What are ways to improve my equipment uptime?

Service Relationship Management

In many larger organizations, both internal and external individuals require and contribute data to particular assets or processes. In the past, this was an extremely inefficient process, often involving a great deal of paperwork and often, outdated information.

Although today's sophisticated technology and accessible cloud-based solutions should easily streamline that process, that's often not the case. For example, many companies have embraced the Internet of Things (IoT); however, most of the data collected is often not used, according to a report by McKinsey & Company.

In order to take full advantage of the technology and data available today, companies should embrace service relationship management (SRM) processes. SRM is all about making sure the right players, whether internal or external to a company, have all the information they need to perform their work efficiently and effectively.

For example, companies that maintain a fleet of vehicles often use technology to track the condition of those vehicles. Many sensors are available today to measure mileage, vibration, and leakage. When certain levels are exceeded, an alert can be sent back to a centralized computer system to generate a service order.

However, this may involve bringing the vehicle back to a central location to perform the work. This can cause unnecessary time and expense for a company. On the other hand, if multiple service providers are working on a company's fleet across a large geographical area, there might be limited information for the service technicians to access in regards to the vehicle's history.

An effective SRM system makes the maintenance records of a vehicle visible to any and all service providers who may have worked on the vehicle in the past, or might be engaged to work on the vehicle in the future. As a result, technicians have access to the information needed in order to perform a higher level of service and identify potential systemic problems.

SRM systems that use cloud platforms in order to provide and collect data from internal and external service parties ultimately help a company improve the uptime of its equipment and assets.

An Electromechanical Reliability Example

Increasing asset uptime will involve different tasks, depending on your industry. One example is in the electromechanical field. According to Cook Consultants, you might want to consider better management of fasteners, publication, alignments, and balance.

Within this industry, companies may want to ensure that the grade, material, and size of fasteners is appropriate for critical assets, as well as audit fasteners twice a year to replace those that are loose or damaged. Belts should be checked for correct tension, and ultrasonic analysis can find pressure leaks throughout the process. Liquid leaks, vibration issues, and electrical connections should also be inspected and corrected as needed.

Lubrication is critical to the proper functioning of a great number of assets; it's important for the correct viscosity grade to be used. Maintenance technicians must understand that additives and thickeners might be present in lubrication products and that care must be taken to avoid cross-contamination. The machines that must be checked routinely for oil levels should be installed in an area where inspection can be done quickly and easily. Limits on particle contamination and water contamination should be set and well understood, and oil quality should be tested regularly.

Alignment instructions should be clear, and laser tools should be employed where possible to ensure proper alignment. If the system includes pipes, they should be installed to minimize movement and strain, especially at joints. Vibration analysis, or other inspection processes, should be used to detect misalignment.

All equipment that requires balancing should be checked before installation, or during rebuilding activities. Vibration analysis can detect mechanical imbalances. Companies should also monitor electrical voltage and current imbalances, in order to maximize the life of the motor.

Most importantly, all aspects of this program should be adopted and actively led by management. Maintenance technicians should be adequately trained or expert third-party contractors should be used to ensure the maintenance is performed correctly.

Benefits of Precision Maintenance

According to the RAM Review, the ultimate goal of precision maintenance is to have assets that are running smoothly, quietly, and at cooler temperatures. Successfully implementing maintenance activities that address root causes mean more efficient energy usage, less friction and wear, lower noise levels, and less generation of heat. All these factors then result in an increase in uptime and a longer lifespan for a company's assets.

Consider that when a company reduces mechanical vibration by 20 percent, it can actually double the life of that piece of equipment. In addition, by reducing the amount of water that gets into lubricating oil by half, a company can lengthen the life of that asset by more than 30 percent. Eliminating half of the contamination from particles in oil by half means of further extension of the lifespan of an asset, probably at least an additional 20 percent improvement.

Unnecessary heat can increase the rate that components, such as insulation and elastomers, degrade. In fact, this rate is cut in half for every 10°C the temperature drops. And finally, a 3 percent voltage imbalance reduces the performance of a motor and increases operating temperature by 18 percent.

Use a CMMS to Streamline Workflow

One more way to improve your equipment uptime goes beyond maintenance planning and monitoring. Often, inefficiencies in your workflow may limit the number of preventive tasks your team can perform in the course of a workday, and it can prolong unplanned downtime whenever it occurs. A great way to remedy these inefficiencies is to use a CMMS with mobile capabilities.

This system allows you to track data and plan work orders, assign work orders to the right level of technician without delay, and provide remote access to equipment schematics and instructions. A CMMS also helps you streamline parts requisitions and inventory management, as well as improve your procedures.

The end result of each of these features is to streamline your maintenance processes and improve time utilization. Your team will stay more on top of scheduled tasks, you’ll do more tasks that truly work, and you’ll resolve unplanned downtimes more quickly.

Streamlining workflow also means standardization and defect elimination. Instead of relying on what’s inside the heads of experienced technicians, a company needs to establish and communicate standard operating procedures, especially for its most critical assets.

Instructions, checklists, and procedures should be communicated at a level of detail, so that anyone stepping into a particular role can understand. As a result, greater efficiency and fewer errors will result, and problems can be tackled by an experienced person.

Finally, be sure to put an appropriate level of power in the hands of technicians. In many cases, technicians and operators are the ones on the front line, who know the ins and outs of a particular asset or process. However, they may not be empowered to resolve any issues that arise.

Consider establishing small action teams that can immediately fix and report problems, as well as suggest long-term solutions. Not only will this put solutions in the hands of the people working on your critical assets, but also it will increase acceptance of a culture that’s about reducing downtime.