Dean Wolever – Airborne Ultrasound Level 1,

Infrared Thermograpy Level 1

Loyd Hopper – Airborne Ultrasound Level 1,

Infrared Thermograpy Level 1

Ross Vanderjagt - Infrared Thermograpy Level 1

Introduction & History

Procedures

Examples,

Suggestions

Savings $$

Age 37, born and live Twin Lake, MI. I am currently employed by Herman Miller Inc. One on the worlds largest Office Furniture manufacture in the world(ranking 3rd). I have been employed there for 14 years. I started in the Powder coat application dept. as a powder applicator then advanced to Powder Technician(10 years), Mid 2004, I transferred to the maintenance dept. in tool repair and preventative maint. My current job duties are Energy savings and Reliability based maintenance. I am certified in level 1 Airborne Ultrasound & level 1 Infrared Thermography.

Spare time: Kids, Racecars, Snowmobiles, Motorcycle, Fab Shop, Vinyl graphics, DJ, & Cage Combat.

Herman Miller began in 1923 as a manufacturer of traditional residential furniture.

Became a leader in “modern” furniture in the 30’s, 40’s & 50’s

1960’s- Transformed to the Office industry with the first Panel System.

Invented and refined ergonomic work seating in the 70’s, 80’s & 90’s

2000’s Reinvented the geometry of systems furniture, and now is the 3rd largest office furniture company in the world.

World Headquarters located in Zeeland, MI

Manufacturing and Distribution: Georgia, Wisconsin, Michigan, China, Italy, and the United Kingdom.

Herman Miller is represented through subsidiaries and corporate offices, Independent dealers, and Licensees in over 40 countries in North America, Asia/Pacific, Europe, Middle East and Latin America.

Had to Convince Management that the predictive science would have pay back-Energy Conservation/Less downtime.

We realized that we had a lot of low hanging fruit with compressed gas leaks.

I (Loyd Hopper) was so convinced that we would show a potential savings in less than 3 months, He would step down from Herman Miller.

Found a Argon leak the first day with a savings over $13,000, Several days later the operator called in a work order stating that he was using less gas and something must be wrong.

In the first year we save a combined savings of $242,000 (In all 3 locations)

In the first 5 months we found 4 Argon Gas leaks totaling over $60,000.00

50% of air leaks are coupling/quick disconnects

In 2008 $164,000 (in all 3 locations)

Average about 20dB on a valve leak

Usually an easy fix by taking off and cleaning rubber seal

Tape fixes everything !! Why ??

Paste thread sealant gets hard and tends to crack easily

Complete valve cost about $ 100

3 O-rings cost less than $1 and takes about 2 min. to repair.

Orifice Leak Rate Reference only

Based on 8760 Hours/

Year AirDiameter

of Leak 150 PSI 125 PSI 100 PSI 75 PSI 50 PSI 25 PSI

1/64" 0.58$ 76.47

0.49$ 64.91

0.41$ 53.35

0.32$ 41.79

0.23$ 30.09

0.14$ 18.40

1/32" 2.37$ 311.42

1.98$ 260.17

1.62$ 212.87

1.27$ 166.88

0.92$ 120.36

0.56$ 73.58

1/16" 9.45$ 1,241.73

7.9$ 1,038.06

6.49$ 852.79

5.08$ 667.51

3.66$ 480.92

2.25$ 295.65

1/8" 37.5$ 4,927.50

31.6$ 4,152.24

26$ 3,416.40

20.3$ 2,667.42

14.7$ 1,931.58

8.98$ 1,179.97

1/4" 150$ 19,710.00

126$ 16,556.40

104$ 13,665.60

81.3$ 10,682.82

58.6$ 7,700.04

35.9$ 4,717.26

3/8" 338$ 44,413.20

284$ 37,317.60

234$ 30,747.60

184$ 24,177.60

132$ 17,344.80

80.9$ 10,630.26

1/2" 600$ 78,840.00

506$ 66,488.40

415$ 54,531.00

324$ 42,573.60

235$ 30,879.00

144$ 18,921.60

5/8" 910$119,574.00

790$103,806.00

649$ 85,278.60

508$ 66,751.20

366$ 48,092.40

225$ 29,565.00

3/4" 1315$172,791.00

1138$149,533.20

934$ 122,727.60

729$ 95,790.60

528$ 69,379.20

323$ 42,442.20

7/8" 1789$235,074.60

1549$203,538.60

1272$ 167,140.80

994$ 130,611.60

718$ 94,345.20

440$ 57,816.00

1" 2338$307,213.20

2023$265,822.20

1661$ 218,255.40

1299$ 170,688.60

938$123,253.20

575$ 75,555.00

20h.p. to 40h.p. wash pump motors

LOVEJOY coupling insert.

Increase of about 20d.B.

Found the dB levels were getting too high( about 25dB)

Outside of booth Inside of booth

3371

ULTRASONIC LEAK DETECTION (ASSEMBLY AREAS)

Job Task

NumberJob Task Description Job Task Long Description

1RECORD ALL LEAKS WITH A PHOTO AND

A REPAIR TAGTHIS WILL MAKE FINDING THE LEAKS EASY

2RECORD THE DB LEVEL AND TYPE OF

GAS OF ALL LEAKS FOUND

3USE THE FOLLOWING FREQUENCY (KHZ)

SETTINGS FOR

COMPRESSED AIR OR INERT GAS LEAKS AND ELECTRICAL ARC = 40KHZ

BEARING WEAR = 30 KHZ

FLOW IN A PIPE OR STEAM TRAPS = 25KHZ

10CHECK ALL JOINTS AND FITTINGS ON

THE MAIN MANIFOLD FOR LEAKS

20

CHECK ALL FITTINGS FROM THE AIR

DRIVEN SCREW GUNS BACK TO THE

MAIN MANIFOLD

30CHECK ALL OF THE FITTINGS ON THE

LIFTSTHIS INCLUDES THE FITTINGS ON THE MANIPULATOR AND THE OVERHEAD TRACK

JOB PLAN REVIEW

5498

RELIABILITY QUANITATIVE/QUALITATIVE ANALYSIS

Job Task

NumberJob Task Description Job Task Long Description Job Task Duration

10 INFRARED SCAN

1. CHECK ALL ELECTRICAL CABINETS FOR ANY TEMPERATURE ANOMALIES

2. CHECK ALL ROTATING BELTS FOR WEAR AND MISALIGNMENT

3. CHECK ALL DRIVE MOTORS FOR TEMPERATURE ANOMALIES

4. CHECK ALL HYDRAULIC SYSTEMS FOR:

A. ELECTRIC MOTOR TEMPERATURE ANOMALIES

B. CHECK HYDRAULIC PUMPS FOR TEMPERATURE ANOMALIES

C. CHECK ALIGNMENT COUPLINGS FOR WEAR OR BREAKAGE BETWEEN MOTOR AND PUMP

D. CHECK TEMPERATURE OF HYDRAULIC OIL AND REPORT ON ANY OVER 190F

5. CHECK SHUNT CABLES FOR TEMPERATURE DIFFERENCES

0.00

20 ULTRASONIC SCAN

1. CHECK ALL ELECTRICAL CABINETS FOR ELECTRIC NOISE INCLUDING

A. CORONA

B. ARCHING

C. MOTOR STARTER CHATTER

2. CHECK HYDRAULIC SYSTEMS FOR:

A. HYDRAULIC PUMP FOR SOUNDS OF CAVITATION, GRINDING OF COMPONENTS, AND BEARING FAILURE.

B. ELECTRIC MOTOR FOR BEARING FAILURE OR INSULATION FAILURE

C. ALIGNMENT ISSUES BETWEEN MOTOR AND PUMP

3. CHECK GEAR BOXES FOR LUBRICATION ISSUES

4. CHECK DRIVE BELT ALIGNMENT

0.00

30FD3055 BRAKE PRESS,

CINCINNATI

PLEASE CHECK

INFRARED

1. ELECTRICAL PANEL

2. VALVES AND HYDRAULIC LINES

3. HYDRAULIC MOTOR

ULTRASONIC'S

1. ELECTRICAL PANEL

2. MOTOR BEARINGS

0.10

40FD3086 BRAKE PRESS,

CINCINNATI

INFRARED

1. ELECTRICAL PANEL

2. VALVES AND HYDRAULIC LINES

3. HYDRAULIC MOTOR

ULTRASONIC'S

1. ELECTRICAL PANEL

2. MOTOR BEARINGS

0.10

50FD3056 BRAKE PRESS,

CINCINNATI

INFRARED

1. ELECTRICAL PANEL

2. VALVES AND HYDRAULIC LINES

3. HYDRAULIC MOTOR

ULTRASONIC'S

1. ELECTRICAL PANEL

2. MOTOR BEARINGS

0.10

60

2938 DECOILER FOR

COVER NOTCHING

SYSTEM

INFRARED

1. ELECTRICAL PANEL

2. ELECTRIC MOTOR

ULTRASONIC'S

1. ELECTRICAL PANEL

2. GEARBOX

0.10

70

2937 DECOILER FOR

LOWER CHANNEL

NOTCHING SYSTEM

INFRARED

1. ELECTRICAL PANEL

2. ELECTRIC MOTOR

ULTRASONIC'S

1. ELECTRICAL PANEL

2. GEARBOX

0.10

80

29953 HYD POWER UNIT

FOR CHANNEL DATA WIRE

MANAGEMENT FIXTURE

INFRARED

1. HYD MOTOR

2. HYD PUMP

3. ELECTRICAL PANEL

ULTRASONIC'S

1. HYD MOTOR

2. HYD PUMP

3. ELECTRICAL PANEL

0.10

902862 NOTCHER, BIG,

LOWER CHANNEL PRESS

INFRARED

1. HYD MOTOR

2. HYD PUMP

3. ELECTRICAL PANEL

ULTRASONIC'S1. HYD MOTOR

2. HYD PUMP

3. ELECTRICAL PANEL

0.10

1002415 NOTCHER, LITTLE,

WIRE COVER PRESS

INFRARED

1. HYD MOTOR

2. HYD PUMP

3. ELECTRICAL PANEL

ULTRASONIC'S

1. HYD MOTOR

2. HYD PUMP

3. ELECTRICAL PANEL

0.10

1102935 STRAIGHTENER,

COVER NOTCHER SYSTEM

INFRARED

1. ELECTRICAL PANEL

2. ELECTRIC MOTOR

3. GEARBOX

ULTRASONIC'S

1. ELECTRICAL PANEL

2. ELECTRIC MOTOR

3. GEARBOX

0.10

120

2936 STRAIGHTENER,

LOWER CHANNEL

NOTCHING SYSTEM

INFRARED

1. ELECTRICAL PANEL

2. ELECTRIC MOTOR

3. GEARBOX

ULTRASONIC'S

1. ELECTRICAL PANEL

2. ELECTRIC MOTOR

3. GEARBOX

0.10

130 WELDER, EIGHT GUN

INFRARED

1. ELECTRICAL PANELS (2)

2. SHUNT CABLES

ULTRASONICS

1. ELECTRICAL PANELS (2)

2. ALIGNMENT ON DRIVE BELT FOR BACK GUAGE

3. BEARINGS ON BALL SCREW

0.10

140

WELDER, CHANNEL, DATA

WIRE MANAGEMENT

FIXTURE

INFRARED

1. ELECTRICAL PANELS (2)

2. SHUNT CABLES

ULTRASONICS

1. ELECTRICAL PANELS (2)

0.05

$350,000 in Compressed gas savings.

$150,000 in cost avoidance for an additional air compressor.

Now able to service an existing compressor while production is running.

Avoided catastrophic pump failures leading to Thousands of dollars.

Approximately 148 hours of production downtime at $600/hr. ($88,800)

WE HAVE CONVINCED

MANAGEMENT THAT PREDICTIVE

SCIENCES WORK !!!!