Keep your new oil clean in 3 steps
Lubricant storage and handling tips for world class contamination control.
The methods by which lubricants are stored, transferred and applied to machines play a large role in the success of a lubrication program. If you start out with contaminated oil, you will never achieve cleanliness targets for most machines. Implementing a world-class lubrication program is a sizable undertaking, but storage and handling is one area where you can affect the quality of lubrication for the whole plant in one stroke.
With few exceptions, new lubricants are unsuitably dirty for most applications. It is therefore imperative that new oil is properly filtered before it is installed for use. A new drum of lubricating oil will typically have a particle count of approximately 19/16/13 or higher. That means that every cubic…
How to extend motor life with PFPE greases
The ongoing journey toward lubrication perfection
In pursuit of lubrication perfection
Lubrication plays a major role in Turkey’s energy production
SKF EnCompass Program launches with new bearing rating life model
EnCompass Program includes pioneering bearing rating life model, newly optimized products, and software
The SKF EnCompass Field Performance Program has launched with development of a pioneering new rolling bearing rating life model, optimized versions of four existing product lines, and innovative software tools to help predict and optimize the performance of bearing arrangements while in real-world service.
The new SKF Generalized Bearing Life Model has been created to help design engineers calculate a more realistic bearing rating life by considering more influencing factors than ever before. The model – built on the strengths of the current model developed by SKF more than 25 years ago and currently ISO-standardized worldwide – enables OEMs and end-users to more closely match bearings to actual application conditions. For the first…
Benchmarking to achieve organizational reliability
Choose the right tool for vibration analysis
Combine vibration monitoring and ultrasound for more cost-effective predictive maintenance
Use vibration monitoring to improve PdM and prevent failures before they occur
Head in the cloud: How disruptive technologies are affecting your plant
In this Big Picture Interview, Dan Miklovic explores asset performance management and the cloud.
Dan Miklovic is principal analyst with LNS Research. He is the author of LNS' Best Practices Guide: Asset Performance Management, and his primary focus is research and development in the asset and energy management practices. Dan has more than 40 years of experience in manufacturing IT, R&D, engineering, and sales across several industries, as well as more than 20 years of industry experience at companies such as Emerson Electric, Mallinckrodt Chemical, Weyerhaeuser, and Scott Products, as well as several consulting companies and software provider Aspen Technology.
PS: Are cloud technologies having a disruptive effect on asset management and condition monitoring?
DM: For asset management, rather than having a disruptive influence,…
What impact is the cloud having on asset management and condition-based maintenance?
Simple steps to accurate alignment
How vibration analysis can detect alignment problems
Thermal growth and alignment
Sound analysis: Best practices for condition monitoring using ultrasound
Implementing ultrasound for condition monitoring applications can be easier than you think.
Over the past decade or so, it has been interesting to see the evolution of maintenance and reliability. To some, the word maintenance brings a perception of general housekeeping duties such as janitorial tasks or changing light bulbs, but for most, maintenance has become almost synonymous with reliability.
I feel like the reliability field is in a transitional phase as more people are becoming more proactive regarding maintenance rather than being reactive once a failure has happened. Additionally, the condition monitoring tools that are available today are very advanced, and in some cases can give the user almost instantaneous information in order to make a diagnosis on an asset. Mobile devices such as tablets and smartphones have been…
How to use ultrasound to improve lubrication practices
How ultrasound technicians are improving reliability at your plant
Make the cultural shift to failure-free operations.
The chemical manufacturing industry is undergoing a paradigm shift with regard to its view toward reliability. Recent trends show an emphasis on creating failure-free cultures where the goal is to detect potential plant and equipment failures before they occur. Making this shift requires the early detection of potential issues, which requires companies to become more proactive and less reactive. This proactive mindset can be cultivated through the use of reliability and maintenance performance-improvement programs that give organizations visibility into their internal structures from the inside out.
Developing a failure-free culture helps achieve what we call “organizational reliability”—an environment that fosters the needed…
Thermography heats up
Use thermography to diagnose electrical problems
IR technology offers a tool with multiple applications
A tale of 2 industrial plants
Regulate water temperature
Welding QC simple with real-time temperature readings
Sealant, coating, and adhesive applications to reduce downtime
Five preventive maintenance tactics that increase plant reliability and control costs.
Maintenance engineers want to maximize the reliability, function, and efficiency of plant equipment and processes while increasing quality and productivity. Equipment failure is an unwelcome but unavoidable reality that negatively affects a facility’s production time, order fulfillment capability and workplace safety.
By looking at data on where equipment failures have historically occurred in hundreds of plants over a number of years, engineers can identify specific areas where failure is most likely to happen and schedule maintenance activities based on these predictions. Through the planned and selective application of sealants, coatings, and adhesives, manufacturers can protect equipment and facilities from wear, damage and…
Reduce corrosion costs
Combat corrosive conditions with prevention and early detection
Perform system maintenance to slow degradation of rotating equipment
Leverage Big Data analytics to your advantage
Preview Plant Services' July 14 webcast to learn how big data will be impacting your plant.
Maintenance people no longer just "fix things." They now have the role of reliability professionals and are responsible for managing a process in which they:
Analyze machine data
Implement procedures to address potential problems
Information needs have changed as well, and big data tools are now available to help. However, many plant teams and asset managers are reporting challenges to making the shift to proactive, predictive maintenance programs at their facilities. On July 14, 2015, at 11:00 a.m. ET, Plant Services will host a webcast on big data featuring a live question-and-answer format with two industry experts. Below are some takeaways from the upcoming presentation.Dan Miklovic, principal analyst at LNS…
GE and Cascade apply new technologies, super-computer capabilities to improve gas turbine combustion
New technologies help avoid machine faults
Your machines are talking to you. Do you always understand what they are saying?
As equipment gets more complex, plant teams are increasingly turning to OEMs and their analytics partners to understand and manage machine performance.
The Plant Services 2015 Disruptive Technology series offers a quarterly look at technology innovations that are generating rapid changes in how plant managers and engineers approach their jobs. The series continues this month by investigating ways that OEM-enabled condition monitoring is starting to impact wider machinery health programs and how remote monitoring programs are changing the relationship between OEMs and plant maintenance and reliability teams.
Your machines are talking to you. Do you always understand what they are saying? Who outside your plant would you allow to listen in and help translate?
Remote condition monitoring (CM) technologies enable effective, efficient predictive maintenance (PdM), and some of the most…
Remote monitoring through turbine retrofit
Work with IT to foster remote monitoring
Maintenance and reliability heats up in China
How wearable and mobile technologies extend the benefits of embedded BI
Small firms breathe easier as Minnesota capital-equipment sales tax rebate program ends
Capital equipment purchases for small businesses are now tax-exempt
After a two-year delay, Minnesota’s much hated 1989 sales tax rebate program for capital equipment purchases ended last week. The change is a major coup for small businesses and the Minnesota Chamber of Commerce, which lobbied hard for legislators to rescind a law many considered an unnecessary hardship.
According to the Minnesota Department of Revenue, about 2,000 factories spend $4 billion each year on new equipment and repair parts and then shell out $270 million for a sales tax they eventually get back. Under the old law, Minnesota factories had to pay sales tax, file returns and wait months to get rebates on every piece of equipment bought or repaired.
The change makes newly purchased capital equipment, parts and repairs tax-exempt.
Gaskets designed to take the heat
Fluid handling tools you can use
Handle fluid with care
Pumps in peril?
Omnify Software announces strategic partnership with Octopart
Integration helps engineers save time during design
Omnify Software, a provider of web-based Product Lifecycle Management (PLM) software for discrete manufacturers, today announces a strategic partnership with Octopart, the electronic parts search engine, in order to give Omnify Empower users direct access to component information in Octopart without leaving their Omnify Empower environment.
The Octopart Search integration is an add-on module to the Empower PLM system. With this module, Empower users can search the Octopart database of a growing list of more than 30 million parts across thousands of suppliers. Users can check and create vendors, vendor parts, and associated items through a formal Part Request in Omnify Empower, while populating attributes/parameters, datasheets, and…
Material handling meets energy efficiency
Big data in the material handling industry: From supply chain to fulfillment
Gearing servo motors for improved performance
Boost motor efficiency for a better payoff
Common sense management of EISA motor changes
13 ways to optimize your compressed air system
What is your compressed air survey ROI?
Compressed air system solutions for deep surface mining
Back to basics: Getting to the bottom of leaks in your compressed air system
Robot kills worker at Volkswagen plant in Germany
A contractor was setting up the stationary robot when it grabbed and crushed him
A robot has killed a contractor at one of Volkswagen’s production plants in Germany, the automaker has said.
The 22-year-old was part of a team that was setting up the stationary robot when it grabbed and crushed him against a metal plate, a VW spokesman said.
Read the full story at theguardian.com.
The robots rocking Chicago's Museum of Science and Industry
Beware shiny objects: Why consumerism's creep should give manufacturers pause
Companies look to drones to boost safety
Video: Faster, stronger, cheaper - China's robotics project
MakerBot CEO: 3D printing going mainstream
Jonathan Jaglom is the new CEO of MakerBot. He comes to the job with strong views of how 3D printing will change markets.
For many consumer and engineering prototyping customers, MakerBot is 3D printing.
Stratasys, MakerBot's parent company, is the largest 3D printer vendor, with over $750 million dollars in sales during 2014, according to Statista. So when a new CEO took them helm of MakerBot in late February, it was big news in the 3D printing world.
Read the full story on InformationWeek.com.
5 trends that will shape our 3D printed future
MakerBot Replicator Desktop 3D Printer wins Red Dot 2015 Design Award
Is manufacturing really new?
Real optimization in a virtual factory
New twists in turbines: How recent developments are delivering business benefits
Understanding the demand for better energy monitoring and management
Mechanical or electrical trip system testing?
Overwhelmed by the IIoT?
In this Big Picture Interview, Kevin Davenport urges mapping technology to business needs, not vice-versa.
Kevin Davenport is senior manager of industry business development for manufacturing with Cisco in San Jose, Calif. Previously a controls engineer, he currently is part of the Cisco team developing the Industrial IP Advantage, an online community created to help manufacturing industry professionals bridge the gap between information technology and operations technology. In February, he showed how growing interest in customized products is affecting industrial manufacturing as part of a panel at the 2015 ARC Industry Forum in Orlando, Fla.
PS: At the ARC Forum, you said that consumers’ growing expectations that they can get products customized or tailored to their specifications is affecting industrial manufacturing, and that the…
Plant Services CMMS/EAM Software Review
Read David Berger's column, Asset Manager
Subscribe to the Asset Management E-News
Sign up for the 2015 asset managment webcast
Cracking the big data federation code
New approach allows users to hook up own batch & streaming data, run queries with fast results
Big data is no longer a war between batch and streaming data processing. It's not either/or, but rather a matter of "and."
Enterprises increasingly need to integrate batch and streaming data processing within a common framework, from runtime to analytics. And yet, with the rise of streaming analytics, integrating streaming data into batch-based systems is non-trivial.
Getting data from disparate data stores and running analytics on them in real-time is a huge technological challenge. While there are two primary approaches to cracking this data federation problem today, a third has emerged that just might offer the most promise.
Read the full story at TechRepublic.
10 ways Big Data is revolutionizing supply chain management
Big data in the material handling industry: The NIST project
Improve plant productivity with communication, data gathering, and analysis
Big data gives manufacturers a new revenue source
Companies don't just have to sell stuff. Now they can sell services.
Thanks to big data, some equipment manufacturers have never been more nimble.
Companies facing anemic demand for new equipment are finding veins of new revenue in selling unique information that they can leverage into sales of replacement parts and consulting services that keep existing machines running longer and more efficiently.
Read the full story on wsj.com.
Smart manufacturing: A path to profitable growth
How the Internet of Things might change your plant
6 mistakes to avoid with EAM software
Bring-your-own-device policies put plant data in the palm of your hand
Small labels, big safety message
Learn what you need to do to comply with latest NFPA 70E safety labeling rules.
Complying with the requirements of NFPA 70E®, the National Fire Protection Association’s Standard for Electrical Safety in the Workplace, is a multi-faceted process and is the responsibility of the facility owner. Each of the five requirements shown in the sidebar is interdependent (i.e., having an arc flash risk assessment performed would be worthless without having labels properly applied to communicate potential life-saving information).
An arc-flash risk assessment is required for any electrical equipment operating at 50V or greater that may require inspections, adjustment, servicing, or maintenance while energized. Equipment that falls into this category is required to have the field marking (label) in place.
An arc-flash risk…
Bradley's approved as EASA accredited service center
How to determine the best electrical safety practices for your plant
Do capacitor systems really save energy?
Electrical safety experts answer your questions
3 ways to improve industrial energy efficiency
Department of Energy report highlights barriers to energy efficiency.
In June, the U.S. Department of Energy (DOE), Washington, D.C., sent Congress a report that highlights various issues that keep industry from achieving better energy efficiency. “Barriers to Industrial Energy Efficiency” also pinpoints opportunities to address many of these factors.
The report and the study that underpins it were prepared in response to Section 7 of the American Energy Manufacturing Technical Corrections Act; it directs the Secretary of Energy to conduct a study, in coordination with industry and other stakeholders, of barriers to better industrial energy efficiency.The report examines three areas that could improve industrial energy efficiency:
demand response (i.e., changes in consumption patterns…
Renewable energy at the tipping point
Energy management motivation: Fighting mixed signals, misaligned goals and unpredictable resources
Track energy costs like you would operating costs
Establishing an energy management dashboard the right way
Your guide to better power quality
Without proper power, an electrical device may malfunction, fail prematurely, or not operate at all.
Power quality determines how fit electrical power is to run consumer devices. Synchronizing the voltage frequency and phase allows electrical systems to function as they're intended to without significant loss of performance or life. The term is used to describe electric power that drives an electrical load and the load's ability to function properly. Without the proper power, an electrical device (or load) may malfunction, fail prematurely, or not operate at all. There are many ways in which electric power can be of poor quality and many more causes of such poor quality power.
The electric power system, in general, comprises electricity generation (AC power), electric power transmission, and ultimately electricity distribution to electric…
Mersen acquires ASP, a Chinese leader in overvoltage protection
Overcome potential problems with power quality
Reduced HVAC energy waste
Take a system-wide approach to energy conservation
Enhanced visualization capabilities designed to advance new product introduction
Building on several years of work with Cascade Technologies, Inc. (www.cascadetechnologies.com), GE (www.ge.com) has announced a multi-year joint development agreement with this Palo Alto-based company. The collaboration will focus on applying and improving simulation software that enables engineers to virtually look inside a gas turbine as it operates and gain a better understanding of the turbulent fluid, chemical and acoustic processes occurring within advanced, low-emissions gas-turbine combustion systems.
“The global energy industry looks to GE as a leader in high efficiency, with current HA gas turbines designed to deliver more than 61 percent combined cycle efficiency. The enhanced simulation and visualization capabilities enabled…
Maintenance and reliability warnings
Select the correct blower technology for industrial wastewater treatment applications
This article discusses the advantages and limitations of each technology in various wastewater treatment applications.
Blower selection is an important decision when designing a new wastewater treatment plant or upgrading existing facilities. The proper selection of blower equipment for the application, as well as purchasing from a reputable supplier, can save thousands of dollars in energy, repairs and maintenance costs. This article provides an overview of the blower technologies available for wastewater treatment, and discusses the advantages and limitations of each technology in various wastewater treatment applications.
Take a look at a municipal wastewater treatment plant near a textile factory in Asia (Figure 1). Is there any question as to why we treat industrial wastewater? The use of blowers for aeration and mixing accounts for 40 to 75 percent…
Requirements for reciprocating compressors in refrigeration systems
Drive down your energy costs with heat of compression recovery
Compressed air systems' waste heat improves plant economics
Heat recovery — Great in theory, tough in practice
Cloud-based climate controls help keep your plant the perfect temperature
Sheila Kennedy says smart systems enable secure remote access, optimize energy consumption across facilities.
Cloud-based climate controls help keep your plant the perfect temperature
It can be difficult to optimize the climate of plant offices, maintenance shops, stockrooms and warehouses, particularly for multi-site or global organizations. New cloud-based systems facilitate transparency and control, reduce energy costs and consumption, and address security concerns.
The new Smart Cloud Climate Control System, developed collaboratively by SoftServe UGE and Panasonic Europe’s heating and cooling solution division, enables simultaneous control of the climate within multiple facilities from a single device. It allows centralized monitoring and one-click temperature optimization in all sites, and it permits the ability react quickly…
Ohio injection molding plant gets cooler and brighter
How to achieve better HVAC and dust collection
Heat recovery and energy efficiency go hand in hand
Flexible plant = enclosure innovations
In this Plant Profile, Rittal's U.S. manufacturing plant enables its "custom off-the-shelf" manufacturing philosophy.
It takes a good home to know how to build a good home – even when constructing protective housing for electronics and electrical components.
So, though it's headquartered in Germany as part of the Friedhelm Loh Group, Rittal Corp. (www.rittal.us) has been operating in the United States for 33 years, manufacturing in Ohio for 26 years, and designing, building, selling, and supporting its enclosures and other products for North America at its plant in Urbana, OH, for about 20 years. The 512,000-square-foot plant is located on 105 acres, and its approximately 600 employees cut, form, weld, paint, and assemble about 1,200 enclosures and wall-mount enclosures per day and more than 50 integrated enclosures with cooling systems per day (Figure…
Improving manufacturing practices through Lean implementation
How to take your plant one step closer to lean
Implementing lean operating systems
Lean manufacturing leads to production gains
Industrial production rises but manufacturing flat
Dip in auto production offsets gains from other manufacturers
Industrial production ticked up 0.3% in June as the mining and utilities sectors saw a boost from an increase in crude oil extraction.
The index of manufacturing, mining and utilities increased slightly in June after falling 0.2% in May, the Federal Reserve said Wednesday.
Read the full story on USAToday.com.
6 tips for fixing your kitting process
Perspective: It's time for manufacturers to start taking responsibility for suppliers
Global manufacturing PMI data: U.S. is still the best
Using reservations at your plant to obtain materials and minimize delays
Illinois loses manufacturing jobs to Tennessee
De-Sta-Co to transfer jobs from suburban Chicago to outside Nashville
Manufacturing company De-Sta-Co, which makes a range of automation and productivity equipment, plans to close its facility in Wheeling, IL, and transfer 100 jobs to a facotry outside of Nashville, TN.
The loss of jobs in the suburb is the latest example of a manufacturer leaving Illinois. Despite some companies expanding here, other manufacturers have shifted production to places like Indiana and Wisconsin, lured by big incentive packages and chasing lower operating costs.
Read the full story on chicagobusiness.com.
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Management of change
What you need to know before implementing change management
Eight common misperceptions of management of change
Closing the gender gap, and with it the skills gap
Expecting women to find their way into manufacturing—and thrive in it—by paying lip service to “diversity” isn’t enough, a Manufacturing Institute study finds.
One of the more obvious ways to fill the U.S. manufacturing sector's skilled-workers gap is by recruiting and retaining more women. A new study finds that manufacturing can attract more women by making a concerted effort to recruit them through their social networks; retaining them through mentorships, better pay and more flexible hours; and fostering girls’ interest in manufacturing careers as early as fourth grade.
Read the full story on IndustryWeek.com.
Why manufacturing is vital to engineering education
Pass-along knowledge for the next generation of engineers and operators
Mentoring the next generation of maintenance and reliability leaders
Fuel sealing systems testing
Evolving certification requirements impact oilfield service companies’ choice in material suppliers.
Oilfield service companies (OFS), the backbone of the oil and gas industry, are closely following the movements of such customers as Halliburton, Schlumberger, Cameron International, FMC Technologies, and Baker Hughes. These customers are also leveraging important trends for their customers simply because they have to in order to maintain their competitive edge.
One key trend that most oil and gas companies seem to be doing a pretty good job at is limiting their exposure to any one region by diversifying into multiple international markets. Experts point to how they have been counting on overseas business due to the better market conditions than in North America in the last few years. For instance, Schlumberger recently set up a joint…
Conveyor maintenance: Moving from preventive to predictive models
Seven tips for picking an outside contractor
Offshoring and outsourcing
The benefits of maintenance outsourcing
Smart safety: Helping plants comply with safety regulations and standards
Sheila Kennedy says integrated safety technologies are helping plants avoid their biggest hazards.
Traditional safety concerns coupled with newer cyber threats are increasing the challenge of ensuring safe and secure industrial operations. Risks to people, property, the environment, and business continuity are at stake. Smarter technologies and safety instrumented systems (SIS) are helping companies comply with safety regulations and standards from entities such as OSHA, the EPA, the IEC, and the ISA.
Layers of protection help prevent systematic failures. Vendor HIMA recommends having a safety platform that is independent from process control system platforms. “Using different technologies significantly increases the effort required to hack both systems,” says Stefan Ditting, product manager at HIMA Paul Hildebrandt…
BP to pay $18.7 billion for Deepwater Horizon oil spill
Require safety compliance in your supply chain
How to measure the safety of your plant
Safety is everyone's job
Arc flash: Trained but not applied
Training is only as good as its application, so follow arc-flash safety rules even if doing so slows you down
The inconvenience of gearing up in personal protection equipment (PPE) encourages employees not to follow arc-flash safety rules, so why are employees trained in the first place? They are trained to cover the liability. The company can say that all electrical and mechanical employees have had arc-flash training, so the company can no longer be held accountable if an accident happens.
Now you have reasons to not follow the training and can claim ignorance as you were not required to take a test at the end of the training. Usually it is good to have some measurement of how well you learned the material. Since you have been trained in arc-flash safety, you, as an individual, are now responsible for your life when working in a control panel…
Are new OSHA rules on electrical safety regular or supersize?
The history of electrical safety
The effect of growth on electrical equipment reliability and safety
Got questions about arc flash? We've got answers.
Arc flash hazard experts answer your questions
Mitigate arc-flash risk
Best practices for conducting an arc flash risk assessment
NFPA 70E 2015: What's changed and what you need to know
Six tips for remote HMI/SCADA users to protect plant operations, drive cost savings
While remote monitoring solutions like HMI can provide cost-savings and increased efficiency, it’s important to understand the security risks associated with this technology and how to protect against them.
When you wake up in the morning, you can program your coffee maker upstairs with your smartphone and get a notification when your cup of coffee is done brewing downstairs. You can also turn up the thermostat with the touch of your phone to increase the temperature before you even get out of bed. This technology is part of the Internet of Things and it is helping to make people’s everyday lives more convenient and efficient.
The Internet of Things revolves around increased machine-to-machine (M2M) communication, and is built on cloud computing and networks of data-gathering sensors. Beyond our daily lives at home, this concept is also becoming widely used in the industrial sector and has been dubbed the Industrial Internet of Things…
Ensure that your critical ICS data is protected
3D scanning: Measurement, made better and faster
The evolving automation architecture: The time to act is now
IFS acquires VisionWaves
IFS to pay cash for operational intelligence software company
IFS, the global enterprise applications company, today announces that it has signed an agreement with the owners of VisionWaves B.V. (“VisionWaves”) to purchase 100% of the company’s shares. The purchase price will be paid in cash.
VisionWaves provides operational intelligence software that helps customers accelerate their strategy realization and boost business performance.
Its unique model-driven, top-down methodology not only provides leaders and decision makers with a clear picture of their business’s performance in real-time, but also enables them to take action and continually improve operations and business models.
By combining VisionWaves with IFS’s industry-focused solutions, customers can benefit from:
6 guidelines for anyone contemplating an industrial IoT project
A new template for device configuration success
Rockwell Automation opens call for nominations for 2015 Manufacturing Safety Excellence Awards
Industrial Internet of Things by any other name
Commissioning and configuring new devices has long been a hassle for industrial manufacturers.
Device configuration historically has been done one device at a time by manually entering values for each parameter that needs to be defined in the device. There are a couple of notable risks to watch out for with this approach. First: It’s easy to make typing errors. Second: It’s not unheard of for a technician working out in the field to miss a new device during the configuration process or to take a device out of service, reconfigure it and then forget to put it back into service. In the latter case, it may look to the control system like it’s working properly, but it’s actually not measuring the process.
Additionally, plants can run into trouble if the individuals doing the configurations don’t have expertise in the…
Changing control architecture
Are smart devices giving us too much information?
Dow Chemical is among those eyeing unmanned aircraft to help cut accident risk.
Anyone who’s seen the devastating footage from post-earthquake Nepal knows drones have already altered the way films and videos are shot. But the technology may soon transform a much less glamorous industry: safety.
Dow Chemical is among those companies that have requested permission from the FAA to use unmanned aircraft commercially, citing safety among their reasons for doing so.
Read the full story on TheNewOrleansAdvocate.com.
Is cellular telemetry right for your machine data?
Unlock energy efficiency potential with wireless automation systems
Fight steam waste with real-time monitoring
Acquisition offers wireless solutions for the oil and gas industry
Maintenance Close-Up: Tool box, electrical enclosure or filter housing
Are you a product pro? Can you correctly identify a product with nothing more than a close-up photo? Test your skills and find out.
Are you the best maintenance worker at your plant? Prove it. Test your product knowledge with Plant Services Maintenance Close-Up. All you have to do is correctly identify the product pictured below. We’ve used a macro lens and some creative cropping to make it a little more challenging.Do you want to test your skills? Just select the answer you think is correct and click the “submit” button.
Maintenance Close-Up: Thermometer, enclosure heater or temperature transmitter
Maintenance Close-Up: Enclosure, switch or lift truck
Electrical enclosure vents
Fight corrosion with fiberglass
Opinion: U.S. should embrace benefits of automation
A new industrial revolution is coming
American factory workers will soon be replaced by sophisticated robots, and this threatens the economic well-being of future generations — or so we're told.
Fear not. Far from dismantling the American workforce, new labor-saving technologies are instead poised to serve as vital engines of job-creation and economic growth for years to come — if leaders are prepared to take advantage of them.
Read the full perspective on jsonline.com.
Will you be working for a robot in the future?
How much do you know about robots?
Running robots mean flowing profits
Selecting the right gear can help servos meet the demand for more complex moves at higher torques and speeds.
At times a motor’s capability may be limited to the point where it requires gearing. As servo manufacturers develop more powerful motors that can muscle applications through more complicated moves and produce higher torques and speeds, these motors require gearheads equal to the task.
Interestingly, only about a third of the motion control systems in service use gearing at all. There are, of course, good reasons to do so. Using a gearhead with a servo motor or using an integrated gearmotor can enable the use of a smaller motor, thereby reducing the system size and cost. There are three primary advantages of going with gears, each of which can enable the use of smaller motors and drives and therefore lower total system cost:
Embracing automation for helicopters
Schneider Electric earns AHRI Standard 1210 certification for VFDs
Why a domestic manufacturing renaissance won't be easy to pull off
Direct-drive technology outperforms traditional motion control systems
Replacing a traditional motion control system with direct-drive technology improves efficiency and design flexibility.
Let’s face it — under trying economic times, you look for any competitive advantage that improves your margins and adds money to the bottom line. A good place to investigate is with machine design. Simplified machines with fewer components that run more efficiently are gaining positive reviews. Better yet, they’re cheaper to build. With a lower total cost of ownership and a quicker return on investment, these innovative, flexible machines are useful investments.
Unfortunately, older rotary and linear motion actuation technologies like gearboxes, transmissions, rack-and-pinion actuation or belt-driven actuators can stand in the way for machine builders who want to take machine design efficiencies to the next level. For example,…
Thomas Wilk investigates how manufacturers are using intelligence effectively on the plant floor.
Since the birth of the smart transmitter in the early 1980s, manufacturers have chased a vision of using intelligent technologies to drive automated process and resource efficiencies on the plant floor.
The latest manifestation of this vision is the Industrial Internet of Things (IIoT), also known as Industry 4.0. Both terms are often used as shorthand to describe the ways that connected machines can monitor physical processes and conditions, and then make decentralized decisions on how to optimize those processes. The potential exists for billions of linked smart devices to collaborate and communicate as part of the IIoT, and to enable customized solutions that help individual plants operate more safely, reliably, and efficiently.
Building for the future: Tooling, training and service under one roof
Where in the World Is Plant Services?: Paul Jeppesen in Philadelphia, Pennsylvania
Maintenance needs assessment
Enterprise asset management and field service management market expected to grow
Lawmakers: Manufacturing universities will help boost U.S. competitiveness
Outdated images of manufacturing are a major barrier to recruiting top new talent to the field, lawmakers and industry leaders say.
Sen. Christopher Coons (D-Del.) says when he visited Dogfish Head Brewery's bottling plant in his state last year, he was struck by the quiet and clean environment where eight members of a 24-person team worked a shift that required the ability to program computers, troubleshoot issues and monitor quality control. This is not the setting some of today's parents might envision, however, when they think of a manufacturer.
Read the full story on USNews.com.
Precision maintenance: Learn by doing
Infant mortality and the “mechanical failure pie"
Southwestern Illinois College Precision Machining Technology Program Renews National Accreditation from NIMS
Training operators and maintenance staff with 3D visualization
Willy Shih, a professor of management at Harvard Business School, has spent more time in factories than in academia.
Willy Shih, a professor of management at Harvard Business School, has spent more time in factories than in academia.
The son of Chinese immigrants, he grew up in Wisconsin and Illinois and earned a doctorate in chemistry at the University of California, Berkeley. Dr. Shih spoke recently with The Wall Street Journal about manufacturing and why a domestic manufacturing renaissance won’t be easy to pull off.
Read the full story on wsj.com.
Do you know what young engineers are looking for?
Is your plant suffering from poor engineering quality? You're not alone.
Implementing lubrication management training
10 STEM initiatives inspiring students this summer
STEM summer programs aim to stoke students' interest in science and tech careers.
For students across the country, summer is synonymous with warm weather and relaxation. But learning doesn't have to end when the school year does, and more and more organizations are taking advantage of the summer break to host programs designed to get students interested in science, technology, engineering and math (STEM) fields.
To view these 10 programs, read "10 initiatives engaging and teaching students the importance of STEM fields" from Control Design.
'A good maintenance technician is hard to come by'
Design, build, program a 120-pound robot; then do homework
Millennials in the plant
The industrial workforce is changing, and we need to give incoming workers the skills and motivation they need to succeed.
Grace never has been a hallmark of the baby boomers, so it should come as no surprise that they are not quietly riding into the sunset of retirement. Younger workers waiting to move up will have to pry the parking passes out of their cold, dead hands.
Reluctance to step aside can be found in all occupations, manufacturing included. The median age of the manufacturing workforce spiked to 46.1 years in 2013, up from 40.5 years in 2000, statistics from the U.S. Dept. of Labor indicate. For high-skilled manufacturing workers, the average age is 57. Thin investment portfolios are the only thing preventing them from plotting their retirements.
Retire they will, of course, or eventually leave the break room feet first.
A U.S. hat-maker's quest to support middle-class manufacturing jobs
Debunking myths about manufacturing jobs
Goal: Zero breakdowns
Training and Career Center
A road map for reliability professionals
Cultivate diversity to get original ideas from your team
Workforce development: Training veterans to fill the skills shortage
In this Plant Profile, a German manufacturer stakes a claim in Michigan to optimize service to North American customers.
Global manufacturer of tube and bar processing machinery Rattunde held an official ribbon-cutting ceremony this past summer to celebrate the July 25 opening its new manufacturing facility in Caledonia, MI.
Rattunde President Rick Stadler cuts the ribbon to officially open the company’s new facility in Caledonia, MI.
Rattunde Corporation is the subsidiary of Rattunde & Co. GmbH, based in Ludwigslust, Germany. Rattunde machinery systems process bar and tube stock into various end products used by manufacturers in the auto, appliance, off-highway, transportation and other industries throughout North America.
Their new 30,000-sq-ft facility employ 16 people, and was erected to build tooling for Rattunde machinery systems as well as to…
Maintenance Deathmatch: Predictive Service's Aerial Point software vs. Endress+Hauser's Liquiline transmitter
Where in the World Is Plant Services?: Jon Stevens in Philadelphia, Pennsylvania
Where in the World Is Plant Services?: Ron Stallworth in Phoenix, Arizona
Check out WATCHMAN Reliability Services
The new TRIO 8-Series and 10-Series Vibration Data Collectors and Analyzers feature a lightweight portable design to meet the demands of the field while delivering data at improved safety and efficiency levels. TRIO Data Collectors are WATCHMAN Portal-Enabled allowing complete visibility into your facility's PdM program with real-time results and business level metrics.
Azima DLI provides predictive maintenance services and products to industry. Often providers of troubleshooting instruments confuse the industrial market as to the differences between their capabilities and true condition monitoring.
Learn how RaaS, or Reliability as a Service, can benefit your new or existing condition based monitoring program. RaaS offers a complete solution that gives you access to the latest data collection technologies, expert advice and visibility across departments while increasing the sustainability of your program.
Azima DLI CEO Burt Hurlock explains how machine health monitoring has evolved and what that means to large-scale enterprises.
In modern business environments, collaborative work models provide better ROI and accountability. Strategic partnerships have become a must, not a luxury. Recognizing the benefits and intelligently selecting and leveraging a PdM service partner allows the plant to keep control of its assets while optimizing productivity and cost effectiveness. This special report investigates how to determine which tasks can be outsourced, what the impact is on uptime and professional growth, and which KPIs can help to measure your success.
Return on investment (ROI) is a divisive issue among maintenance professionals. In a recent joint survey by Plant Services and Azima DLI, more than half of respondents indicated they didn't measure their return on predictive maintenance and condition monitoring investments. The ability to quantifiably measure the effectiveness of a department's execution and output could serve as the difference between increasing the annual budget and receiving further cuts. This special report helps to explain the benefits of tracking and reporting ROI.
How many companies want to buy more maintenance? None, obviously. Management wants to invest in predictability, cost-effectiveness and on-time delivery. Yet most plants still operate in run-to-fail mode and spend too much on repairs. Learn how to make the move to a successful PdM program and find out the six ways you can switch from run-to-fail to run-to-profit.
Engineers see the value of predictive maintenance (PdM), but unfortunately there's no line on the spreadsheet for it. The difficulty of demonstrating return on investment (ROI) is one of the top barriers to success identified by plant engineers and middle management. Read this Special Report and learn how to prove the cost-effectiveness of your PdM program.
The current crop of predictive maintenance (PdM) management software now delivers instantaneous decision-making power for those engineers and plant managers charged with wringing the maximum utility from their facilities while conserving maintenance costs. Capable of instantly analyzing and interpreting vibration data – along with ferrography, used-lubricant analysis and visual inspections – today's PdM software not only delivers integrated and prioritized information to plant managers in their offices, but throughout the entire organization via enterprise-wide "electronic in-trays," text messages, pager alerts and even HTML pages accessible via a common Web browser.
The Conoco Phillips Ferndale Washington Refinery was constructed in 1954. Ferndale is an integrated single train fuels refinery with the following operating units: FCC, HF Alkylation, Reformer and the typical array of supporting units. The refinery's capacity is 110,000 Bbl's per day and it has about 1,000 pieces of equipment. The rotating equipment group has full responsibility for the condition, effectiveness and mechanical integrity of the machinery. The staff consists of three rotating equipment reliability engineers, one part time vibration monitoring technician and a maintenance superintendent.
This paper presents a comparison of machinery condition monitoring results obtained through the use of troubleshooting tools and traditional predictive maintenance instruments and software.
Mill technicians at Orchids Paper suspected that two roll bearings were deteriorating on their most critical paper machine. Relying on Azima DLI's WATCHMAN Insight program to provide early warnings on impending machine faults, the Mill technicians collected vibration data from the suction pressure roll and top press roll bearings. The data was then posted to Azima DLI's Reliability Portal for an analyst to review.
A potentially catastrophic electrical fault was discovered at Total Petrochemicals during a routine annual infrared thermography survey performed by Azima DLI. The reactor appeared to be operating normally but the infrared inspection revealed a faulty wire connection and critical heat damage to the aluminum bus bar that would otherwise have gone undetected until failure.
When one of its two Through Air Fans developed a large crack in a blade, Kimberly Clark’s Owensboro, Kentucky paper mill was six weeks away from its scheduled outage. Taking the damaged fan down early would cripple mill production by 50% for weeks, but trying to run the fan until the shutdown could result in catastrophic consequential damage if it failed. Azima DLI was hired to take frequent vibration readings and determine whether the fan could stay in operation until the outage. If the fan had to be taken out of service, the mill faced nearly $5 million in production losses.
Cloud Computing is opening up many possibilities in the world of Predictive Maintenance (PdM). The benefits are quickly realized by companies who choose to leverage this technology.
You must have a lean and reliable operation in order to maximize profits. Knowledgeable decisions become essential to preventing costly mistakes. Any industrial plant depending on mechanical production assets needs to ensure maximum performance and reliability. Failure to do so, can lead to unexpected downtime that can reduce or completely interrupt plant production and profit generation.
Leading companies do not compromise their machine condition monitoring programs and jeopardize their profits. A proper asset reliability program is critical to your machinery health and should be performed by the industry's leading experts. WATCHMAN Reliability Services by Azima DLI puts the industry's leading experts on your team, offering you the greatest defense against unplanned and costly downtime.
WATCHMAN Professional is a premium machine condition monitoring service program that provides predictive monitoring for plants or enterprises with 250 or more machine assets where unplanned outages cannot be tolerated.
WATCHMAN Insight is a comprehensive machine condition monitoring service program that provides predictive monitoring for moderate sized plants or enterprises with 75 to 250 machine assets where unplanned outages are disruptive and costly.
WATCHMAN Select is a machine condition monitoring service program that provides predictive monitoring coverage for smaller plants or enterprises with 15-150 machine assets.
Engine and compressor analysis is used to diagnose the presence of mechanical problems to avoid catastrophic failure and allow repairs to be effected on a scheduled basis. Additionally, fuel savings achieved by properly balancing engines and by replacing leaking compressor valves routinely saves enough in fuel and electricity costs to pay for a subscription-based analysis program.
Azima DLI provides a full range of condition monitoring services, including infrared testing, an inspection process using infrared cameras as a means to “see” and “measure” thermal energy emitted from equipment at your plant. In other words, it allows us to see what the human eye cannot.
Among its condition monitoring services, Azima DLI provides a highly reputable oil analysis program. Oil analysis is part of the tribology field, which is the science and technology of interacting surfaces in relative motion.
Durable, powerful, and lightweight, the new TRIO 8-Series vibration data collectors feature a thin 10” tablet controller giving users more visible area while in the field. The CX8 and CA8 series of vibration data collectors and diagnostic instruments are durable with an IP-52 environmental rating. These controllers offer tremendous portability while still maintaining a durable standard expected in today’s industrial environments.
TRIO CX10 and CA10 provide a rugged 10” tablet that is up to the demands of harsh industrial environments. The TRIO CX10 and CA10 vibration data collectors and diagnostic instruments are lightweight at just 2.9 pounds and just 1.2 inches thick but are rugged enough for your IP-65 rated environments and have stringent MIL-STD-810G standards for protection against dust, water, vibration, drops, extreme temperatures and varying altitudes.
Azima DLI's training courses are designed to provide you with the knowledge and tools you need to meet all of your condition monitoring program goals. Our flexible course offerings range from onsite training at your facility to web-based classes that allow you to work at your own pace. You will always be getting the highest quality of training from our expert staff of condition monitoring professionals.
Azima DLI is the leader and premier provider of predictive maintenance analytical services and products that align with customers' high standards for reliability, availability and uptime. We deliver machine health reliability solutions with global reach that reduce risk, improve safety, increase production and optimize efficiency.
Azima DLI's subscription based programs are delivered through a suite of predictive maintenance best practices, best technology and best customer solutions at the plant and enterprise level. Our WATCHMAN Reliability Services utilize flexible deployment models, proven diagnostic software and unmatched analytical expertise to deliver sustainable, scalable and cost-effective condition-based maintenance programs. The company's offerings enable customers to implement comprehensive, predictive maintenance programs that ensure asset availability and maximize productivity. Azima DLI is headquartered in Woburn, Massachusetts with offices across the U.S. with international representation in Asia-Pacific, Central America, Middle East, Europe and South America. To learn more please visit us at www.AzimaDLI.com
To learn more about how WATCHMAN Reliability Services can deliver outstanding value to your company, contact us at toll free U.S. at 800-482-2290, international at (+1)781-938-0707, or visit us online at www.AzimaDLI.com.
Azima DLI World Headquarters
300 TradeCenter, Suite 4610
Woburn, MA 01801 USA
toll free 800-482-2290
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Poulsbo, WA 98370 USA
Azima DLI Government Services
1050 NE Hostmark Street, Suite 101
Poulsbo, WA 98370 USA