Machine Health Management

 24 Training Hours

 

Introduction

This training will create and support existing documented Reliability Processes and act as a reference process to better enable the Reliability department in developing and delivering best in class Reliability Practices. The training will communicate why, what, how and when, but not specifically who.  

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Machine health Management (MHM) is a living risk analysis process which determines the most effective mix of Reactive, Preventive, Predictive, and Proactive maintenance practices as well as applicable engineering solutions order to provide the required reliability at the minimum cost.

 

These maintenance strategies, rather than being applied independently, must be integrated to get the best net value and to optimize facility and equipment availability and efficiency within its operating environment.

 

This workshop will provide students with a practical interactive and process approach enabling them to see firsthand the value of monitoring, identifying, documenting, and implementing improvements for equipment, processes, or human failures (MHM facilitation).

 

All machines have three basic loading or stress phases that need to be considered individually and then collectively. 

 

Depending on the machine and system being looked each are subject to greater or lesser loading or stress types and there each require different types or degrees of "management control or management": 

 

The three basic phases that the developed of a MHM Program must consider are:

1. Start Up phase

2. Steady State loading phase

3. Shut down - Cool down Phase.

 

Items monitored in the startup phase may include data like bode plots that map the frequency and phase angle to ensure the startup progresses transitions through critical frequencies quickly. Other consideration may be as simple as confirming oil pressure has buildup in engines. 

 

Steady state management is the bulk of management data and targets the majority of process and equipment failure modes. It is prudent to note that a large percentage of damage is initiated within the startup and shutdown phases. Management data from the steady state may just show an effect of improper startup and shutdown management. 

 

Shut down – Cool down Phase is often overlooked as part of health management. This leads to failures initiated by things like repeated hot starts and lack of rundown lubrication. The majority of equipment lasts best in a steady state environment, there for unreliable equipment compounds the damage throughout a process block.  

Machine health management will provide a clear understanding of the maintenance program requirements. The balancing of the operational expectations and maintenance requirements will result in the highest equipment availability numbers. 

 

Objectives

 

• Explain how to design and develop a Machine Health Management program.

• Better understand what the role of MHM is in achieving operational excellence.

• Explain key machine centered management concepts.

• Learn how to facilitate the implementation of a Machine health management program that is focused on high value assets

• More effectively identify and cost-justify different asset management strategies designed to meet strategic goals.

• Understand what needs to be considered in the implementation of MHM programs.

 

Methodology

 

• This course was developed using over 30 years of experience of world class best practices. The focus is on value adding business decision making process and understanding how manage critical physical assets.

• The exchange of instructor and students’ experiences, case studies and practical exercise complements positively the lecture.

 

Benefits

 

• Understand how MHM manages the risk recognition and generates solutions that will contribute to improved:

  • Reliability

  • Availability

  • OEE

  • profit margins. 

• Understand key machine centered management concepts

• Learn about integrating risk data and cost benefit analysis

• Better prioritize proposed solutions based on cost benefit and return on investment

• Improve the asset management program efficiency.

• Learn about the benefits of traceability between maintenance activities and their link to root cause and failure modes

• Maximize production up-time, manage information, risk, and time.

• Reduce Unscheduled Downtime and Production Interruptions.

• Reduce Maintenance costs

 

Who should attend?

 

Both experienced industry personnel looking to take their career to the next level as well as management who want to take their facility to the next level.

 

This workshop will provide students with world-class, interactive, training with practical and industry specific case studies to understand risk management of critical asset using MHM methodology.

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• VPs and Directors

• Maintenance Managers

• Maintenance Superintendents

• Maintenance Engineers

• Maintenance Planners

• Reliability Engineers

 

 

Key Topics

 

• Binder document control (Information Quality Control policies and practices)

• Machine Center Scope (Clarity of resource application to ensure focus and efficiency)

• Machine Performance Management (Performance targets, actual and continuous improvement projects).

• Production life cycle management Philosophy (Demand projections, Operational Strategies, target % utilization and loading requirements).

• Maintenance Life Cycle Management Philosophy (Maintenance Strategies and tactics, including an outline of the 3-year projected Maintenance interventions and projected downtime for both scheduled and unscheduled 

• Machine Parts Stocking policies, stocking and repair practices 

• Machine Information Management policies (data collection, analysis and reporting policies and practices).

• Machine Renewal Program Specifications (Machine End of Life replacement policies and “minimum acceptable performance output” decision point specifications