Powertrain Project for a
Wastewater Treatment Plant

W e hear a lot of talk about “Lean maintenance.” Here’s my question: Why does
the “maintenance” department even exist?
Six steps to design a preventive
maintenance program

Remote Monitoring of Solids and

The term “maintenance” implies maintaining things the way they’ve been, sometimes Liquids Inventory in Silos
for decades. In today’s competitive marketplace, to only maintain inevitably leads to
Use Automation to Monitor
the company’s demise. So why have a department dedicated to maintaining those ma- Inventory in Silos
chines and processes? Five strategies to achieve world-
class preventive maintenance
In my experience, 90% of factories are operating with systems and methods that are STVM Washdown Station
outdated. Antiquated, actually. These are systems that do not support continuous
Wisconsin Cheese Group
improvement and are in fact wasteful and don’t add value. For the people on the plant Increases Uptime with STVM®
floor, these systems are viewed as more of a task than a valuable tool. For manufactur- Washdown Station

ers to stay competitive in the rapidly changing marketplace, it will require that they let How to write a maintenance task
procedure
go of these outdated methods and embrace the future. Imagine factory workers utiliz-
ing mobile technology to instantly share ideas and have visibility of current conditions Product Launch - The OnTrak
SmartLube
and past history.
Ultrasound and the IIoT: the
Future of Condition Monitoring
What if maintenance technicians were wearing Google Glass while troubleshooting
problems? We live in a time when cars are starting to drive themselves, yet plants are How to develop an asset
maintenance strategy
still using pen and paper and solutions that were developed more than 20 years ago to
track activities.
3
Why do factories still have ‘maintenance’ departments?
Why do factories still
An engine of continuous improvement have ‘maintenance’
departments?
Sure, there will always be people who complete the functions of repairing equipment,
Timken Power Systems Industrial
but in the future, their department will be called something else because they’ll be
Drivetrain Repair Services
tasked with doing less maintaining than improving activities. Some people refer to it
Pump Powertrain Project for a
as “Lean maintenance,” but I prefer “Lean manufacturing” because in reality, mainte- Wastewater Treatment Plant
nance and production are inseparable.
Six steps to design a preventive
maintenance program
In factories that have a true Lean culture, maintenance sees itself as an engine of con-
Remote Monitoring of Solids and
tinuous improvement, and management empowers them to do so. Think of NASCAR. Liquids Inventory in Silos
The uniformed pit crew is front and center near the track. They are part of the race,
Use Automation to Monitor
and their job is to coordinate as a team to help the driver finish the race as fast as pos- Inventory in Silos
sible. To do so, they take into account mileage, tire wear, and a host of other factors to Five strategies to achieve world-
work as little and as fast as possible when they need to, all while making decisions on class preventive maintenance
the fly by constantly monitoring information. STVM Washdown Station

Wisconsin Cheese Group

What if factories treated their maintenance people the same way? By putting the main- Increases Uptime with STVM®
tenance team front and center and empowering technicians to immediately suggest Washdown Station

improvements based on real-time data, velocity and productivity will increase. Unfor- How to write a maintenance task
procedure
tunately, in most factories I’ve seen, the maintenance department is tucked away in
the back. It’s dirty and oily, and the manager doesn’t feel like they are part of the op- Product Launch - The OnTrak
SmartLube
erations team. Morning meetings usually become a finger-pointing exercise, with the
finger usually pointed at maintenance. Ultrasound and the IIoT: the
Future of Condition Monitoring

If this is to change, the mentality around maintenance must evolve. How to develop an asset
maintenance strategy

4
Why do factories still have ‘maintenance’ departments?
Why do factories still
Moneyball on the factory floor have ‘maintenance’
departments?
Technology is allowing more manufacturers to see data in real-time in a way that iden-
Timken Power Systems Industrial
tifies what the biggest problems are. Not having real-time data is a lot like coaching a
Drivetrain Repair Services
baseball game without being present. You just can’t gather enough information to see
Pump Powertrain Project for a
a clear picture and make adjustments in the moment. Wastewater Treatment Plant

Six steps to design a preventive

Analysis of real-time data will also help guide further improvement after the fact. Think maintenance program
Moneyball on the factory floor. Just as analytics were used to more accurately identify
Remote Monitoring of Solids and
good traits in previously undervalued baseball players, real-time data on the factory Liquids Inventory in Silos
floor can give technicians and engineers immediate feedback on what needs to be
Use Automation to Monitor
changed or fixed. This will empower maintenance departments to be one of the main Inventory in Silos
drivers of improvement. Five strategies to achieve world-
class preventive maintenance
I personally observed a government contractor on the East Coast implement a tech- STVM Washdown Station
nology system that allowed everyone—floor workers and executives—to see tracking
Wisconsin Cheese Group
data, align goals between departments, and identify repetitive downtime issues. A Increases Uptime with STVM®
few months later the maintenance technicians were presenting to the VP of operations Washdown Station

solutions they had developed for problems no one even previously knew existed-or How to write a maintenance task
procedure
even worse, were viewed as normal. One machine was eating up nearly half an hour of
downtime a day with needed repairs. Data allowed maintenance technicians to discov- Product Launch - The OnTrak
SmartLube
er they could decrease needed repairs down to half an hour a month.
Ultrasound and the IIoT: the
Future of Condition Monitoring
Over the longer term, this access to useful, real-time data empowered the people on
the plant floor to continue to drive improvements. After one year, the factory was able How to develop an asset
maintenance strategy
to produce 20% more product with significantly fewer resources. Additionally, over the
following three years they increased operational availability by 15%, improved preven-
5
Why do factories still have ‘maintenance’ departments?
Why do factories still
tative maintenance compliance with the government from 65% to 100%, and reduced have ‘maintenance’
equipment downtime by 50%. departments?
Timken Power Systems Industrial
Drivetrain Repair Services
The factory maintenance supervisor said, “I finally got my life back.” He no longer
spends every day—plus nights and weekends—receiving calls and texts about prob- Pump Powertrain Project for a
Wastewater Treatment Plant
lems.
Six steps to design a preventive
maintenance program
Not only did the factory enhance bottom-line results and make things easier for man-
Remote Monitoring of Solids and
agers, maintenance techs were empowered to improve things instead of making the Liquids Inventory in Silos
same adjustments and repairs to machines. No doubt technicians were going home
Use Automation to Monitor
to their families and saying, “I solved a problem at work today,” and, “They’re not just Inventory in Silos
asking me to fix something over and over every day, they’re actually asking me to use
Five strategies to achieve world-
my mind. They’re open to my suggestions, and they’ve implemented my ideas.” This class preventive maintenance
makes people feel more valuable, and it motivates them to want to solve more prob-
STVM Washdown Station
lems and improve more processes.
Wisconsin Cheese Group
Increases Uptime with STVM®
Sadly, a lot of companies overlook the value of ideas from employees on the factory Washdown Station
floor. How to write a maintenance task
procedure

Continuous improvement brings more work and adds jobs Product Launch - The OnTrak
SmartLube
The way to keep factories from shrinking, having to move operations, or even closing is
to continually show that those factories are keeping up with the global economy, and Ultrasound and the IIoT: the
Future of Condition Monitoring
they’re more effective today than they were yesterday. Real-time data with technology
is leading to improved bottom-line results and takes emotion and territorial disagree- How to develop an asset
maintenance strategy
ments out of discussions on improvement.

6
Why do factories still have ‘maintenance’ departments?
Why do factories still
Some people fear the loss of jobs with onboarding new technology. In my experience, have ‘maintenance’
it’s been the opposite. You save jobs because you ensure the plant will continue to ex- departments?
ist. By incorporating continuous improvement across the entire factory, I’ve seen plants Timken Power Systems Industrial
Drivetrain Repair Services
become more efficient, with more work coming to the plant, which actually led to hir-
ing people. I’ve also seen companies refuse to reduce technician headcount because Pump Powertrain Project for a
Wastewater Treatment Plant
they could see that they were driving improvement, resulting in bottom-line savings for
the company. Six steps to design a preventive
maintenance program

Remote Monitoring of Solids and

A technology-based tool provides instant access to information about what’s going on, Liquids Inventory in Silos
what’s happened in the past, and what they need to do to solve the problem. It also
Use Automation to Monitor
creates a more cohesive community environment where employees can more easily Inventory in Silos
share information and ideas on how to fix problems.
Five strategies to achieve world-
class preventive maintenance
So I’m looking forward to the day when the term “maintenance” doesn’t exist in a
STVM Washdown Station
manufacturing facility.
Wisconsin Cheese Group
Increases Uptime with STVM®
Essentially, that day is here—in successful factories. Washdown Station

How to write a maintenance task

But if factory owners keep on maintaining things, ignore the use of technology—which procedure

is improving systems in all kinds of industries—and remain complacent, they will be Product Launch - The OnTrak
challenged by more agile competitors. SmartLube

Ultrasound and the IIoT: the

Future of Condition Monitoring
Bob Argyle
Bob Argyle is the chief customer officer for Leading2Lean, a Nevada-based manufac- How to develop an asset
maintenance strategy
turing tech solution provider. Leading2Lean is a CFE Media content partner.

7
Timken Power Systems Industrial Drivetrain Repair Services
Why do factories still have
‘maintenance’ departments?

Timken Power Systems

Industrial Drivetrain
Repair Services
Pump Powertrain Project for a
Wastewater Treatment Plant

Six steps to design a preventive

maintenance program

Remote Monitoring of Solids and

Liquids Inventory in Silos


Use Automation to Monitor
Inventory in Silos

Five strategies to achieve world-

class preventive maintenance

STVM Washdown Station

Wisconsin Cheese Group

Increases Uptime with STVM®
Washdown Station

Timken Power Systems Industrial Drivetrain How to write a maintenance task

procedure
Repair Services
Product Launch - The OnTrak
Timken Power Systems combines centuries of expertise SmartLube
of six leading service providers to deliver complete Ultrasound and the IIoT: the
electromechanical support from a single trusted source. So Future of Condition Monitoring
whether it’s gears grinding to a halt, burned-out motors, worn How to develop an asset
out bearings, or malfunctioning controllers, you get every maintenance strategy
result you need—all from one name.
8
Pump Powertrain
Project for a
Wastewater
Treatment Plant
The electromechanical solution only Timken
Power Systems (TPS) could deliver

L ocated on a vital waterway in the Northeast, this plant

serves a major metropolitan area, treating 125 million
gallons of wastewater daily. It’s where you can find the en-
tire TPS portfolio at work as part of a multi-year, multi-mil-
liondollar project to upgrade the facility.

Since winning the project in 2017, the TPS team has sup-
ported its large-scale upgrade from diesel-powered di-
rect-drive pumps to methane-powered engines that drive
generators and support the electrification of the plant.
According to Mike D’Angelo, Timken Power Systems
National Sales Manager for the US, “Five refurbished
Pump Powertrain Project for a Wastewater Treatment Plant
Why do factories still have
‘maintenance’ departments?

Timken Power Systems Industrial

Drivetrain Repair Services

Pump Powertrain
Project for a
Wastewater Treatment
Plant
Six steps to design a preventive
maintenance program

Remote Monitoring of Solids and

Liquids Inventory in Silos

Use Automation to Monitor

Inventory in Silos

drivetrains will utilize a complete set of power system solutions, including AC motors, Five strategies to achieve world-
class preventive maintenance
motor starter controllers, gearboxes and floor bearings.”
STVM Washdown Station

All of these components represent an integrated electromechanical solution from Wisconsin Cheese Group
Increases Uptime with STVM®
Timken Power Systems: Washdown Station

How to write a maintenance task

• Philadelphia Gear: Gearboxes procedure
• Timken: Tapered roller bearings
Product Launch - The OnTrak
• Schulz Group: Electric motors, controller systems for wound-rotor motors SmartLube
• Smith Services: Engineering calculations for system design support
Ultrasound and the IIoT: the
Future of Condition Monitoring
Bill McCloy, territory account specialist for the project, explained the advantage of a holis- How to develop an asset
tic solution: “As the OEM for the existing installation, we knew we could handle the gear- maintenance strategy
box part of the solution,” he says. “But it was the TPS dynamic that made the difference.” 10
Pump Powertrain Project for a Wastewater Treatment Plant
Why do factories still have
‘maintenance’ departments?
That dynamic includes the 600 pages of electrical
specifications in the request for proposal that Schulz
Group and Smith Services handled flawlessly —
“ Providing both electrical
and mechanical capabil-
Timken Power Systems Industrial
Drivetrain Repair Services

along with the unique contribution of Timken, the Pump Powertrain

ities, TPS can build an
world’s leading authority on tapered roller bearings. Project for a
engineered solution for Wastewater Treatment
customers from any of our Plant
The clear difference in a competitive gear/motor/bearing and Six steps to design a preventive
bidding process
While they faced competitive pressure from indus- ”
crane facilities. maintenance program

Remote Monitoring of Solids and

try giants, both D’Angelo and McCloy believe that TPS rose to the top of list due to Liquids Inventory in Silos
outstanding service and attentiveness throughout the bidding process. “We were in Use Automation to Monitor
constant contact with the project’s civil engineers and decision makers right up until Inventory in Silos

the end,” says Rich Chrzanowski, general manager at TPS — Northeast region. “This Five strategies to achieve world-
was the largest electromechanical project we’d ever bid on, and we wanted to make class preventive maintenance

sure everything was quoted to the exact specifications of the bid package.” STVM Washdown Station

Wisconsin Cheese Group

Vigilance beyond the installation Increases Uptime with STVM®
Washdown Station
As each refurbished drivetrain is delivered to the wastewater treatment plant, there is
equal importance placed on frequent consultation during installation, and the avail- How to write a maintenance task
procedure
ability of training for ongoing maintenance of each system.
Product Launch - The OnTrak
SmartLube
That’s what it means for any mission-critical application that benefits from Timken
Ultrasound and the IIoT: the
Power Systems. Future of Condition Monitoring

How to develop an asset

The Timken Power Systems (TPS) group is a leading service provider offering repair maintenance strategy
and overhaul for the entire industrial drivetrain, end-to-end in the United States.
11
Six steps to design a preventive Why do factories still have

maintenance program
‘maintenance’ departments?

Timken Power Systems Industrial

Drivetrain Repair Services
Six steps for creating an effective efficient and sustainable preventive Pump Powertrain Project for a
maintenance program for your facility Wastewater Treatment Plant

Six steps to design

P reventive maintenance (PM) may seem a no-brainer, but if you make assumptions
and cut corners, your results won’t match the effort. Follow these six steps and
you’ll create an effective, efficient and sustainable preventive maintenance program for
a preventive
maintenance program
Remote Monitoring of Solids and
your facility. Liquids Inventory in Silos

Use Automation to Monitor

1. PM procedure design: Doing the effective things Inventory in Silos
To define your process, begin at the end: What results does your company want from Five strategies to achieve world-
a PM program? If it’s savings you seek, this should come from achieving minimal un- class preventive maintenance
planned downtime and minimal lost production opportunity time, minimal spare parts STVM Washdown Station
costs, minimal maintenance labor costs, minimal manufacturing interruptions, max-
Wisconsin Cheese Group
imum manufacturing time available per machine, maximum quality of products and Increases Uptime with STVM®
Washdown Station
maximum machine life spans. These areas are where the majority of the savings will be
found. How to write a maintenance task
procedure

The best PM procedures are written by people who understand OEM recommenda- Product Launch - The OnTrak
SmartLube
tions. These individuals also understand their machines’ performance history and ser-
vice requirements in your plant environment. They look at the age of each machine. Ultrasound and the IIoT: the
Future of Condition Monitoring
They examine its static and dynamic systems. They look at its foundation, support, me-
How to develop an asset
chanical, electrical, electronics, control, pneumatic and hydraulic systems. They analyze
maintenance strategy
how power losses, power spikes, environmental impacts and operator errors can affect
each machine.
13
Six steps to design a preventive maintenance program
Why do factories still have
‘maintenance’ departments?
To catch and repair machine problems before their components fail, a detailed analysis
must take place. If your PM program architects don’t closely examine these causes of Timken Power Systems Industrial
Drivetrain Repair Services
machine failures, they’ll also miss some of the inspections that will need to be baked
Pump Powertrain Project for a
into your program’s task list.
Wastewater Treatment Plant

The PM procedures should also include a list of specialty tools that will be needed, Six steps to design
a preventive
such as torque wrenches, drills, scissors lifts, forklifts, etc. Procedures should spell out
maintenance program
how to safely work with and maintain these tools.
Remote Monitoring of Solids and
Liquids Inventory in Silos
2. PM procedure scheduling: Efficient use of people and re-
Use Automation to Monitor
sources Inventory in Silos
Once the proper procedures are written and uploaded in your Computerized Mainte- Five strategies to achieve world-
nance Management System (CMMS), each needs to be scheduled. In most plants, this class preventive maintenance
means setting up daily, weekly, monthly, quarterly, semi-annual and annual PM events. STVM Washdown Station
While not all machines require daily or weekly preventive maintenance checks, most
Wisconsin Cheese Group
will require monthly, quarterly, semi-annual and annual exams. To develop a quarterly Increases Uptime with STVM®
PM schedule, many take their monthly PM and add a few things that don’t need to be Washdown Station

inspected monthly but do need to be inspected more than twice per year. This also How to write a maintenance task
procedure
applies to semi-annual and annual PM’s, which are quarterly PM’s that contain addition-
al inspections twice per year or more. If these schedules are set up properly, your PM Product Launch - The OnTrak
SmartLube
time will be kept to a minimum.
Ultrasound and the IIoT: the
Future of Condition Monitoring
3. PM lubrication engineering
How to develop an asset
One of the most misunderstood tasks in preventive maintenance is the lubrication of maintenance strategy
rotating and reciprocating machine components. What’s more, many think a PM pro-
gram is a glorified lubrication program. Many questions need to be answered before
14
Six steps to design a preventive maintenance program
Why do factories still have
‘maintenance’ departments?
you set up PM lubrication

END INACCURATE protocols. As one per- Timken Power Systems Industrial

Drivetrain Repair Services
forms lubrication tasks,

SILO INVENTORY some visual and maybe a

few physical inspections
Pump Powertrain Project for a
Wastewater Treatment Plant

ONE CALL, ENDLESS SOLUTIONS can be made. Based on Six steps to design
a preventive
these tasks, PM proce-
maintenance program
dures can be written.
Remote Monitoring of Solids and
Liquids Inventory in Silos
Get trained professionals
Use Automation to Monitor
involved with choosing Inventory in Silos
Sensors. Wireless. the best lubricant for
Five strategies to achieve world-
80 GHz non-contact radar, Reduce wiring costs and
3D scanners, laser, or SmartBob. simplify installation.
each application. All the class preventive maintenance
major lubricant OEM’s
STVM Washdown Station
SofTware. have these services avail-
Inventory on a phone or PC Wisconsin Cheese Group
using BinView® or Binventory.® able—take advantage Increases Uptime with STVM®
of them! It’s important Washdown Station
to understand what lu- How to write a maintenance task
bricant should be used, procedure

how much to be used per

Local Display. Product Launch - The OnTrak
SmartLube
Walk or drive-up consoles application and at what
and digital panel meters.
intervals. After the first Ultrasound and the IIoT: the
Future of Condition Monitoring
application, track each
Climb
less. machine to determine How to develop an asset
Stress maintenance strategy
less. where changes need to
Call 800-278-4241 or visit binmaster.com. be made to lubricant
15
Six steps to design a preventive maintenance program
Why do factories still have
‘maintenance’ departments?
types, application quantities and application frequency.
Timken Power Systems Industrial
Drivetrain Repair Services
Lube lists and instructions need to be added to each PM task with lube procedures
Pump Powertrain Project for a
for critical machines. Where will lubes be stored and in what controlled environment?
Wastewater Treatment Plant
Does the oil and grease storage area meet all environmental, legal, sanitary and safety
requirements? Who will be doing the inventory and ensuring that adequate lubrication Six steps to design
a preventive
supplies are maintained? Are the proper procedures in place for disposing of waste
maintenance program
oils and lube-contaminated materials? Review, adopt and implement the lubrication
Remote Monitoring of Solids and
best practices that work for your facility and machines.
Liquids Inventory in Silos

Use Automation to Monitor

4. PM training: Back on the chain gang Inventory in Silos
Training for PM tasks is critical. It can make the difference between catching a seem-
Five strategies to achieve world-
ingly-small issue that prevents a hugely expensive repair, or missing a problem that class preventive maintenance
shuts down your line for days or weeks. STVM Washdown Station

Wisconsin Cheese Group

Here are some examples why training is a must: Increases Uptime with STVM®
Washdown Station

Almost every maintenance tradesman believes they know the best way to apply lubri- How to write a maintenance task
cants and how much to apply. One question is always “What is the very first thing you procedure

physically do when you walk up to a bearing that needs to be greased? What do you Product Launch - The OnTrak
SmartLube
do first?” Only one out of 500 people tell me that they need to clean the business end
of the grease gun and clean off the grease zerk so they don’t pump dirt and debris into Ultrasound and the IIoT: the
Future of Condition Monitoring
the bearing.
How to develop an asset
maintenance strategy
The proper way to lubricate a roller chain is after it is cut to length, submerse it in a
shallow pan of five-weight oil and let it sit for a few minutes and let all air bubbles es-
16
Six steps to design a preventive maintenance program
Why do factories still have
‘maintenance’ departments?
cape to get all the air out and the oil into the internal components of the chain assem-
bly; pins, rollers and inside side plates. This lubricates the chain at all points that you Timken Power Systems Industrial
Drivetrain Repair Services
can’t see, where 90% of the metal-to-metal contact normally take place. As a result of
Pump Powertrain Project for a
this lubrication, the life expectancy of the chain will be approximately ten times what it
Wastewater Treatment Plant
would be if the lubrication had not been applied.
Six steps to design
a preventive
The chain lubrication example is one of hundreds of procedures that even the most
maintenance program
experienced maintenance people miss. How many maintenance workers really under-
Remote Monitoring of Solids and
stand how to go about a formal, in-depth root cause analysis of machine component
Liquids Inventory in Silos
failure? How many will give you usable feedback on machine conditions when they turn
Use Automation to Monitor
in their PM work orders? If your facility’s goal is minimal downtime, they need to be Inventory in Silos
taught to prolong the life of the equipment they’re working on.
Five strategies to achieve world-
class preventive maintenance
5. PM program management Plan STVM Washdown Station
Metrics drive everything these days, and PM management is no exception. If the facili-
Wisconsin Cheese Group
ty has a good work order (WO) system in place that captures maintenance labor hours, Increases Uptime with STVM®
materials and reasons for each WO, these could be measured: Washdown Station

How to write a maintenance task

• How many corrective WO’s have been required for each piece of your equipment procedure

Product Launch - The OnTrak

SmartLube
• Which WO’s address breakdowns
Ultrasound and the IIoT: the
Future of Condition Monitoring
• Which WO’s require spare parts
How to develop an asset
maintenance strategy
• How many man-hours are required per WO

17
Six steps to design a preventive maintenance program
Why do factories still have
‘maintenance’ departments?
Capturing WO detail will also help you track surges and decreases in equipment costs,
and fine-tune the frequency of PM tasks. Timken Power Systems Industrial
Drivetrain Repair Services

Pump Powertrain Project for a

Keep your PM management on track by regularly asking and answering these ques-
Wastewater Treatment Plant
tions:
Six steps to design
a preventive
• What are the best CMMS reports to use for gathering the most important informa-
maintenance program
tion in the least amount of time?
Remote Monitoring of Solids and
Liquids Inventory in Silos
• What is the most effective way to report the successes of the PM program to upper
Use Automation to Monitor
management and to the individual managers of the departments we perform for? Inventory in Silos

Five strategies to achieve world-

• Do we spread the PM responsibility among all the maintenance people or just class preventive maintenance
some of them?
STVM Washdown Station

Wisconsin Cheese Group

• What are the advantages (or disadvantages) of having a dedicated PM team that Increases Uptime with STVM®
only performs PM work? Washdown Station

How to write a maintenance task

• How do we know if our workers are actually performing the PM’s tasks or simply procedure

pencil-whipping the WO? Product Launch - The OnTrak

SmartLube

• How do we know if tasks are being performed correctly? Ultrasound and the IIoT: the
Future of Condition Monitoring

6. Communicate, communicate, communicate How to develop an asset

maintenance strategy
The best PM program ever designed will still fail if maintenance workers don’t un-
derstand how they will benefit and put their efforts into making it a success. If they
18
Six steps to design a preventive maintenance program
Why do factories still have
‘maintenance’ departments?
haven’t seen benefits from past PM programs, prepare to turn around negative per-
ceptions. Timken Power Systems Industrial
Drivetrain Repair Services

Pump Powertrain Project for a

While PM program design is crucial, communicating to workers is essential. They need
Wastewater Treatment Plant
to know what will be done. Who will be doing what, and when. What performance
measures they need to meet. You’ll need to answer 99 percent of their questions up Six steps to design
a preventive
front.
maintenance program
Remote Monitoring of Solids and
Workers need to know that the PM program is fluid, that continuous improvement is
Liquids Inventory in Silos
the goal and that everyone’s input is valued. Besides the all-important training, your
Use Automation to Monitor
communications must help workers understand that PM will remove work from their Inventory in Silos
plates.
Five strategies to achieve world-
class preventive maintenance
Ken Staller
STVM Washdown Station
Daniel Penn Associates senior consultant Ken Staller has more than 30 years of proj-
Wisconsin Cheese Group
ect engineering, project management and maintenance management experience in Increases Uptime with STVM®
machine manufacturing, pulp and paper, pharmaceutical and automotive industries. Washdown Station
Daniel Penn Associates is a CFE Media content partner. How to write a maintenance task
procedure

Product Launch - The OnTrak

SmartLube

Ultrasound and the IIoT: the

Future of Condition Monitoring

How to develop an asset

maintenance strategy

19
Remote Monitoring of Solids and Liquids Inventory in Silos
Why do factories still have
‘maintenance’ departments?

Timken Power Systems Industrial

Drivetrain Repair Services

Pump Powertrain Project for a

Wastewater Treatment Plant

Six steps to design a preventive

maintenance program

Remote Monitoring
of Solids and Liquids
Inventory in Silos


Use Automation to Monitor
Inventory in Silos

Five strategies to achieve world-

class preventive maintenance

STVM Washdown Station

Wisconsin Cheese Group

Increases Uptime with STVM®
Washdown Station

Remote Monitoring of Solids and Liquids How to write a maintenance task

procedure
Inventory in Silos
Product Launch - The OnTrak
Monitor the inventory of solids and liquids in silos from SmartLube
anywhere at anytime. Stay connected to your measurement Ultrasound and the IIoT: the
data while away from the plant, working from home, social Future of Condition Monitoring
distancing, traveling, or on vacation. How to develop an asset
maintenance strategy

20
 Use Automation Imagine your job didn’t involve climbing silos,
guesswork, or inventory shortages. Instead, each
day you stayed safe; inventory was convenient,
to Monitor accurate, and reliable.

Inventory in Silos That’s what level sensors and software can do for
your plant—both easily and affordably.

Measurement starts with the sensor.

In most cases, the most important job of a level sensor in
a silo or hopper is to ensure adequate material is flowing
through the system to avoid process interruptions and
reduce cycle times.

Level sensors are

easily installed or
retrofit on most any
silo. Level sensors
measure distances
with very high levels
of accuracy, gener-
ally within +/-0.2”.
The types of sensors
best suited for solids
and powders are immune to A gateway does the job of a
wireless access point, modem
the noise and dust that occurs and router.
Use Automation to Monitor Inventory in Silos
Why do factories still have
‘maintenance’ departments?
when filling the silos. Liquid level sensors
offer technologies that can compensate for Timken Power Systems Industrial
Drivetrain Repair Services
foam, condensation, turbulence, and inter-
Pump Powertrain Project for a
face measurement. Today’s sensors report
Wastewater Treatment Plant
inventory levels in real-time and are highly
Six steps to design a preventive
reliable with a long service life and require maintenance program
minimal maintenance.
Remote Monitoring of Solids and
Liquids Inventory in Silos
Sensor technologies to measure
Use Automation to
solids, powders, or liquids. Monitor Inventory in
A dust-penetrating non-contact radar is the Silos
go-to sensor for non-contact continuous level Five strategies to achieve world-
measurement. The advent of narrow-beam 80 class preventive maintenance
GHz technology ensures reliable operation in STVM Washdown Station
dust and fast update rates. For large, active
Wisconsin Cheese Group
hopper or silos that need continuous tracking Increases Uptime with STVM®
a non-contact radar can measure levels in real-time and Washdown Station
Non-contact 80 GHz radar
update in just seconds. In addition to radar, there are other measures accurately and How to write a maintenance task
updates levels in seconds. procedure
types of sensor technology that may be better suited to the
application or your budget. Product Launch - The OnTrak
SmartLube

A 3DLevelScanner can account for surface variations of the material in the silo and Ultrasound and the IIoT: the
Future of Condition Monitoring
account for conditions such as cone up or down. It is also the only sensor to measure
multiple points on the material surface and account for irregularities when calculat- How to develop an asset
maintenance strategy
ing volume.

22
Use Automation to Monitor Inventory in Silos
Why do factories still have
‘maintenance’ departments?
Bob-style or weight-and-ca-
ble sensors work much like Timken Power Systems Industrial
Drivetrain Repair Services
a tape measure. They take
Pump Powertrain Project for a
measurements at predeter-
Wastewater Treatment Plant
mined time intervals such
Six steps to design a preventive
as once an hour or several maintenance program
times a day, or on demand.
Remote Monitoring of Solids and
They have been utilized in Liquids Inventory in Silos
processing industries for
Use Automation to
more than two decades.
Monitor Inventory in
They are budget-friendly, Silos
mechanical devices with a
Five strategies to achieve world-
long service life. Point level sensors alert to full status to class preventive maintenance
prevent overfilling silos.
STVM Washdown Station
A battery-powered laser level sensor can be
Wisconsin Cheese Group
used if conduit and power is not readily available. This type of sensor can save signifi- Increases Uptime with STVM®
cantly on wiring costs and hiring electricians. Laser technology performs best in low- Washdown Station
dust applications such as silos containing granules or pellets. How to write a maintenance task
procedure

Measuring liquid or slurry tanks. Product Launch - The OnTrak

SmartLube
Non-contact radar level sensors can also be used in liquid applications at processing
plants. Liquids and slurries are easily continuously measured, even if condensation Ultrasound and the IIoT: the
Future of Condition Monitoring
or turbulence are present. An 80 GHz level sensor focuses the signal in a very narrow
beam angle, allowing for precise aiming to avoid obstructions in the tank such as agi- How to develop an asset
maintenance strategy
tators, mixers, fittings, or heating coils.

23
Use Automation to Monitor Inventory in Silos
Why do factories still have
‘maintenance’ departments?
A level sensor is not a scale.
Timken Power Systems Industrial
It is important to understand that level sensors measure the Drivetrain Repair Services
distance to the material from the sensor at the top of the vessel.
Pump Powertrain Project for a
They don’t weigh anything. Wastewater Treatment Plant

Six steps to design a preventive

If the expectation is an accurate weight, a strain gauge or load cell may maintenance program
be a better option. This type of technology is best installed at the time a silo Remote Monitoring of Solids and
is commissioned, as it is extremely difficult (sometimes impossible) Liquids Inventory in Silos
and expensive to retrofit in an existing silo.
Use Automation to
Monitor Inventory in
Simplicity lies in Silos
the system. Five strategies to achieve world-
Thanks to sophisticated class preventive maintenance

software that does the STVM Washdown Station

math for you, the distance Wisconsin Cheese Group
to the material in a silo can Increases Uptime with STVM®
Washdown Station
be converted to an esti-
mate of mass or volume. How to write a maintenance task
procedure
The accuracy of the esti-
mate is dependent upon Product Launch - The OnTrak
SmartLube
entering the correct silo
Ultrasound and the IIoT: the
dimensions into the soft- Future of Condition Monitoring
ware and the evenness or
How to develop an asset
irregularity of the piling or maintenance strategy
topography of the material in the silo. Processors of all types use storage silos to
supply material into the production process.
24
Use Automation to Monitor Inventory in Silos
Why do factories still have
‘maintenance’ departments?
Processing and purchasing personnel can
rely on the software for timely alerts and Timken Power Systems Industrial
Drivetrain Repair Services
trend reporting. They can see their silo
Pump Powertrain Project for a
inventories in multiple areas in the plant
Wastewater Treatment Plant
as well as when they are off site. Readings
Six steps to design a preventive
in the software program are also used by maintenance program
purchasing managers to monitor invento-
Remote Monitoring of Solids and
ry, place orders in a timely manner, and to Liquids Inventory in Silos
know when to schedule deliveries.
Use Automation to
Monitor Inventory in
User-friendly software Silos
platforms. Five strategies to achieve world-
As far as software is concerned, you need class preventive maintenance
to determine if you want software in- STVM Washdown Station
Software makes real-time inventory data
stalled on your local area network (LAN) to available on a mobile device.
Wisconsin Cheese Group
access from a PC or a cloud-based software-as- Increases Uptime with STVM®
a-service (SaaS) that is accessed from the internet on a phone, tablet, or PC. Washdown Station

How to write a maintenance task

procedure
Both are easy to work with and highly affordable. A software program installed on
your local network is a one-time software purchase per plant location. The software Product Launch - The OnTrak
SmartLube
accommodates up to 120 silos.
Ultrasound and the IIoT: the
Future of Condition Monitoring
Cloud-based programs are subscriptions based upon the number of silos you are
monitoring. The cost is several dollars per month per silo, plus a cellular program if How to develop an asset
maintenance strategy
one is needed.

25
Use Automation to Monitor Inventory in Silos
Why do factories still have
‘maintenance’ departments?
Cloud-based programs have the benefit of not requiring an IT expert to install or
manage the program. Updates to the software are provided by the host company, Timken Power Systems Industrial
Drivetrain Repair Services
who will also provide the necessary training and ongoing support.
Pump Powertrain Project for a
Wastewater Treatment Plant
Both LAN and SaaS programs offer similar features. Both have easy-to-use, graphical
Six steps to design a preventive
interfaces. Bins can be sorted by type and status. An administrator can control who maintenance program
has access to the program and what information is available to them. Historical re-
Remote Monitoring of Solids and
ports can be quickly downloaded for specific time periods. Liquids Inventory in Silos

Use Automation to
Perhaps the most loved feature of inventory management software is automated
Monitor Inventory in
alerts. Sent via text or email, these alerts help plants ensure that silos or hoppers Silos
don’t run empty and interfere with production. When used in tandem with purchasing,
Five strategies to achieve world-
orders can be placed in a timely manner and deliveries scheduled so as not to inter- class preventive maintenance
fere with production.
STVM Washdown Station

Wisconsin Cheese Group

SECTION: Increases Uptime with STVM®
Point level indicators prevent overfills and hopper outages. Washdown Station

A point level indicator alerts when material reaches a certain point in the silo or hop- How to write a maintenance task
procedure
per. They are commonly used to prevent overfilling silos and ensuring that hoppers
have adequate material to feed into the production process. They do not measure con- Product Launch - The OnTrak
SmartLube
tinuously, but instead indicate when material reaches a certain point.
Ultrasound and the IIoT: the
Future of Condition Monitoring
Rotaries are the most tried and true level control. They operate by rotating a paddle in
the material and when it reaches the level of the paddle, it stops turning and sends an How to develop an asset
maintenance strategy
alert via a relay. Conversely, it can alert to a low level in a hopper if the material falls to
a level below the paddle and starts turning. These devices are offered with paddles for
26
Use Automation to Monitor Inventory in Silos
Why do factories still have
‘maintenance’ departments?
very light to heavy materials. Rotaries are inexpensive, last a long time, and are offered
in fail-safe models if supplying material consistently is critical to a process. Timken Power Systems Industrial
Drivetrain Repair Services

Pump Powertrain Project for a

A capacitance probe can be a great next step if you are using a rotary and want to
Wastewater Treatment Plant
move up to the next level. Capacitance sensors are designed for a wide array of ap-
Six steps to design a preventive
plications and can easily be customized with different types of probes, lengths, or maintenance program
extensions. These sensors may be used for high, mid, and low- level detection in bins,
Remote Monitoring of Solids and
silos, tanks, hoppers, chutes, and other types of vessels where materials are stored, Liquids Inventory in Silos
processed, or flowing.
Use Automation to
Monitor Inventory in
The vibrating rod is another point level sensor commonly used in process indus- Silos
tries such as plastics. It works by vibrating when uncovered; when the vibration
Five strategies to achieve world-
stops upon being covered by material, it sends an alert. It has sensitivity settings class preventive maintenance
that can be adjusted for pellets or powders. A vibrating rod is not recommended
STVM Washdown Station
if static electricity is present as it can cause the material to cling to the blade and
Wisconsin Cheese Group
cause a false signal. Increases Uptime with STVM®
Washdown Station

SECTION: How to write a maintenance task

procedure
Three things to consider when specifying a system.
1. The type, size, or number of silos you have. Product Launch - The OnTrak
SmartLube
If there is material in a silo, tank, or hopper— there is a sensor to measure it. Begin de-
Ultrasound and the IIoT: the
signing your system by creating a list of the silos, their dimensions, the type of material
Future of Condition Monitoring
stored inside, and any existing equipment installed or used on the silo. This ensures
How to develop an asset
the sensor can be matched to its job. Nuances such as access to, or structure in, the maintenance strategy
vessel may also be contributing factors to sensor specification.

27
Use Automation to Monitor Inventory in Silos
Why do factories still have
‘maintenance’ departments?
Also note if the silos are grouped in any way by location. Silos grouped together phys-
ically can be addressed with wiring configurations such as daisy-chaining. Silos dis- Timken Power Systems Industrial
Drivetrain Repair Services
tanced further from power can be good candidates for battery-operated sensors and
Pump Powertrain Project for a
wireless devices. An inventory management system can be used across multiple plants
Wastewater Treatment Plant
or corporately for hundreds of silos.
Six steps to design a preventive
maintenance program
Dryers, day bins, chillers, coolers, and IBCs are also excellent candidates for level
Remote Monitoring of Solids and
sensors and inventory monitoring. They can be easily added to the same system as Liquids Inventory in Silos
silos.
Use Automation to
Monitor Inventory in
2. How frequently you need measurements updated. Silos
Consider if you want measurements updated constantly or if readings at intervals
Five strategies to achieve world-
throughout the day will suffice. Continuous level sensors do as they name implies, they class preventive maintenance
update continuously and in real time. Readings taken at preset time intervals or on-de-
STVM Washdown Station
mand may also work for your plant. Technologies such as radar update in just seconds;
Wisconsin Cheese Group
while wireless laser is best for intervals every hour or 3 or 4 times a day to conserve Increases Uptime with STVM®
battery life. A SmartBob can be programmed at set time intervals such as marking the Washdown Station
beginning or end of a shift. Bobs also can take a measurement on demand with the How to write a maintenance task
push of a button or be set every couple of hours. procedure

Product Launch - The OnTrak

3. Where people see the data. SmartLube

From a communications standpoint, determine where people need to access the data. Ultrasound and the IIoT: the
Future of Condition Monitoring
Solutions can be designed to offer visibility from a control room, office, remote loca-
tion such as corporate headquarters, or from home. SaaS offers the option to log in to How to develop an asset
maintenance strategy
view inventory anywhere you have an internet connection.

28
Use Automation to Monitor Inventory in Silos
Why do factories still have
‘maintenance’ departments?
Another common device to provide convenience in the plant is a control console or
digital panel meter. These can be installed for walk up or drive-up access, indoors or Timken Power Systems Industrial
Drivetrain Repair Services
outdoors. For example, a driver delivering resin should check the silo level before they
Pump Powertrain Project for a
start loading material into a silo. They can confirm the entire load will fit into the silo
Wastewater Treatment Plant
and prevent the risk of overfilling. These push-button devices are easy to use and can
Six steps to design a preventive
be used for view-only access to data on the plant floor. maintenance program

Remote Monitoring of Solids and

Customize the system to your Liquids Inventory in Silos
operation. Use Automation to
As inventory systems are very flexible, they Monitor Inventory in
are used in most any size operation. An im- Silos
portant budgetary consideration is scalabili- Five strategies to achieve world-
ty. Some plants want to add level sensors to class preventive maintenance
silos incrementally or choose to selectively STVM Washdown Station
monitor only silos that are very active.
Wisconsin Cheese Group
Increases Uptime with STVM®
Vendor managed inventory can be a valu- Washdown Station

able strategy for processing facilities, espe- How to write a maintenance task
procedure
cially when supply chain chains are stressed.
Providing suppliers access to inventory Product Launch - The OnTrak
SmartLube
enables them to be proactive in ensuring
supplies are adequate and deliveries are Ultrasound and the IIoT: the
Future of Condition Monitoring
scheduled to prevent shortages.
Wireless laser level sensors How to develop an asset
eliminate the expense of running maintenance strategy
conduit and hiring electricians.

29
Use Automation to Monitor Inventory in Silos
Why do factories still have
‘maintenance’ departments?
Solutions for every type of processing facility.
Timken Power Systems Industrial
Different materials may require another type of sensor technology. For example, dust Drivetrain Repair Services
can impact the short-term performance of some technologies that have trouble see-
Pump Powertrain Project for a
ing though dust while the silo is being filled. Wastewater Treatment Plant

Six steps to design a preventive

It is easy to have a variety of sensor types at a single location, each suited to the size maintenance program
of vessel and the type of material in it. There are sensors compatible with analog or Remote Monitoring of Solids and
4-20 mA outputs, Modbus, or HART that can be applied as needed for the job to be Liquids Inventory in Silos
done.
Use Automation to
Monitor Inventory in
For the most part equipment used by food, beverage, chemical, plastic, mining, Silos
cement, biofuels, recyclers, and many other industries is very similar. What you are Five strategies to achieve world-
manufacturing doesn’t matter so much how the material behaves and how active the class preventive maintenance
vessel or hopper is. STVM Washdown Station

Wisconsin Cheese Group

An automated inventory system using level sensors and software is highly affordable. Increases Uptime with STVM®
It offers simplicity and speed, while allowing plant personnel to be safe and more ef- Washdown Station

fective (and happy) in their jobs. One quick call can get your plants needs specified. How to write a maintenance task
procedure

Product Launch - The OnTrak

SmartLube

Ultrasound and the IIoT: the

Future of Condition Monitoring

How to develop an asset

maintenance strategy

30
Five strategies to achieve world- Why do factories still have

class preventive maintenance

‘maintenance’ departments?

Timken Power Systems Industrial

Drivetrain Repair Services
A step-by-step process ensures better results, reliability. Pump Powertrain Project for a
Wastewater Treatment Plant

M ore than ever, manufacturers must focus on establishing preventive maintenance

programs as a base to build upon their competitive strategy within the market.
After all, premium performance of production equipment drives profitability and can
Six steps to design a preventive
maintenance program

Remote Monitoring of Solids and

transform an organization’s operational success. Liquids Inventory in Silos

Use Automation to Monitor

To ensure high performance, manufacturers should focus on implementing a world-class Inventory in Silos
preventive maintenance program, which occurs when organizations spend 90% or more of
Five strategies to
their time on preventive maintenance without requiring the machinery to be taken offline. achieve world-class
preventive maintenance
A focus on preventive maintenance benefits the organization in a number of ways. STVM Washdown Station
First, it significantly reduces the costs associated with maintenance. Breakdown main-
Wisconsin Cheese Group
tenance costs can be as much as five times higher than the same activity done in a Increases Uptime with STVM®
planned fashion, and that doesn’t even take into account the revenue loss from de- Washdown Station

creased product inventories. How to write a maintenance task

procedure

Second, preventive maintenance allows the maintenance organization to focus on Product Launch - The OnTrak
SmartLube
high-level priorities. Elevating your planning from a tactical approach to strategic can help
extend the life of essential assets. Additionally, the maintenance team can become a key Ultrasound and the IIoT: the
Future of Condition Monitoring
proponent for larger strategic decisions within the organization, such as capital planning.
How to develop an asset
maintenance strategy
Consider these five strategies to help your team establish a world-class preventive
maintenance program and experience the resulting operational gains.
31
Five strategies to achieve world-class preventive maintenance
Why do factories still have
‘maintenance’ departments?
1. Conduct a review
Timken Power Systems Industrial
Prior to beginning any preventive maintenance procedures, especially if there aren’t Drivetrain Repair Services
any already in place, conduct a review and understand what assets and programs cur-
Pump Powertrain Project for a
rently exist. Without insight into current activities, it can be impossible to understand Wastewater Treatment Plant
key gaps and areas for improvement.
Six steps to design a preventive
maintenance program
The review should capture: Remote Monitoring of Solids and
Liquids Inventory in Silos
• Assets. Without a strong understanding of owned assets and their associated con- Use Automation to Monitor
ditions, you can’t put a solid preventive maintenance program in place. Inventory in Silos
• Procedures. Understanding the organization’s current library of procedures can Five strategies to
help you quickly identify any gaps that may exist in the processes. It can also pro- achieve world-class
vide context to where your team’s priorities already lie. preventive maintenance
STVM Washdown Station
• People. Knowing how the maintenance team spends their days can help organiza-
Wisconsin Cheese Group
tions realize better ways to leverage their talent. While the activity can be time-inten- Increases Uptime with STVM®
sive, it also can be the most fruitful as employees will often share where they see key Washdown Station

gaps in current processes and procedures that may not be otherwise obvious. How to write a maintenance task
procedure

2. Establish standardized operating procedures for reactive Product Launch - The OnTrak
SmartLube
and preventive maintenance
Ultrasound and the IIoT: the
As organizations grow larger, either by adding more shifts or locations, doing things Future of Condition Monitoring
the way they’ve always been done won’t necessarily work anymore. A U.S.-based metal
How to develop an asset
manufacturing organization that was quickly growing learned this the hard way. After maintenance strategy
adding two additional facilities with the same equipment, they noticed one plant had
significantly more downtime than the other.
32
Five strategies to achieve world-class preventive maintenance
Why do factories still have
‘maintenance’ departments?
The engineers and technicians
were conducting preventive Timken Power Systems Industrial
Drivetrain Repair Services
maintenance on a regular ba-
Pump Powertrain Project for a
sis, and were also diligent in
Wastewater Treatment Plant
responding to reactive main-
Six steps to design a preventive
tenance requests quickly and maintenance program
efficiently. Even so, the unprec-
Remote Monitoring of Solids and
edented downtime for the new Liquids Inventory in Silos
location was so high it was im-
Use Automation to Monitor
pacting its profitability. Inventory in Silos

Five strategies to
The organization compared pre- achieve world-class
ventive maintenance procedures preventive maintenance
that had been conducted on the
STVM Washdown Station
equipment in the past month and
Wisconsin Cheese Group
found they were incomparable to Increases Uptime with STVM®
each other. Because they didn’t Washdown Station
have standardized operating pro- How to write a maintenance task
cedures in place, the staff at each procedure

facility had to navigate the waters Product Launch - The OnTrak

on their own—determining the SmartLube

best way to approach different Ultrasound and the IIoT: the

Future of Condition Monitoring
scenarios based only on the infor-
mation they had been given. How to develop an asset
maintenance strategy

By establishing standardized oper-

33
Five strategies to achieve world-class preventive maintenance
Why do factories still have
‘maintenance’ departments?
ating procedures across the board, organizations can greatly improve the outcomes from
both reactive and preventive maintenance. These procedures can be as simple as outlining Timken Power Systems Industrial
Drivetrain Repair Services
the types of tools that should be used on particular maintenance requests, or as complex
Pump Powertrain Project for a
as outlining the exact procedure to take apart a piece of equipment for repair or main-
Wastewater Treatment Plant
tenance upkeep. In the case of this manufacturer, they were able to institute established
Six steps to design a preventive
procedures to bring downtime to normal levels. maintenance program

Remote Monitoring of Solids and

3. Create a reliability and maintenance policy with an improve- Liquids Inventory in Silos
ment plan Use Automation to Monitor
Planning sits at the center of becoming more cost-effective with your maintenance Inventory in Silos

activities. To prevent failure, establish a sound reliability and maintenance policy that Five strategies to
incorporates an improvement plan. Industry experts recommend that the improvement achieve world-class
plan outlines documentation for a 3- and 5-yr timeline. preventive maintenance
STVM Washdown Station
The policy itself should establish objectives, goals, and key responsibilities for the
Wisconsin Cheese Group
team. Other essential elements in the document include: Increases Uptime with STVM®
Washdown Station

• Current state versus future goals How to write a maintenance task

procedure

• Key performance indicators (KPIs) Product Launch - The OnTrak

SmartLube

• Importance of KPIs and organizational value Ultrasound and the IIoT: the
Future of Condition Monitoring

• Internal recognition for reaching goals How to develop an asset

maintenance strategy

• Importance of reliability to the entire organization

34
Five strategies to achieve world-class preventive maintenance
Why do factories still have
‘maintenance’ departments?
• How maintenance feeds into plant competitiveness
Timken Power Systems Industrial
Drivetrain Repair Services
• Timeline and key internal stakeholders
Pump Powertrain Project for a
Wastewater Treatment Plant
• How employees can submit comments and feedback.
Six steps to design a preventive
maintenance program
Once you’ve determined your policy and improvement plans, think about how you will
Remote Monitoring of Solids and
store it and how employees will access it. By leveraging a technology solution, like a Liquids Inventory in Silos
computerized maintenance management system (CMMS), ensure that it’s readily at the
Use Automation to Monitor
hands of everyone to review and access at any time. Inventory in Silos

Five strategies to
4. Leverage technology to advance your preventive mainte- achieve world-class
nance program preventive maintenance
For decades, plant automation has helped optimize plant equipment. To this day, it STVM Washdown Station
has helped manufacturing organizations significantly reduce costs, both from a produc-
Wisconsin Cheese Group
tion and people standpoint. Increases Uptime with STVM®
Washdown Station

So, where does preventive maintenance technology fit in? In leveraging CMMS solu- How to write a maintenance task
procedure
tions, there’s the opportunity to use the data you gain in plant automation to take your
preventive maintenance up a notch. Product Launch - The OnTrak
SmartLube

Using manual processes, such as spreadsheets or even paper documents, to manage Ultrasound and the IIoT: the
Future of Condition Monitoring
your preventive maintenance schedules consumes time, promotes redundancies, and
drains resources. A CMMS solution allows all data to be automatically updated on a How to develop an asset
maintenance strategy
regular schedule and include the exact information that is necessary to complete the
PM request.
35
Five strategies to achieve world-class preventive maintenance
Why do factories still have
‘maintenance’ departments?
For an engineer or technician working out in the field, they can use their mobile device
to pull up all the information they need—the specific request, procedure information, Timken Power Systems Industrial
Drivetrain Repair Services
and inspection details—and record their work and findings as they go.
Pump Powertrain Project for a
Wastewater Treatment Plant
In addition, a CMMS solution can track how teams are spending time on a daily basis
Six steps to design a preventive
to help departments plan more effectively in the future. Leveraging business intelli- maintenance program
gence and reporting capabilities offer maintenance departments the opportunity to
Remote Monitoring of Solids and
showcase activities and how they are obtaining key performance indicators. Liquids Inventory in Silos

Use Automation to Monitor

5. Secure 100% execution of preventive maintenance in line Inventory in Silos

with the 10% rule Five strategies to

Oftentimes, organizations will assign a 10-day or even a 30-day deadline for monthly achieve world-class
preventive maintenance procedures to give technicians the time they need to execute preventive maintenance
tasks. When this occurs, it’s likely your preventive maintenance procedures are being STVM Washdown Station
completed sporadically, which can limit their effectiveness.
Wisconsin Cheese Group
Increases Uptime with STVM®
For instance, a monthly preventive maintenance task comes up at the beginning of Washdown Station

July, but due to vacations and other issues within the plant, it’s delayed until the end of How to write a maintenance task
procedure
the month. It’s still considered as completed on time and, thus, in compliance.
Product Launch - The OnTrak
SmartLube
In August, the technician has enough time to complete preventive maintenance on the
second day of the month. September comes along and has many of the same prob- Ultrasound and the IIoT: the
Future of Condition Monitoring
lems as July, so it’s not completed until the end of the month.
How to develop an asset
maintenance strategy
Lack of consistency within these months makes it difficult for preventive maintenance,
which needs to be done on a regular and consistent schedule, to work for your orga-
36
Five strategies to achieve world-class preventive maintenance
Why do factories still have
‘maintenance’ departments?
nization. Because of this, it’s important to focus on the 10% rule of preventive mainte-
nance: the task must be executed within a 10% variation of the time frequency of the Timken Power Systems Industrial
Drivetrain Repair Services
request. In the case of a 30-day preventive maintenance activity, it must be completed
Pump Powertrain Project for a
within 1.5 days on either side of the due date to be compliant.
Wastewater Treatment Plant

Six steps to design a preventive

Aiming for 100% compliance in line with the 10% rule can significantly improve your maintenance program
preventive maintenance outcomes, as it will optimize reliability of equipment and
Remote Monitoring of Solids and
reduce equipment failures, propelling you into a world-class preventive maintenance Liquids Inventory in Silos
organization.
Use Automation to Monitor
Whether an organization manages preventive maintenance activities manually or via Inventory in Silos
an extensive asset lifecycle management program, there is always room for improve-
Five strategies to
ment—even when there’s zero-reactive maintenance. achieve world-class
preventive maintenance
Once a reliability and maintenance policy and associated improvement plans are in
STVM Washdown Station
place, it requires constant refining to ensure it meets the dynamic demands of the in-
Wisconsin Cheese Group
dustry and organization. Increases Uptime with STVM®
Washdown Station
In fact, organizations with world-class preventive maintenance programs spend time How to write a maintenance task
each quarter to assess the current state of the program and how it can be improved. procedure

Once established, however, it opens doors to extend your maintenance program be- Product Launch - The OnTrak
yond that by integrating predictive maintenance techniques and technologies. SmartLube

Ultrasound and the IIoT: the

Future of Condition Monitoring
Lora Mays
Lora Mays is a product marketing manager at Accruent, which provides real estate How to develop an asset
maintenance strategy
and facilities management solutions to more than 4,000 customers in 120 countries.

37
STVM Washdown Station
Why do factories still have
‘maintenance’ departments?

Timken Power Systems Industrial

Drivetrain Repair Services

Pump Powertrain Project for a

Wastewater Treatment Plant

Six steps to design a preventive

maintenance program

Remote Monitoring of Solids and

Liquids Inventory in Silos

Use Automation to Monitor

Inventory in Silos

 Five strategies to achieve world-

class preventive maintenance

STVM Washdown
Station
Wisconsin Cheese Group
Increases Uptime with STVM®
Washdown Station

STVM Washdown Station How to write a maintenance task

procedure
The STVM® Washdown Station delivers a high temperature
Product Launch - The OnTrak
wash at a user-defined temperature using our proprietary SmartLube
mixing valve to combine steam and water. Our Silent Type
Ultrasound and the IIoT: the
Venturi Mixing Valve (STVM®) design is self-scouring to Future of Condition Monitoring
minimize mineral buildup and reduce maintenance frequency.
How to develop an asset
maintenance strategy

38
 Wisconsin W isconsin Cheese Group, LLC., is a manufacturer
and distributor of Hispanic cheeses located in
Monroe, Wisconsin.

Cheese Group Operated by more than 30 employees, the facility re-

Increases Uptime cently identified a need for a process sanitizing wash-

down station and contacted ThermOmegaTech ® to find

with STVM®
a solution.

For production facilities everywhere, time is money. Lines

Washdown need to keep moving, batches completed, and dead-

lines met. To stay on track, the brief pause in the cho-

Station
reographed movements of people, parts, and product to
sanitize equipment must be minimized.

Employees cannot be waiting around for water to warm

up or for routine maintenance to be completed.

To satisfy Wisconsin Cheese Group’s need for consistent

washdown water temperature and timely maintenance,
the STVM® Washdown Station was recommended.

The STVM® Washdown Station delivers a high tempera-

ture wash at a user-defined temperature using our propri-
etary Silent Type Venturi Mixing (STVM®)
Wisconsin Cheese Group Increases Uptime with STVM® Washdown Station
Why do factories still have
‘maintenance’ departments?
Valve to combine steam and water. Our mixing
valve’s design is self-scouring, which prevents Timken Power Systems Industrial
Drivetrain Repair Services
mineral buildup in tight spaces and reduces
Pump Powertrain Project for a
maintenance frequency.
Wastewater Treatment Plant

Six steps to design a preventive

To minimize downtime during routine main- maintenance program
tenance, the STVM ® Washdown Station has a
Remote Monitoring of Solids and
simple cartridge design and is in-line service- Liquids Inventory in Silos
able. The operator simply switches out the
Use Automation to Monitor
STVM ® Cartridge with a spare and the unit is Inventory in Silos
operating again in minutes. Five strategies to achieve world-
class preventive maintenance
The facility installed 12 STVM® Washdown STVM Washdown Station
Stations and have reported positively. “We
Wisconsin Cheese
needed consistent hot water for sanitation and
Group Increases
we really liked the cartridge technology,” Dave Uptime with STVM®
Treuthardt of Wisconsin Cheese Group com- Washdown Station
mented. “The washdown stations were easy to
How to write a maintenance task
install and run effectively.” procedure

Product Launch - The OnTrak

ThermOmegaTech ®’s STVM® Washdown Station is available for purchase through the SmartLube
company’s food and beverage channel partner – ACE Sanitary. Visit their website at Ultrasound and the IIoT: the
www.AceSanitary.com Future of Condition Monitoring

How to develop an asset

About ThermOmegaTech : For over 35 years, ThermOmegaTech has been a leader
® ® maintenance strategy

in the design and manufacture of self-actuated thermostatic technology. Founded in

40
Wisconsin Cheese Group Increases Uptime with STVM® Washdown Station
Why do factories still have
‘maintenance’ departments?
1983, ThermOmegaTech ® is a privately
held organization with 40,000 square Timken Power Systems Industrial
Drivetrain Repair Services
feet of manufacturing and office facility
Pump Powertrain Project for a
located near Philadelphia, Pennsylvania.
Wastewater Treatment Plant

Six steps to design a preventive

The company provides innovative solu- maintenance program
tions for a wide range of applications
Remote Monitoring of Solids and
including freeze & scald protection, Liquids Inventory in Silos
mixing & diverting, steam traps, thermal
Use Automation to Monitor
bypass, tepid water delivery, washdown, Inventory in Silos
balancing, drain tempering, and many Five strategies to achieve world-
other applications where temperature class preventive maintenance
control is critical. STVM Washdown Station

Wisconsin Cheese
Key industries it serves include railroad, commercial plumbing, aerospace & defense
Group Increases
and industrial. Over 95% of its products are manufactured, calibrated, and tested in- Uptime with STVM®
house. R&D, prototype development, and integrated solutions are managed on site. Washdown Station
ThermOmegaTech ® is AS9100D certified and its products are distributed and used
How to write a maintenance task
worldwide. procedure

Product Launch - The OnTrak

SmartLube

Ultrasound and the IIoT: the

Future of Condition Monitoring

How to develop an asset

maintenance strategy

41
How to write a maintenance Why do factories still have

task procedure
‘maintenance’ departments?

Timken Power Systems Industrial

Drivetrain Repair Services
Thorough maintenance task procedures document the repair process and Pump Powertrain Project for a
make everyone accountable for their actions. Wastewater Treatment Plant

Six steps to design a preventive

W hile asset maintenance analysis tools have become more sophisticated, provid-
ing simple, clear and actionable maintenance task procedures remain essential.
maintenance program

Remote Monitoring of Solids and

Liquids Inventory in Silos
A trip down maintenance memory lane Use Automation to Monitor
As a young technician, I was tasked to develop a simple maintenance checklist for a Inventory in Silos

critical piece of equipment. Prior to that, my company’s maintenance plan was “fix it Five strategies to achieve world-
when it breaks.” class preventive maintenance

STVM Washdown Station

So where did I start? I found the technical publication for the asset I was tasked to Wisconsin Cheese Group
maintain. It had great disassembly and reassembly procedures and some recommend- Increases Uptime with STVM®
Washdown Station
ed checks: grease bearings, check oil level, inspect gear teeth. However, it was sparse
on details for these checks. After years of use, the manual was worn, and pages were How to write a
missing. maintenance task
procedure
Luckily, even during my early career we were capturing machines’ history data on 5” Product Launch - The OnTrak
SmartLube
X 7” index cards using an asset identification numbering system that those in the U.
S. Navy and Coast Guard know as the allowance parts list (APL) number. I sat down Ultrasound and the IIoT: the
Future of Condition Monitoring
with the machinery history data cards and the technical manual. I read what was rec-
How to develop an asset
ommended by the machine’s original equipment manufacturer (OEM). I reviewed this
maintenance strategy
asset’s failures and the tasks we were performing to maintain it.

42
How to write a maintenance task procedure
Why do factories still have
‘maintenance’ departments?

Timken Power Systems Industrial

Drivetrain Repair Services

Pump Powertrain Project for a

Wastewater Treatment Plant

Six steps to design a preventive

maintenance program

Remote Monitoring of Solids and

Liquids Inventory in Silos

Use Automation to Monitor

Inventory in Silos

Five strategies to achieve world-

class preventive maintenance

STVM Washdown Station

Wisconsin Cheese Group

Increases Uptime with STVM®
Courtesy: CFE Media and Washdown Station
I found out the work being documented on the machinery
Technology
history card did not reflect all the work being done to the as- How to write a
set. There was some information, but it reflected our fix-it-when maintenance task
it-breaks maintenance philosophy. With guidance from my supervisor, a leader ahead procedure
of his time, we decided to start with basic checks that would be conducted pre-and Product Launch - The OnTrak
SmartLube
post-operation; monthly, quarterly, semi-annually, and annually.
Ultrasound and the IIoT: the
Future of Condition Monitoring
I looked at the OEM recommendations and then the breakdowns shown on the ma-
chinery history. It became apparent our lubrication program was not adequate: We How to develop an asset
maintenance strategy
were over greasing the points that were accessible and not greasing the ones that
were out of sight. It also became evident the asset was not being properly operated.
43
How to write a maintenance task procedure
Why do factories still have
‘maintenance’ departments?
Avoid errors of
Timken Power Systems Industrial
omission Drivetrain Repair Services
The lessons I learned from that
Pump Powertrain Project for a
early-career experience continue Wastewater Treatment Plant
to serve me today. In working Six steps to design a preventive
with various organizations and maintenance program
assets, I’m challenged to rectify Remote Monitoring of Solids and
the problems caused by inade- Liquids Inventory in Silos
quate maintenance documenta- Use Automation to Monitor
tion. My experiences have made Inventory in Silos

me a stickler for detailed mainte- Five strategies to achieve world-

class preventive maintenance
nance procedures and checklists
based off failure modes, mainte- STVM Washdown Station
nance task analysis, and operator Wisconsin Cheese Group
and maintainer training. Increases Uptime with STVM®
Washdown Station

Most of us have graduated from How to write a

5” X 7’” index cards to comput- maintenance task
procedure
erized maintenance management
systems (CMMS), from greasy Product Launch - The OnTrak
SmartLube
technical manuals to electron-
ic manuals on a tablet or other Ultrasound and the IIoT: the
Future of Condition Monitoring
handheld device. However, many
How to develop an asset
organizations still struggle to use
maintenance strategy
good procedures when executing
maintenance programs.
44
How to write a maintenance task procedure
Why do factories still have
‘maintenance’ departments?
Creating a maintenance task list
Timken Power Systems Industrial
The best way to stay on track with your asset maintenance program? Stick to a step by Drivetrain Repair Services
step task list.
Pump Powertrain Project for a
Wastewater Treatment Plant
1. Set up a method to quickly identify the asset and its maintenance re-
Six steps to design a preventive
quirements. maintenance program
During one site assessment, I spent almost a 1/2 hour with a new technician trying to Remote Monitoring of Solids and
locate a piece of equipment on the floor. Because the facility had recently been mod- Liquids Inventory in Silos
ified and a new site map had not been created, it took the supervisor another 10 min- Use Automation to Monitor
utes to finally locate it. Take a picture of the asset. Identify its location on the facility Inventory in Silos
map. Many organizations now barcode or QR code their assets so the technician can Five strategies to achieve world-
capture the tag from their device and immediately get detailed information for that class preventive maintenance

asset. STVM Washdown Station

Wisconsin Cheese Group

2. Now that we have identified the asset, do we have everything we Increases Uptime with STVM®
Washdown Station
need to do the job?
I hate going back to the storehouse to get a part I need that should have been identi- How to write a
fied or a torque wrench that should have been called out. How common is this for the maintenance task
technicians at your site? procedure
Product Launch - The OnTrak
SmartLube
What tools do we need? A standard wrench set or a special stubby wrench to fit into
a tight space? A belt tension gage for checking v-belts? A straight edge if you do not Ultrasound and the IIoT: the
Future of Condition Monitoring
have a tension gage? Do we need any lubricants? What type of grease should I use?
Can’t I use either a Lithium (12-Hydroxy Stearate) or a Lithium Complex grease? No, How to develop an asset
maintenance strategy
the temperature ranges are different. Be specific when calling out lubricants, and train
personnel in proper lube procedures. Will we need to change filters on the asset? Doc-
45
How to write a maintenance task procedure
Why do factories still have
‘maintenance’ departments?
ument on the procedure the name and part number of the filter or other parts that will
be required. Timken Power Systems Industrial
Drivetrain Repair Services

Pump Powertrain Project for a

3. Are there any special requirements for this job? Wastewater Treatment Plant
Are we sending the right person to do the job? The scheduler must know who to as-
Six steps to design a preventive
sign to the task. Can an apprentice handle it? Or do we need a master technician? maintenance program

Remote Monitoring of Solids and

4. Considerations for step-by-step procedures. Liquids Inventory in Silos
Organizations that send technicians with minimal skills and training may want incredi-
Use Automation to Monitor
bly detailed instructions that are truly error-proof, where steps are called out down to Inventory in Silos
the number of turns of the screwdriver required to remove a screw. Five strategies to achieve world-
class preventive maintenance
I recommend keeping procedural steps as concise as possible. Include pictures or STVM Washdown Station
graphics. Write procedures that match the technicians’ levels of competency and train-
Wisconsin Cheese Group
ing. Keep the detail at the right level. Now you can even embed videos and show the Increases Uptime with STVM®
technician what they should be doing. Washdown Station

How to write a
Are there special circumstances the technician needs to be aware of? Call out warn- maintenance task
ings (items that can cause personal injury), cautions (which emphasize steps that could procedure
result in equipment damage if not properly performed) and notes to emphasize these Product Launch - The OnTrak
circumstances or steps. SmartLube

Ultrasound and the IIoT: the

Future of Condition Monitoring
There should be a space available on the maintenance form for the technician to add
“condition found” and “condition left” comments. In what state did they find the asset How to develop an asset
maintenance strategy
before performing maintenance? Are there discrepancies that need attention, such as
a leak or a loose fastener that requires corrective maintenance?
46
How to write a maintenance task procedure
Why do factories still have
‘maintenance’ departments?
The form should also include space for the technician to comment on how they left the
asset. Did they take care of the loose fastener? Wipe up the leak? Identify what needs Timken Power Systems Industrial
Drivetrain Repair Services
to be fixed? Start a corrective work order?
Pump Powertrain Project for a
Wastewater Treatment Plant
Provide a sign off space if there are any special steps that require quality assurance.
Six steps to design a preventive
Does the technician want a second party to verify that they performed a critical step maintenance program
correctly? Do they need another pair of eyes to make sure the seal cover is torqued
Remote Monitoring of Solids and
correctly? Is it worth the time/cost to have someone verify it? Liquids Inventory in Silos

Use Automation to Monitor

Finally, your form should use the terminology common to your industry, the trade Inventory in Silos
being tasked to perform the work and the document style prescribed by the organi- Five strategies to achieve world-
zation. class preventive maintenance

STVM Washdown Station

Give the maintenance task a final review Wisconsin Cheese Group
After developing the task, take a break. When it comes time to review, ask these ques- Increases Uptime with STVM®
Washdown Station
tions:
How to write a
• Can I explain how this task minimizes the risk of failure occurring? Is the asset maintenance task
properly and clearly identified with a common name and tag ID? procedure
Product Launch - The OnTrak
SmartLube
• Did I choose the correct skill needed for the task? Is that skill currently available?
Will I need to provide initial training? Ultrasound and the IIoT: the
Future of Condition Monitoring

• Have I identified the safety precautions, tools, parts and consumables the techni- How to develop an asset
maintenance strategy
cian will need? Are those items readily available? Nothing frustrates techs like trips
to the storeroom to get a required tool or part that wasn’t called out.
47
How to write a maintenance task procedure
Why do factories still have
‘maintenance’ departments?
• Have I identified all the warnings, cautions and notes needed to ensure the safety
of personnel, equipment, and the facility? Timken Power Systems Industrial
Drivetrain Repair Services

Pump Powertrain Project for a

• Are my procedure steps in logical sequence? Do they make sense? Have your
Wastewater Treatment Plant
technicians review and walk through the procedure. Incorporate their feedback
Six steps to design a preventive
into the final procedure. maintenance program

Remote Monitoring of Solids and

Operators and technicians are your eyes, ears and noses on the plant floor. Their feed- Liquids Inventory in Silos
back loop is critical to continuous improvement. Give them a way to provide comments
Use Automation to Monitor
and ideas and let them know you are looking at it. To this goal, did I include white Inventory in Silos
space in the asset maintenance procedures for technicians to add their comments on Five strategies to achieve world-
the condition they found and left the asset? class preventive maintenance
Are there critical steps on the task that require quality assurance (QA)? Who can sign STVM Washdown Station
off on the check? Have I provided specifications on what is satisfactory/unsatisfactory?
Wisconsin Cheese Group
What does good look like? Increases Uptime with STVM®
Washdown Station

Finally, get the technician to own their work by signing off that it was properly complet- How to write a
ed. This allows the maintenance task to be closed out. maintenance task
procedure
Hank Kocevar, CMRP Product Launch - The OnTrak
Hank Kocevar, CMRP, is a senior consultant to Daniel Penn Associates, a CFE Media SmartLube

content partner. Ultrasound and the IIoT: the

Future of Condition Monitoring

How to develop an asset

maintenance strategy

48
Product Launch - The OnTrak SmartLube
Why do factories still have
‘maintenance’ departments?

Timken Power Systems Industrial

Drivetrain Repair Services

Pump Powertrain Project for a

Wastewater Treatment Plant

Six steps to design a preventive

maintenance program

Remote Monitoring of Solids and

Liquids Inventory in Silos

Use Automation to Monitor

Inventory in Silos

 Five strategies to achieve world-

class preventive maintenance

STVM Washdown Station

Wisconsin Cheese Group

Increases Uptime with STVM®
Washdown Station

How to write a maintenance task

procedure
Product Launch - The OnTrak SmartLube
Product Launch - The
UE Systems is excited to share our latest innovation - the
OnTrak SmartLube
OnTrak SmartLube. This webinar will be an overview of how
we are Disrupting Bearing Lubrication Prescriptive Bearing Ultrasound and the IIoT: the
Future of Condition Monitoring
Monitoring and Precision Lubrication from Anywhere,
Anytime! How to develop an asset
maintenance strategy

49
 Ultrasound W hen a powerful and versatile technology such as
Ultrasound meets the Internet of Things, new solu-
tions arise that will take condition monitoring of assets to

and the IIoT: a whole new level. The development of ultrasonic sensors
and their integration with data collection points promise

the Future to be a game changer when it comes to continuous and

remote monitoring of industrial assets.

of Condition Why Ultrasound?

Airborne & structure-borne ultrasound has certainly be-

Monitoring come a major player in condition monitoring. Once con-

sidered just a leak detector, more maintenance & reliability
professionals are beginning to realize all of the benefits
associated with using ultrasound for condition monitoring
applications.

The P-F Curve with which we have all become familiar with
reflects that trend: ultrasound is considered one of the first
lines of defence against unplanned downtime, being able
to spot bearing failures at a very early stage.

Besides, ultrasound is well known for its versatility: the

technology can be applied to different domains such as
leak detection, bearings condition monitoring & lubrica-
tion, steam traps & valves inspections and electrical in-
spections.
Ultrasound and the IIoT: the Future of Condition Monitoring
Why do factories still have
‘maintenance’ departments?
Traditionally, and still nowadays more commonly, ultrasound technology is used in
maintenance and condition monitoring practices via handheld devices. These have Timken Power Systems Industrial
Drivetrain Repair Services
been going through their own enhancements and many of them are sophisticated in-
Pump Powertrain Project for a
spection devices and data collectors which can greatly improve any reliability program.
Wastewater Treatment Plant

Six steps to design a preventive

The Surge of Ultrasonic Sensors maintenance program
The ultrasonic handheld devices certainly still play an important role, but when we cou- Remote Monitoring of Solids and
ple the technology with the capabilities that the internet brings us, we can create pow- Liquids Inventory in Silos
erful monitoring solutions by using ultrasonic sensors connected to network-enabled Use Automation to Monitor
devices. The sensors are always listening, as if an inspector was always there inspecting Inventory in Silos

the asset, continuously, 24/7. They collect data from assets in the form of dB readings Five strategies to achieve world-
and send them to central devices who will process the data. This brings, of course, a class preventive maintenance

huge potential for improvements on maintenance & reliability programs. We can now STVM Washdown Station
setup alarms, notifications, trend the condition of assets… all automatic, seamless and Wisconsin Cheese Group
taking advantage of the well-known benefits of ultrasound technology. Increases Uptime with STVM®
Washdown Station

Sensors for mechanical assets How to write a maintenance task

procedure
Imagine you have an asset at your facility, let’s say a bearing. This is a critical asset that
Product Launch - The OnTrak
simply can’t fail. An ultrasound sensor can be permanently mounted on the bearing,
SmartLube
continuously collecting dB readings and sending them to a data processing box. Is the
dB reading abnormal? You get notified by email or SMS. You are always on top of your Ultrasound and the
IIoT: the Future of
assets condition. Alarms can be setup according to your needs: want to know when a
Condition Monitoring
bearing needs lubrication? When there’s a damage on it? Want to have a sound re-
How to develop an asset
cording of the bearing when an alarm is reached? Everything is possible since mainte- maintenance strategy
nance managers will be able to setup their own alarm thresholds and notifications. And
make unplanned downtime a thing of the past.
51
Ultrasound and the IIoT: the Future of Condition Monitoring
Why do factories still have
‘maintenance’ departments?
Sensors for electrical assets
Timken Power Systems Industrial
The same applies to ultrasound applications requiring airborne sensors, such as elec- Drivetrain Repair Services
trical inspections. Place the airborne sensors next to your critical equipment, and they
Pump Powertrain Project for a
will be constantly listening to these assets. As soon as something abnormal is picked Wastewater Treatment Plant
up by the sensors, data in the form of dB readings & sound recordings will be sent to a
Six steps to design a preventive
central processing box, which will again trigger the setup alarms and notifications. Ul- maintenance program
trasound has proven to be an excellent technology when it comes to finding electrical Remote Monitoring of Solids and
faults such as corona, tracking, arcing or mechanical looseness. Coupled with online Liquids Inventory in Silos
sensors, improvements in safety and inspection methods could be huge. Use Automation to Monitor
Inventory in Silos

New Ultrasound based IIoT Solutions Five strategies to achieve world-

class preventive maintenance
There are already easy to implement solutions on the market that couple ultrasound
technology with sensors and network-connected devices, allowing for truly continuous STVM Washdown Station
and remote monitoring. Wisconsin Cheese Group
Increases Uptime with STVM®
Washdown Station
For bearings and other mechanical assets, there is for example the On-Trak, a remote
IIoT bearing monitoring system using UE Systems’ Ultra-Trak 750 sensors. The system How to write a maintenance task
procedure
is composed of 16 sensors and a central processing box that can be connected to the
Product Launch - The OnTrak
network via wifi, ethernet or cellular data. Data from the sensors can be easily viewed
SmartLube
on any laptop, tablet or phone. Real time insights and notifications can be used to con-
stantly monitor lubrication & condition insights. Additionally, data can be integrated to Ultrasound and the
IIoT: the Future of
cloud platforms such as Azure, AWS, Google, IBM Watson, PTC, Thingworkx, etc. As
Condition Monitoring
part of the of the On-Trak suite of solutions, UE has released SmartLube: a powerful,
How to develop an asset
accurate and easy-to-use application designed to monitor bearing friction and remote-
maintenance strategy
ly lubricate from anywhere, anytime on any supported device.

52
Ultrasound and the IIoT: the Future of Condition Monitoring
Why do factories still have
‘maintenance’ departments?
Another solution for bearing monitoring is the 4Cast, working with the RAS (Remote
Access Sensors) from UE Systems. Up to 4 sensors can be connected to a 4Cast box, Timken Power Systems Industrial
Drivetrain Repair Services
which then connects to the network via Ethernet to provide data insights from the
Pump Powertrain Project for a
bearings. Data is then sent to UE Systems DMS 6 software for trending an analysis. The
Wastewater Treatment Plant
great advantage of the 4Cast is its ability to also record and store sound samples from
Six steps to design a preventive
the monitored bearings – this feature, together with the ability to create instant alarms, maintenance program
makes the 4Cast a great solution for critical and slow speed bearings.
Remote Monitoring of Solids and
Liquids Inventory in Silos
For electrical safety there is a solution such as the 4Site available. Similar to the 4Cast,
Use Automation to Monitor
it can record & store dB readings and sound samples from up to 4 sensors. In this case, Inventory in Silos
and since we are talking about electrical inspections, these sensors are airborne. On- Five strategies to achieve world-
line continuous ultrasound inspection can be performed at all voltage levels (low, me- class preventive maintenance
dium and high) and is used to detect corona, partial discharge or tracking, arcing and STVM Washdown Station
mechanical vibrations (transformers).
Wisconsin Cheese Group
Increases Uptime with STVM®
Conclusion Washdown Station

From handheld devices to connected sensors – this is the natural progression of ultra- How to write a maintenance task
procedure
sound technology when used in industrial environments for maintenance, condition
monitoring and reliability. Such as other technologies, integration in the IoT world will Product Launch - The OnTrak
SmartLube
become a fact, and though the current solutions are already bringing exciting ad-
vancements, there is still much to discover and explore. What we know for sure, is that Ultrasound and the
with the currently available solutions, maintenance departments have very effective IIoT: the Future of
Condition Monitoring
weapons to fight against issues such as unplanned downtime and electrical equipment
failures. How to develop an asset
maintenance strategy

53
How to develop an asset Why do factories still have

maintenance strategy
‘maintenance’ departments?

Timken Power Systems Industrial

Drivetrain Repair Services
Ask the basic questions too often overlooked, to improve asset management Pump Powertrain Project for a
Wastewater Treatment Plant

D oes your organization struggle to develop the right asset or equipment strategies
and practices? Do you fight to get traction from the programs that can help build
or improve existing strategies? Ask these basic yet often overlooked questions to help
Six steps to design a preventive
maintenance program

Remote Monitoring of Solids and

your teams improve and support the organization’s asset maintenance program. Liquids Inventory in Silos

Use Automation to Monitor

1. What percentage of your assets are critical? How many Inventory in Silos

have rankings assigned in our EAM/CMMS? Five strategies to achieve world-

class preventive maintenance
Critical equipment is the equipment or systems that would significantly impact the
company’s strategic goals were it to fail. Significant impact is determined and quanti- STVM Washdown Station

fied by your organization’s guiding principles. Do you know what those guiding princi- Wisconsin Cheese Group
ples are? Increases Uptime with STVM®
Washdown Station

How to write a maintenance task

If the asset fails, would it have major quantifiable consequences such as lost produc-
procedure
tion, safety or environmental consequences or other outcomes that degrade the com-
Product Launch - The OnTrak
pany’s reputation? SmartLube

Ultrasound and the IIoT: the

Determine what assets are critical to your operation. Review your asset criticality as- Future of Condition Monitoring
signments. Understanding why the asset is assigned is critical if this is the case. How
How to develop an
are high criticality assets distributed in the targeted area or system? If you do not cur-
asset maintenance
rently have criticality assigned for assets, start assigning them. strategy

To help a company develop asset strategies for critical equipment, myself and col-
54
How to develop an asset maintenance strategy
Why do factories still have
‘maintenance’ departments?
leagues did an analysis of a plant using SAP as their EAM/CMMS. When reviewing the
data, we found that less than 50% of the assets in SAP had a criticality indicator as- Timken Power Systems Industrial
Drivetrain Repair Services
signed. Of the items assigned an indicator, more than 75% were ranked as critical.
Pump Powertrain Project for a
Wastewater Treatment Plant
This company’s criticality assignment process reminded me of the adage, “If everything
Six steps to design a preventive
is important then nothing is important.” Is the radio in your vehicle as critical to the maintenance program
function of the vehicle as the brakes? Take a new look at assigning a ranking to assets
Remote Monitoring of Solids and
based on an organization’s criteria, mission and values. Liquids Inventory in Silos

Use Automation to Monitor

2. What are the criteria for identifying bad actors? Inventory in Silos
Identify the assets causing pain in the process. Use carefully selected criteria to identi- Five strategies to achieve world-
fy bad actor assets. Don’t just use work order counts or anecdotal evidence, e.g. “I’m class preventive maintenance
working on the conveyor every day.” Consider beginning with the assets having the STVM Washdown Station
biggest impact on production. Look at total downtime costs and repair costs. Don’t
Wisconsin Cheese Group
overlook items that have significant environmental or safety costs but may have mini- Increases Uptime with STVM®
Washdown Station
mal lost production cost.
How to write a maintenance task
procedure
Focus on equipment that really matters. What is failing that causes the greatest pro-
duction loss and consumes the most resources? Incorporate a defect elimination pro- Product Launch - The OnTrak
SmartLube
cess using root cause analysis (RCA) to identify significant failure causes. Take action to
eliminate the causes. Ultrasound and the IIoT: the
Future of Condition Monitoring

Company XYZ identified a compressor as a bad actor. It required frequent work orders How to develop an
to remedy excessive vibration. When the compressor was down, production dripped asset maintenance
strategy
by 10%. While doing the analysis it was discovered the compressor wasn’t really a bad
actor. The compressor was being run higher than design specifications. This resulted
55
How to develop an asset maintenance strategy
Why do factories still have
‘maintenance’ departments?
in excessive vibra-
tions, causing the Timken Power Systems Industrial
Drivetrain Repair Services
compressor to trip.
Pump Powertrain Project for a
Wastewater Treatment Plant
Moral to this story:
Six steps to design a preventive
Choose the right maintenance program
criteria to analyze
Remote Monitoring of Solids and
your bad actors. Liquids Inventory in Silos
Then eliminate the
Use Automation to Monitor
defect and oper- Inventory in Silos
ate the equipment Five strategies to achieve world-
within parameters. class preventive maintenance
Courtesy: CFE Media and
The compressor wasn’t sized properly for the function it was Technology STVM Washdown Station
being asked to perform.
Wisconsin Cheese Group
Increases Uptime with STVM®
3. Do we have an asset management plan? Washdown Station

If the answer is no, begin by developing an overall strategy. Once your strategy prior- How to write a maintenance task
procedure
itizes areas of focus, develop the asset management plan from those strategic priori-
ties. This is a comprehensive project. It should be detailed like a work order or mainte- Product Launch - The OnTrak
SmartLube
nance procedure.
Ultrasound and the IIoT: the
Future of Condition Monitoring
What human and technical resources will be required? How much time will you need?
What key data fields will you capture? How many RCM’s, FMEA’s, Asset Strategies or How to develop an
optimizations are you going after as proof of concept? Keep your first effort manage- asset maintenance
strategy
able in size and have metrics for measuring what success looks like.

56
How to develop an asset maintenance strategy
Why do factories still have
‘maintenance’ departments?
Focus your initial effort to get the most bang for the buck. If an asset has suffered from
chronic failures, was an RCA done? Have the recommendations been implemented? Timken Power Systems Industrial
Drivetrain Repair Services
Have they been effective? Can you associate any of your existing maintenance tasks to
Pump Powertrain Project for a
the failure modes or risks they are mitigating?
Wastewater Treatment Plant

Six steps to design a preventive

Do you have good start-up, maintenance, operating and shut-down procedures? Do maintenance program
these clearly identify the steps necessary for precision maintenance? Are parts and
Remote Monitoring of Solids and
tools identified? Are torque values called out? Are parameters for setpoints defined? Liquids Inventory in Silos
Are there QA sign offs for critical steps if needed?
Use Automation to Monitor
Inventory in Silos
In another example, another company we worked with was proud of their maintenance Five strategies to achieve world-
plans. They had detailed procedures for production assets. However, they had neglect- class preventive maintenance
ed some of the non-production but equally critical areas like the fire system. STVM Washdown Station

Wisconsin Cheese Group

During the plant tour I noted a few corroded valves and a fire pump tagged out of Increases Uptime with STVM®
service. I asked about the maintenance plan for the fire system and was informed a Washdown Station

plan really didn’t exist. The fire system was viewed as a run to fail or “we fix it when it How to write a maintenance task
breaks” system. The fire system was troublesome: valves stuck, piping leaks and old procedure

pumps that were difficult to support. The company did nothing preventive for fear Product Launch - The OnTrak
SmartLube
of causing more problems. They did the minimum testing required when a regulator
showed up, fixed what was noted and that was all. Ultrasound and the IIoT: the
Future of Condition Monitoring

Safety and environmental systems should carry equal or more weight in an asset strat- How to develop an
egy development as that assigned to production systems. At this site, I made a mental asset maintenance
strategy
note of the emergency exits and portable extinguishers. Interestingly, the company
had contract maintenance for the portable extinguishers!
57
How to develop an asset maintenance strategy
Why do factories still have
‘maintenance’ departments?
4. Do we have support and buy-in from the whole team?
Timken Power Systems Industrial
To obtain necessary support and buy-in for your asset management program, be pre- Drivetrain Repair Services
pared to show the benefit of allocating resources to achieve it. If downtime is averted,
Pump Powertrain Project for a
how much will risk be reduced and potential dollars saved? Wastewater Treatment Plant

Six steps to design a preventive

Show the value but be up front with your team. Let everyone know that this is a long- maintenance program
term strategy, and the real benefit may be months down the road. Involve the people Remote Monitoring of Solids and
that know the asset best – the operators and maintainers – from the start. Show them Liquids Inventory in Silos
the WIIFM, “What’s In It For Me.” Communicate the project’s impact up to manage- Use Automation to Monitor
ment and down to the plant floor. Inventory in Silos

Five strategies to achieve world-

Not long ago, a plant manager wanted 50 or more asset strategies developed and class preventive maintenance

implemented during the year. The project team presented their recommended course STVM Washdown Station
of action: review criticality, develop bad actor criteria, then identify the top 10 assets Wisconsin Cheese Group
for the pilot project. Unfortunately, the plant manager chose a piece of equipment that Increases Uptime with STVM®
Washdown Station
had gone down over the weekend as the first asset to be reviewed. “We will have a
strategy to make sure that failure never happens again ,” he pronounced to the team. How to write a maintenance task
procedure

That plant manager had a knee jerk reaction to a fresh failure that the team did not Product Launch - The OnTrak
SmartLube
see as a worthy candidate. The plant manager’s decision wasn’t data driven. It didn’t
Ultrasound and the IIoT: the
consider the recommendation of the assembled team. The team suggested that doing
Future of Condition Monitoring
an RCA would be more appropriate, but the plant manager wanted a strategy for the
failed asset, so that was the first strategy developed. How to develop an
asset maintenance
strategy
The asset that had failed wasn’t on the top 10 list, but the plant manager wanted it done
first. The project immediately lost creditability with the implementation team as just
58
How to develop an asset maintenance strategy
Why do factories still have
‘maintenance’ departments?
being another project of the month that wouldn’t last. While the plant manager was on-
board with the project, he had lost the buy-in of the project implementation team. Timken Power Systems Industrial
Drivetrain Repair Services

Pump Powertrain Project for a

5. Do we understand our current data before we begin? Wastewater Treatment Plant
Evaluate your information on hand. What is the cost of an hour of lost production for
Six steps to design a preventive
the line? An hour of technician time? You need this information to start to build the maintenance program
business case for your strategy.
Remote Monitoring of Solids and
Liquids Inventory in Silos
Do your homework get the existing procedures, BOM’s, and Technical references that Use Automation to Monitor
are available for the asset. What past work has already been done that you can lever- Inventory in Silos
age? Are your CMMS/EAM key data fields identified and is there actionable data avail- Five strategies to achieve world-
able? Can you connect maintenance tasks to failure modes? If you have a strategy, can class preventive maintenance
you improve it or do you need a new strategy? Do not re-invent the wheel. But you can STVM Washdown Station
upgrade from a tubed tire to a steel belted radial.
Wisconsin Cheese Group
Increases Uptime with STVM®
Washdown Station
6. If you have strategies or maintenance plans in place, are
they working? How to write a maintenance task
procedure
While reviewing a plant’s asset strategies we found that planned maintenance had a
Product Launch - The OnTrak
35% completion rate because the plant was in a reactive state. While talking with tech-
SmartLube
nicians, we discovered they didn’t have faith in the CMMS data. They couldn’t do a real
Ultrasound and the IIoT: the
time query of the asset history or check part status. They didn’t have necessary parts or Future of Condition Monitoring
consumable noted on work orders.
How to develop an
asset maintenance
When they went to do a preventive maintenance procedure, they wound up doing a strategy
corrective maintenance action. With a company technician, I observed an air handler
inspection that should have taken maybe an hour. The work order had the wrong fil-
59
How to develop an asset maintenance strategy
Why do factories still have
‘maintenance’ departments?
ters called out. One of the three drive belts were thrown, and we didn’t have any spare
belts with us. There were no belt alignment tools available. The motor was installed in Timken Power Systems Industrial
Drivetrain Repair Services
such a way we couldn’t get to one of the hold down bolts to remove the belts.
Pump Powertrain Project for a
Wastewater Treatment Plant
We implemented the company’s improvised solution of rolling the belts on and off.
Six steps to design a preventive
Three hours later a corrective work order was written for the motor mounting and the maintenance program
tech had marked up the ‘inspect” work order with good notes and taken pictures.
Remote Monitoring of Solids and
Liquids Inventory in Silos
Managers should walk around with their operations and maintenance team to see what
Use Automation to Monitor
conditions they deal with. They must evaluate an existing asset strategy from cradle to Inventory in Silos
grave: Where did it come from? How are you implementing it? Five strategies to achieve world-
class preventive maintenance
Are you capturing the data necessary to measure success and make improvements? STVM Washdown Station
The organization where I shadowed the technician wasn’t, but they were starting to –
Wisconsin Cheese Group
which is why I was there. Increases Uptime with STVM®
Washdown Station

7. Who should be on our team? How to write a maintenance task

procedure
Find the experts: the recognized best operator/technician who knows the asset and
its pinch points. The CMMS guru who can quickly find your downtime, cost and parts Product Launch - The OnTrak
SmartLube
information. “Get the right people on the bus,” and in the right seats.
Ultrasound and the IIoT: the
Future of Condition Monitoring
In one instance, I was working with engineers, maintenance technicians and supply per-
sonnel to build an asset management strategy. At one point, the team disagreed on how How to develop an
an asset was operated. The engineers knew how it was supposed to be operated. The asset maintenance
strategy
maintenance techs could speak to what they saw when the equipment was running. But
no one could speak to how it really operated and why a particular failure was occurring.
60
How to develop an asset maintenance strategy
Why do factories still have
‘maintenance’ departments?
While management initially deemed operators time too valuable to free up for our
analysis, we convinced them to bring in operators from all the shifts. We discovered Timken Power Systems Industrial
Drivetrain Repair Services
that no one was operating the equipment as designed; all shifts were operating it dif-
Pump Powertrain Project for a
ferently. Each team would adjust the asset at the beginning of their shift. The operators
Wastewater Treatment Plant
were all aware of the proper procedure, but “that isn’t how we do it on our shift”.
Six steps to design a preventive
maintenance program
You must have the right people available. They don’t have to be physically participat-
Remote Monitoring of Solids and
ing in the analysis 100% of the time or in the same location. They do need to know the Liquids Inventory in Silos
process, what the goals are and be available to answer questions, even if the answers
Use Automation to Monitor
come the next day. Let the team know where the bus is going and get people on and Inventory in Silos
off the bus as the journey continues. Five strategies to achieve world-
class preventive maintenance
Some tips on teams STVM Washdown Station
Focus the team by communicating goals, providing initial training, and explaining how
Wisconsin Cheese Group
recommendations will be implemented and measured. Make sure they understand Increases Uptime with STVM®
Washdown Station
what the goal is, why the effort is important, when the systems need to be completed
and how each asset/system strategy will be implemented. How to write a maintenance task
procedure

Publish what your measures of effectiveness will be. It will make the team accountable. Product Launch - The OnTrak
SmartLube
Show the team the big picture and explain what role they play! Train them on what good
asset strategies, operation procedures, maintenance tasks, planning & scheduling and Ultrasound and the IIoT: the
Future of Condition Monitoring
EAM data look like. Let them know what is important to the organization and why.
How to develop an
I learned a valuable lesson from the plant manager who had different priorities than asset maintenance
strategy
his analysis team. We took the ‘pain of the weekend’ asset he wanted to prioritize and
used it to our advantage. This high-profile preventive maintenance asset became the
61
How to develop an asset maintenance strategy
Why do factories still have
‘maintenance’ departments?
template for our strategy process. The team used its strategy analysis to determine if
the asset really was as critical as the manager thought. It was not. However, the analy- Timken Power Systems Industrial
Drivetrain Repair Services
sis did reveal areas for improvement in the asset strategy. A small gear case breather
Pump Powertrain Project for a
had been overlooked on the equipment, which when clogged caused the gearcase to
Wastewater Treatment Plant
pressurize, resulting in a shaft seal oil leak.
Six steps to design a preventive
maintenance program
8. Do you have a communication plan? Remote Monitoring of Solids and
Monitor and communicate your results using analysis tools like Weibull and Reliabili- Liquids Inventory in Silos
ty Growth to measure the impact of the strategy changes made. Monitor the strategy Use Automation to Monitor
to ensure it is having the desired impact. Communicate how the strategies are work- Inventory in Silos
ing and progress towards meeting short-term and long-term goals. Capture lessons Five strategies to achieve world-
learned and refine your strategy development plan and tackle the next asset or system. class preventive maintenance

STVM Washdown Station

Once while working on an asset strategy program, we had completed the analysis, re-
Wisconsin Cheese Group
vised maintenance plans and procedures and were rolling out new procedures to the Increases Uptime with STVM®
Washdown Station
shop floor to be evaluated. We soon discovered a problem. While the plant, reliability,
maintenance and supply management functions were aware of the project, only line/ How to write a maintenance task
procedure
shift supervisors and maintenance personnel involved in the analysis really knew what
was going on. The asset strategy management initiative was never communicated to the Product Launch - The OnTrak
SmartLube
plant floor or other departments such as the safety team. We found out there was a note
about starting the project, but never any status updates after the initial announcement. Ultrasound and the IIoT: the
Future of Condition Monitoring

In summary How to develop an

asset maintenance
In sum, the steps discussed will support your organization’s asset management team in
strategy
its journey to develop a robust asset management strategy and a plan that keeps oper-
ations running consistently.
62
How to develop an asset maintenance strategy
Why do factories still have
‘maintenance’ departments?
Take inventory. Understand what assets you have and the condition they are in. This
information will help you schedule maintenance and replacement of your assets. Timken Power Systems Industrial
Drivetrain Repair Services

Pump Powertrain Project for a

Prioritize your assets. Prioritize or rank the assets value to the operation of the orga-
Wastewater Treatment Plant
nization.
Six steps to design a preventive
maintenance program
Develop an asset management plan. Plan for the maintenance or renewal of your as-
Remote Monitoring of Solids and
sets. This includes planning the resources necessary to maintain the operation of your Liquids Inventory in Silos
system. Develop a budget and calculate required reserves. Ensure that funds needed
Use Automation to Monitor
for maintenance or renewal of your valuable assets are understood. This includes main- Inventory in Silos
taining your human assets. Five strategies to achieve world-
class preventive maintenance
Implement your asset management plan. Once you have determined the necessary STVM Washdown Station
resources work with management to carry out the plan and ensure that you secure the
Wisconsin Cheese Group
technical and financial means to accomplish the mission. Increases Uptime with STVM®
Washdown Station

Review and revise the plan. Once you have developed an asset management plan, How to write a maintenance task
do not stick it in a drawer or on the shelf gathering dust (computer file) and forget procedure

about it! Your asset management plan should help shape your operational blueprint. It Product Launch - The OnTrak
SmartLube
is a flexible document that should evolve as you gain more actionable information and
as priorities shift. Ultrasound and the IIoT: the
Future of Condition Monitoring

Hank Kocevar, CMRP How to develop an

Hank Kocevar, CMRP, is a senior consultant to Daniel Penn Associates, a CFE Media asset maintenance
strategy
content partner.

63
 Maintenance

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