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Asset Efficiency Optimization for Improved Profitability.

S.S. Pamnani

SKF Bearings India Ltd., Mumbai.

AbstractFrom Drying Cylinder to Press Roll, Smallest Motor to Largest Pump and Calender to Reeler - and everything inbetween - if there is a problem, the bearing knows. As the key interface between moving parts, the bearing isliterally the diagnostic heart of the machine. Misalignment, unbalance, looseness and friction, are all.telegraphedthrough the bearing. Understanding the information coming from this diagnostic "pulse" and then applying thelatest and best technology to the problem is the key to raising machine productivity and lowering operating cots.This is achieved through" Asset Efficiency Optimization Program leading to an improved productivity."

When we did our own bearing and machinemaintenance we were always playing catchup withtechnology. Tie-up with experts keep us running andlets us concentrate on doing our business of makingour core product - the Paper." "Anybody can tellyou that something is wrong. Tie-up with expertswho have experience to tell you exactly what iswrong ... fix the problem ... and help you make sureit dose not happen again." "Who knows how industrywill take plant productivity to the next level? Thebearing knows! Keeping a finger on the pulse ofyour plant's productivity."

The Asset Efficiency Optimization concept picksup where plant asset management programs typicallystop. AEO enables a plant to produce the sameamount for less cost, or to produce more for thesame cost.

It is a system of organizing and applying assets Global Average- from personnel to machinery - bringing togetherknowledge and technology to achieve the greatestreturn on investment. By applying the power ofSKF's technology and service solutions, you canbenefit from AEO program, which assists in achievingyour organization' s overall business objectives.These include reduced costs, greater productivity,better utilization of resources, and as a result,increased bottom line profitability.

INTRODUCTION

Achieving Asset Efficiency' objectives is asignificant challenge. Very often, management isaware of the significant benefits that can be achievedfrom a well-run asset management program. However,

in some organizations, actually achieving assetefficiency can present a major challenge. Fewcompanies have the-resources or expertise toimplement the rapidly developing new technologiesprocesses and cultural changes that are so importantto achieve timely, yet long-term successes. It is notuncommon for corporations to begin the process inearnest, only to be hindered by an incompletestrategy or insufficient planning or benchmarking.The result is typically over or underspending ofcapital and maintenance resources, and ultimate ly,failure to achieve efficiency objectives.

'Maximum Efficiency

Operator-DrivenReliability

Pro-Active ReliabilityMaintenance

Predictive Maintenance

PreventiveMaintenance

For every 10% changeReacti ve/C orrect i vefrom Reactive toProactive Maintenance= ~ 2% uptime increase

Minimum Efficiency

Fig. 1: Minimum efficiency

IPPTA J., Vol. 15, No.4, Oct.-Dec., 2003 55

Fig. 2 In brief below are the Steps involved in AEO implementation with SKF expertise:

Assessment•Determine the current situation- Maintenance Situation_ Supply and Stores Process um Efflclencv- Predictive Maintenance

Maintenance Strategy

• PM / PdM Focus• Reliability Focus• Reliability Focus• Asset Optimization

Maintenance Engineering

• Planned & Predictive Maintenance Procedures• Computerized Maintenance Management System

Documentation• Spare Part Optimisation

Supply Process

• Trouble Free Supply• Electronic Supply Process• Stores and Supply Assessment

Proactive Reliability Maintenance

• Predictive Maintenance• Vibration Monitoring• Thermography• Lubrication Analysis• ODS (Operating Deflection shape) Analysis• Diagnostics and Root Cause Analysis• Key Performance Indicators• Operational Review

Machine Maintenance

• Machine Alignment• Precision Balancing• Lubrication & Filtration Management• Root Cause Failure Analysis• Technology Advice & Machine Upgrading• Bearing Installation

Machine Improvements

• Upgrade, Rebuild and Redesign• Design Engineering• Refurbishment and Repair of Machines• Refurbishment of Bearings• Instrument/Equipment Calibrations

Training

Building & Enhancing Competence- Proactive Reliability Maintenance- Condition Monitoring & Analysis- Maintenance & Skill- Software Calculations- Lubrication & Seal

...

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Operator·Oriven Reliability

1: Pro-Active ReliabilityMainttllanc8.'4

Prediclive Maintenance••

F.rmry 1RC1ttivt inProactiveM,'"~2 % uotilll

.•.Minimum Efflclencv

Fig, 2

Bearing Maintenance

Integrated Maintenance Solutions

• Guaranteed return without capital investment

Maintenance strategies are changing rapidl

Maximizing the efficiency and integrity of a planand its equipment in the most effective mannerequires a shift from traditional maintenance activitywhich is both reactive and functional, into a proactivmaintenance process that is fully integrated intoverall plant activity. This is what Best-in-Clasmaintenance departments do to achieve optimizatiogoals.

Putting reliability as the cutting edge

Many of today's multi-national organizations aradopting an innovative approach to maintenanccalled Operator Driven Reliability (ODR). With thavailability of today's rugged, handheld industriacomputers, operators have the ability to collect, storand assess machine condition, process. vibratioand inspection data. Operation Driven Reliabilitybridges the gap between operations. maintenancereliability and engineering in the quest for improveplant-wide reliability.

56 IPPTA J., Vol. 15, No.4, Oct.-Dec., 2003

Moving towards an integrated, proactive reliabilitymaintenance strategy starts with understanding whereyou stand today, and defining your objectives forthe future. The chart illustrates the range ofmaintenance practices.

• The Reliability Maintenance ChallengeMapping a course to enhanced productivityand profitability.

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The critical factors that affect the success areculture, technology and processes. A completesolution is to focus on all these parts to improveas a whole. Whatever may be your current assetmanagement strategy. SKF's Reliability Systems offersthe knowledge, services and the products needed toachieve your productivity goals.

The Future of Asset Management based onIntegrated Platform.

SKF's range of products and services - fromcondition monitoring and decision support systemsto bearings and seals - are all designed to providethe solutions that will ultimately lead to increasedbottom line profitability for our customers. Our focuson technology and seamless interface with plant-wide systems supports four key areas in an effectivemaintenance process.

Decision Support

SKF has the ability to facilitate consistent, accurate"and effective decisions on plant equipment andprocesses with use of support software.

Condition Monitoring

As a leading supplier of condition monitoring.products, SKF offers a complete range- form hand-held data collectors /analyzers to online surveillanceand machinery protection systems. These productsoffer seamless interface to CoMo" analysis software,CMMS, ERP etc.

Maintenance Tools and Lubricants

SKF offers complete range of maintenance productse.g. Mechanical Tools, Pullers, Induction Heaters,Oil Injection Pumps, Hydraulic Nuts, Shaft & BeltAlignment Tools, Thermometers, Stethoscope,Greases, Automatic Lubricators, Oil Check Monitor,Rust Inhibitors, Anti-Corrosive & Fretting Agents,etc.

Component innovation & solution products

Explorer Series - SRB, CARB, ACBB, SRTB, CRB etcwith higher capacity Carb - A beginning of New Erafor Pulp & Paper Industry. Case hardened SRB, &CARB for Drying & Yankee Cylinders. No-Wear

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Assessment

Fig. 3

IPPTA J., Vol. 15, No.4, Oct.-Dec., 2003 57

Case Study: Paper Mill

Process Production Downtime Downtime Increased2002 (Tonne) 2000 (hours) 2002 (hours) 2002 (Tonne)

Pulp Dryer 303 57 0 1.643 •Paper Machine 89 31 0.7 252

OMC 61 21 0 119

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Fig. 4 An Integrated

MJinlenant CAAB8Tools ~

h~ •Platform for Asset Efficiency Optimization

58 IPPTA 1., Vol. 15, No, 4, Oct.-Dec., 2003

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Vear2002

Result: I Millioo Dollar Incremental in Production .

VtarlOGJ

•Bearing for Super Calenders. Triple Ring Bearingsfor Deflection-Compensating Rolls. Multi-row radialbearings for Doctors. Insulated Bearings for Electric.Motors. SKF - Drive-up method for mountingbearings. SNL and Special Housings IRockers forPulp & Paper Industry.

Electronic Purchasing is here - endorsia.com

In order to reduce cost associated with purchasing,supply and inventory management SKF has built alarge & strong network of distributors connected toa Central Warehouse and nearest Logistic Center.They have global accessibility about bearingavai lability.

SKF expertise extends far beyond bearings. Ourexperience includes virtually every industry and youcan benefit from SKF's advanced capabilities inmanufacturing and research.

We are at your service to offer "SKF's AssetEfficiency Optimization" Because no other companyin the world is better prepared to help you boostplant productivity by maximizing machine uptime andeliminating costly, unexpected downtime.

SKF can help you optimize asset efficiency toincrease profitability. Today, reliance on supplierexpertise is often recognized as one of the mostpractical and cost-effective means to enhance internalcompetencies. SKF enables customers to benefit froma dedicated entity called SKF Reliability Systems.

CONCLUSION

Proper maintenance is a key contributor to thedelivery of asset performance when it is planned andimplemented according to sound business drivers,such as return on capital, cash flow, asset integrityand protection of reputation. An effective strategycontinually identifies areas with the highestcommercial and safety risk, and then measures howwell specific activities reduce that risk It encompassesall aspects of human talent, machine expertise, correctassessinent, well planned strategies and engineeringpractices, supply process, asset knowledge, machineimprovements and continuously thriving for higheststandards so as to provide the greatest return oninvestment.

59 IPPTA J., Vol. 15, No. 4, Oct.-Dec., 2003