A Publication of SKF Condition Monitoring Volume 10, Number 1

From The Desk Of Dan Bradley

SKF Acquires USA Maintenance Technology–

Engineering Company Just a Part of
the Solution
By Dan Bradley
Engineering and Research, Inc. ([email protected])

SKF has acquired 100% of the shares of Erin Engineering and A recent
Research, Inc. This technology and services company provides Harvard
maintenance engineering and application knowledge for the reliability Business
and performance of client’s assets concentrating on the power Review
generation and hydrocarbon processing industries in the USA. With article noted
annual revenue of some 14 MUSD, Erin employs 45 people at its the paradox
Walnut Creek, California headquarters and 45 additional persons in between
five locations throughout the United States. technology
Erin’s portfolio of products and services include software for investment Dan Bradley,
maintenance, application engineering and reliability. Their services and President
SKF Condition Monitoring
include maintenance program assessments and diagnostics, streamlined productivity
reliability-centered maintenance, maintenance engineering and gains. The article explored why
reliability services, predictive maintenance, reliability-based design some companies enjoyed huge
reviews and training. productivity increases while
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never saw a return on their
“Erin offers maintenance engineering services investment. Why?
In companies that improved
which complement to those provided by our productivity they observed two
recently acquired UK Company, Development traits. First, technology enables
productivity. It does not guarantee
Engineering Inc. (DEI). The synergy of the two it. Companies that benefited from
companies will provide a strong base in the large productivity increases also
(continued on page 17)
maintenance-engineering field…
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I N S I D E
SKF has built a strong reputation in providing product and
engineering solutions to problems in rotating and related equipment, by Vibracon® SM ....................... pg. 2
supplying components as well as a highly skilled field service Managing the Life Cycle of
engineering capability. Erin has specific competencies in maintenance Your Reliability Program .......... pg. 3
strategies with success largely built on developing effective procedures Reliability on the Cutting Edge ... pg. 10
for the execution of RCM (Reliability Centered Maintenance), RCM
(continued on page 2) New Products ....................... pg. 14

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SKF Acquires USA Maintenance... (continued)

Engineering and Research, Inc.

analysis, and leadership of the practical

implementation of maintenance improvements for
their clients.
“Erin offers maintenance engineering services
which complement to those provided by our
recently acquired UK Company, Development
Introducing the
Engineering Inc. (DEI). The synergy of the two
companies will provide a strong base in the
Vibracon® SM–
maintenance-engineering field and will enhance
the total maintenance service capability that SKF is
The universal
offering the market,” says Phil Knights, President
of SKF Service Division.
adjustable chock
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Vibracon ®
SM elements are becoming more and
“Joining with SKF means more the favorite method for mounting and chocking
machinery like diesel engines, turbines, gearboxes,
that Erin will now have access compressors, generators, E-motors and bearings.
to their global technology An ideal foundation for machinery, the product
permits quick and extremely accurate alignment. In
resources and service network.” many cases, costly machining of foundations or base
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frames can be avoided.
The spherical top of the Vibracon® SM element
“Joining with SKF means that Erin will now allows deviations of up to 4° to be accommodated.
have access to their global technology resources This in combination with the height adjustment
and service network. In addition, the condition capability eliminates the possibility of a soft foot.
monitoring products and the integrated Vibracon® SM elements can be used in packaged
Maintenance SolutionsTM (IMSTM) maintenance units between the machinery, the base frame and also
contracts of SKF extends the range of solutions we on board of ships between foundation and machinery.
can provide customers,” says Gene Hughes, Vibracon® SM chocks also drastically reduce
President of Erin. “In turn, Erin affords SKF a alignment and mounting time.
greater presence in the U.S. and entry to key Machine Support B.V. of the Netherlands holds
industries such as power generation. the patent for this innovative solution. The design
This acquisition is part of SKF´s strategy to derives from Machine Support’s long involvement in
expand into the service market by selling not only the mounting and alignment of machinery and
bearings and seals but also mechanical and associated measuring tasks. The system is approved
engineering services, preventive and predictive by all major classification societies and machinery
maintenance, and condition monitoring solutions, manufacturers.
in order to provide total life cycle management of For more information on the Vibracon SM
customers’ assets. The benefit for customers is elements, please contact your local SKF Reliability
improved plant reliability, which in turn raises Systems representative or visit the website at
productivity levels and improves overall www.machinesupport.com. Questions may be
competitiveness. emailed to [email protected]

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TECHNICAL PAPER TECHNICAL PAPER TECHNICAL PAPER

Managing the Life-Cycle of Your Reliability

Program to Keep It On Track
by: Luis Econom, SKF Condition Monitoring, Doug Johnson, SKF Condition Monitoring

Abstract
Take a birds eye view of your reliability effort. How
do you maintain a top notch program for the long
term? This session will cover the range of issues
related to continuous improvement of the reliability
program, from establishing a program to developing
recommended practices to adoption of technology,
skill level of personnel, turnover and more. This is a
must for individuals who want to step back from the
fighting fires mode to see where your program is and
where it can go.

Technological Advances
Since the mid-1950’s vibration analysis has changed
mechanical systems from a slow, labor-intensive, protect the surrounding environment. This is the
mystical black magic to the current state of being an world as we have grown to know it today. Coupling
effective tool critical to the success of modern these valuable tools with the skills of an experienced
industry. Within the past decade, refinements in analyst and a competent mechanical support staff,
instrumentation and techniques make it possible for these basic precepts of machinery analysis can be
the detection and root cause analysis of most accomplished: detect a potential mechanical
machinery problems, and enable the enlightened problem prior to critical condition, and be a
industrial manager to make cost-effective decisions, detective to diagnose the cause and sequence of
which results in higher profits that show up on the indications as the problem develops.
financial bottom line.
• So why aren’t all businesses enjoying the same level
• So why aren’t all businesses enjoying the same level of success? Why do some PdM programs fail?
of success? Why do some PdM programs fail?
Now is the time to back up, regroup, and take a Upon extensive examination of three primary
bird’s eye view of what makes the business of segments of industrial environments (paper
predictive maintenance (PdM) successful. The key manufacturing, power generation, petrochemical/
phrase is, “the business of predictive maintenance.” hydrocarbon processing), the conclusions drawn are
The technology of plant operations and the very similar to those cited in any current business
maintenance practices are not the problem. management journal:
Instrumentation is compact, portable, intuitive, and
has become a common tools to the maintenance • Optimum integration between available technology
community. Techniques in evaluating the data from and the conduct of business must be effective and
these instruments continue to be improved through cooperative in order to optimize resources and
commercial and industry-specific training. profits.
Sophisticated surveillance and protection systems
can be installed which not only indicate machinery • Every technology, and thus, every business, rely on
condition, but actually are able to automatically shut consistent standardization of processes and process
a machine down to protect its integrity and to improvement in order to be successful.

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Managing the Life-Cycle of… (continued)

Most simply put, in context, reliability maintenance • What machinery is the source of the most downtime
technology must be incorporated into the day to day – and how is loss of production cost
operational process of running the business. This is captured?
the result most obvious of observations: the
predictive maintenance program is a system of risk • What is the current maintenance style (reactive,
assessment. quick response, or perhaps methodical planning of
For this reason, the Principles of Proactive downtime, etc.)?
Reliability Maintenance (PRM) must be reviewed, and
tools identified which are the foundation for the • What are the availability requirements by
successful predictive maintenance process. These are operations/production?
essential in capturing the success in order to identify
• How much inventory is maintained in spare parts
proper business value.
and what is the turnover of spares inventory? How
The first step is to visualize the eight steps in
much of this repairs inventory is unusable due to
reliability maintenance as a process of taking the
shelf-life damage?
business from a set of known conditions, developing
and reinforcing elements of continuous improvement, • What environmental restraints are imposed by local
to an effective business element from which tangible and federal codes, and what is the cost associated
value can be determined. with these requirements?
In order to determine what company/business assets
are available and what the risks are imposed during and more…
accepted plant operation, an audit, or evaluation, is
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ These are just a few of the many hundreds of
considerations which must be examined in order to
“Candidate systems are identified determine what works, what needs to work, and what
obstacles can be improved or overcome in order to
based on economic and performance become a more effective element of business practice
for bringing the maintenance activity into the business
criteria, followed by an assessment of value profile.
Once the audit is performed, the “top 10” issues or
what kind of data provides the best obstacles can be examined. Not every process needs
to be fixed. Not all processes can be fixed at once.
visual profile of machinery Target those things which will have the largest
positive dynamic impact first. Gaining confidence
performance.” and teambuilding between the maintenance
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organization and production management is absolutely
essential – and yet is one of the most overlooked and
performed. Since this is a discovery process, both an understated necessities for survival. Since the
overview and a detailed look is taken at such items as: variables of personnel and business climate change
over time, the audit or evaluation process is also a tool
• What machinery is critical to production? which should be employed every two to three years, to
ensure the program is providing the continued proper
• How many of the critical machines have redundancy return on investment.
in order to minimize risk of production stoppage. The second logical step in building the PRM
process is the development and execution of the
• What machinery has the highest cost associated with predictive maintenance program. The majority of
repairs and loss of production? predictive maintenance efforts over the past decade

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• Adding the PdM assignment to personnel already

working at capacity in their other maintenance tasks

• Lack of documented procedures for program

operations and corrective action flow

• Poor integration of the PdM effort into the overall

plant maintenance and operations effort

• Poor follow-through of corrective actions, Poor

coordination with Operations for machinery
inspection and corrective actions

• Inconclusive results based only on a single

measurement parameter (example, making
judgment based only upon vibration data, with no
regard for lubrication inspections, temperature data,
process measurements which affect machinery
performance, etc.).

There are far too many examples of issues such as

these, and in most cases, no single element
are successful in finding certain problems and having precipitates failure, but rather a cascade of events lead
sufficient diagnostic ability to resolve the problems to disaster. The bottom line becomes obvious and
identified. However, the single most obvious failure simple: the program must be planned, documented,
in program development is the lack of documented and operated in a predictable, standardized manner.
processes for establishing consistent, repeatable Resources such as standards from ASME, ASTM,
programs, identification of standards, and corrective publicly-available military standards, references such
actions resulting from program activity. Nearly half of as GMAP (General Machinery Assessment Program),
all programs fail the initial attempt within 12-18 ISO, and other, are available for researching and
months, and either require reinvestment in a program building the procedures necessary to initiate a
restart, or the expectations have been so strained by reliability maintenance program. In all cases, the
inconclusive results that confidence is lost in the recommended initial steps are the same:
program. This becomes such a barrier that the
predictive maintenance effort will never gain the • Survey the machinery to be incorporated in the
support required to become a functional asset to the inspection program, and document the machinery
business organization. Some of the obvious sources of characteristics (bearings, speeds, nameplate data,
these shortfalls include, but are certainly not limited configurations, etc.) before the data collection
to: process begins.

• Poor or inconsistent training of personnel, which • Consider all relevant mechanical dynamics.
results in improper or inconclusive data being taken Besides vibration data, lubricant inspections and
analysis, temperature measurements, process flows
• Assigning personnel to operate the program without and feed speeds may all have a marked effect on
proper preparation or supported management buy-in how machine condition can be assessed. No single

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TECHNICAL PAPER TECHNICAL PAPER TECHNICAL PAPER
Managing the Life-Cycle of… (continued)

measurement parameter is adequate for assessing brought into the PdM operation as a result of
machine risk. It may not be economically or advancement, etc.
tactically feasible to have a database for all
parameters in the initial steps, however, a • Develop the initial database, in a fail safe,
comprehensive understanding of relevant influences ‘standardized’ manner. The initial data should be
is essential in ascertaining machinery performance. conservative, so that the machinery characteristics
can be captured, even if the data acquisition
• Establish priorities based upon machinery technique may be refined in the course of the
criticality to operations, and develop a strategy of program. Alert levels can be assigned based on
monitoring, both technically, and how often the available guidelines, until experience dictates re-
machine(s) should be monitored in order to evaluation of the alert levels.
minimize risk of loss.
• Take data often enough that machinery behavior
• Draft a guideline outlining the program can be trended, and the assessment truly indicates
expectations, goals, and operational plan of how the the machinery condition based not only on specific,
PdM business will be conducted. There are two single-date data, but can also be evaluated based on
elements of this document: the strategic aspects, term experience, more commonly called trend
that identify options and expectations, that will analysis.
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• Evaluate the data with respect to corrective

“Many factors contribute actions and extending machinery life. One of the
most common frustrations in any new program is
to machine failure. The easiest identifying a huge number of conditions in alert
status, and being overwhelmed by the list of
to capture are design problems, recommended actions. Measurable success will be
more obvious if the first five worst offenders are
wear, etc., however, some managed and corrected, then take on the next five,
are more subtle in source.” etc. This accomplishes two goals:

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take the plant down first

outline the roles of the respective departments in (2) you develop detection-cause- correction
maintaining machinery health, and the tactical processes and are able to utilize measurable success
elements, which are the “nuts and bolts” of the in developing skills and company support.
mechanics of the assessment process. This
document has many purposes, and should be a • Document processes used, diagnostic tools used,
“living document”, constantly revised and and results, including financial impact. Without
improved as the program grows and improves. providing proper and timely documentation, the
This not only will assist the maintenance operation lessons of success are never learned, and the
and related plant operations visualize and cooperate financial gain never achieves necessary visibility.
in the execution of the maintenance function, but
will also assist in developing a strategy of • Review the processes and tactical implementation.
maintenance availability versus operational These are the elements of building the foundation
availability. The side benefit of the program of success.
document is to provide a guide for staff being

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TECHNICAL PAPER TECHNICAL PAPER TECHNICAL PAPER

These steps can be aware of actions

most easily captured causing reactions,
in three points: we are better able to
• Assess need by refine our ability to
Discovery and/ properly service and
or Audit. maintain machinery.
• Establish the As programs and
initial plan. personnel become more
• Execute: refined, and the processes
Implement the of detection, diagnostics, and
program. prevention become more effective, the
• RE-assess the program. success of these practices must be captured in terms of
production and finance. In a progressive maintenance
Hand-in-hand with the detection of machine and operations relationship, key performance
changes comes the necessity to diagnose the actual indicators, or KPI’s, may be identified. This is the
machine behavior. This is another area which has assessment of where the operation was before
improved markedly within the past five years or so, program implementation, followed by the tactical
because the vision of the job at hand has gotten more effort of PdM, and then evaluating the outcome of that
proactive: it is not enough to identify a bad bearing, a effort. This can be identified as a decrease in repair
misalignment or imbalance condition, or any of the parts inventory, increased machine availability,
list of other machinery behaviors. Due to increasing decrease in required overtime, and other targets which
economic pressure and higher product demands are visible advantages to the company business team.
(translated to increased demand for machine KPI’s have dual roles:
availability), it has become an essential skill be able to
correlate data from various sources, and determine the First, they identify the return on investment for the
root cause of the problem. What causes a “bad tactical implementation of the reliability
bearing”? What caused the misalignment in the program.
machine train? Many factors contribute to machine
failure. The easiest to capture are design problems, Second, they identify areas which move to
wear, etc., however, some are more subtle in source. successful levels, and identify areas which need
Misalignment can be caused by a change in the improvement or re-evaluation of the tactical
mechanical foundation, or thermal growth, change in processes required.
material, etc. In complex machine trains, a
misalignment caused by a material change in This may be a monthly or quarterly review of
foundation material can cause a bearing to fail over activity, results, benefits, and next targets, but in all
time. Replacing the bearing will never resolve the cases, it is obvious that this review must be often
problem. enough that forward motion of the program can be
Other problems are more simple in nature, however, maintained, or brought back on track if the direction
their impact can be catastrophic. Recent advent of of the program wavers. This typically involves a
vibration-based (using acceleration enveloping) grease cross-sectional team of staff and management, which
monitoring programs indicate inadequate lubrication can best represent the technical and business vision of
due to elevated temperatures, or over-greasing of the organization.
bearings disrupting heat transfer capabilities in day to The outcome of the KPI review becomes the basis
day plant environments. Ten years ago, the only for the operational review of the reliability program.
grease monitoring consideration was to ensure there This function takes the program strategy, tactical
was enough grease provided. As we become more implementation and results – both positive and

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TECHNICAL PAPER TECHNICAL PAPER TECHNICAL PAPER

Managing the Life-Cycle of… (continued)

negative – and evaluates the program’s current status, certain level of complacency can be afforded, because
and the functional elements of overall plant operations the match is correct.
impacted by the program. In some cases, processes of Economic change occurs when increased output is
the production line can be modified in order to required to increase profits, quality of product
optimize machine availability. Economic decisions becomes more demanding, or downsizing increases
can be made with regard to capacity of existing risk of shortfall. From this changing economic
machinery and availability, versus purchasing climate comes a need for continuous improvement.
additional support machinery to support increased Production is constantly challenging the operating
production demands. Seasonal or time critical envelope to run faster, make more product, and run
requirements can be reviewed, and support strategies longer between planned downtime. When the
can be planned accordingly. This also provides an maintenance organization is tasked to accept
opportunity for management review of tactical responsibility for maintaining this level of operation, a
elements with which the PdM process can be second phase of the program must be examined – the
improved, parts and personnel assets better managed, path of continuous improvement. Look again at the
etc. The feedback from the operational review structure.
directly impacts the management of the PdM program, Increasing capacity of a machine process is
and improvements are made as the program evolves. becoming more and more prevailing in current
This fundamental process of Audit, PdM, KPI business climate, however, a methodology must be
measurements, and Operational Review is the process incorporated into the strategy to prevent huge
of Proactive Reliability Maintenance, or PRM, as economic risk. That risk may be as simple and
introduced earlier. In many operations, implementing familiar as accepting current level of machinery
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downtime and planned production output, or could be
as disastrous of not only not being able to increase
“Increasing capacity of a production, but actually incurring financial risk in the
machine being down more often, and planned
machine process is becoming more production schedules becoming unstable and
unpredictable.
and more prevailing in current Technology upgrades do not only include current
state-of-the-art machine modifications (capital
business climate, however, a investments) and process improvements, but must also
encompass planned design and maintenance practice
methodology must be incorporated innovations consummate with the machine’s
technology advancements. Scope of machinery
into the strategy to prevent huge inspections may have to expand to include NDT
economic risk.” procedures, precision alignment/tramming, and
additional fail-safe considerations due to the technical
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pushing of the machine envelope. Special bearing
the PRM process takes a minimum of 18 months, and designs, such as CARB™ bearings, may become
more typically may take up to two and three years to appropriate for a hostile environment installation, and
incorporate into the accepted business practices of the with that would come the requirement to ensure
company. The key points to success involve proper installation techniques are observed, etc., by
documentation and improving the PdM processes. In the maintenance activity. In some cases where a
many cases, successful companies create a comfort machine wreck could be catastrophic at high output
zone, and the program stabilizes at this performance demands, and upgrade from a manual to an automated
level. At this time, maintenance problems are few, surveillance system may be prudent. The intent of
and correlates well with production requirements. A technology upgrading should never be to chase

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technology, but rather, must be an evaluation of return with new product or requirements results in failure
on investment. The key criteria in determining this and increased economic risk.
course of action should be risk. Once this assessment The final consideration within the boundaries of
is made, and the decision is based to upgrade the developing the maintenance strategy and risk
technology path, then the initial system of Assess – assessment is the supply of the proper equipment,
Establish – Execute – Reassess must be reviewed, and proper skills and proper timing. Current business
documented modifications to the PRM program must climate does not support hundreds of thousands of
be initiated in anticipation of increasing demands on dollars of repair parts inventory with unpredictable
the PRM team. turnover. The effective PRM and continuous
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for a risk management system which allows detection
“Current business climate does of a machine change, methods for increasing machine
life during a manageable failure mode, and scheduling
not support hundreds of thousands of a maintenance activity with the required parts
available at the right time. In many cases, supply is
of dollars of repair parts inventory managed by purchasing methods which are price-only
based, and without regard to the special applications
with unpredictable turnover. requirements of the components being sought. The
The effective PRM and result is unsuitable parts being purchased based only
on price, but within the requirements of the
continuous improvement program application, the parts undergo recurring failure, and
increases risk for production. A coordinated effort to
outlined here is the foundation for assess historical operational performance related to
maintenance requirements may indicate specific areas
a risk management system.” of needed improvement. This is an opportunity for
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to team together to achieve a target of less risk, in both
With the advent of technology upgrades must come production and financial terms.
the commitment of continued training, for two The concepts are simple, and are not new to
reasons: industry. The demands have increased for economic
stability, and for predictable performance. The tools
1.) Increasing technology demands increased technical are available for achieving successful risk assessment
competence, and, which results in increased production reliability and
financial accountability, however, the process
2) Personnel improvement, attrition, and promotion becomes the most fundamental key to survival. The
creates a demand for competence and skills training. time is now to review the entire scope of machinery
reliability, and become proactive in strengthening the
This training does not fall just within the realm of processes most likely to ensure successful
the PRM process, but must also encompass disciplines maintenance practices. Take the time to document the
of improved bearing mounting techniques, specialty processes which are most successful. Review those
lubrication requirements, machine dynamics and areas which provide the least payback in effective
process evaluation, as well as machinery operations, machinery management. Document the technical and
etc. Management teams are encouraged to plan and financial successes for management and for internal
fund the appropriate training of staff for immediate experience growth. Make the business of PRM
and long term increased reliability of processes and provide the return on the investment required in
machines. Failure to consider and plan proper training today’s business climate.

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 OPERATOR RELIABILITY OPERATOR RELIABILITY OPERATOR RELIABILITY

Reliability on
the Cutting Edge
M any of today’s leading multi-national organizations
are adopting an innovative approach to maintenance
called Operator Driven Reliability (ODR) and having
great success-both in extending MTBF (mean time
between failure) and realizing cost savings in the area
of maintenance and reliability. The concept is simply a
framework for organizing the activities of plant
operations personnel in concert with a company’s
reliability maintenance practices. Operators are those
closest to plant machinery 24 hours per day, and
typically are the first to notice the smallest changes in
machine operation. Involving them as key resources in
a plant’s reliability effort is a logical and highly cost
effective means to improve machine and process technologies such as process control, Computerized
operation. Maintenance Management Systems (CMMS), and new
The term Operator Driven Reliability relates to generations of electronic hand-held computing
maintenance practices that are owned and managed by equipment. Evolution of these trends resulted in the
operators. It encompasses the maintenance activities term ODR.
they perform, as well as the interaction with
ODR can be considered to comprise three elements:
maintenance and other departments of the organization
• Equipment Operating Procedures (EOP): These
that impact the reliability of plant machinery. The
typically originate from the original equipment
practices related to ODR are typically preventive in
manufacturer (OEM) at plant start-up, but may then
nature and are undertaken in order to optimize
undergo a process of evolution, in-line with
equipment life cycle costs by identifying opportunities
developing experience and expertise in plant
for reliability improvement.
operation
Below are excerpts from SKF’s comprehensive
ODR implementation guide which highlight some of • Operator Involved Maintenance (OIM): This term
the key aspects of a successful program. Contact your describes the activities that address daily co-
local SKF representative for additional information. ordination needs between equipment operators and
maintenance department. Examples would include
Definition of Operator Driven Reliability initiating maintenance work-orders, arranging for
ODR, then, is a company-wide, team-based process machines to be made available, so that necessary
optimizing the operation of an industrial production maintenance work can be carried out, organizing
plant, and which augments classic operator duties. necessary permits, etc. The term OIM also
ODR impacts equipment effectiveness, contributing to encompasses operator participation in other,
optimal production, and to financial return on reliability-related activities such as root cause failure
investment. ODR incorporates operational, technical analysis (RCFA) or maintenance strategy review
and financial metrics, balanced to meet the business (MSR) processes. A prime objective of OIM is to
plan of the industrial enterprise. improve the support strategy for the equipment.
Another term that has historically been used is OIM ensures that operations understands and fulfills
Operator-Based Maintenance (OBM). OBM also its role in ensuring plant-wide reliability
stresses the involvement of operators in maintenance
tasks and the sharing of ownership. A parallel trend in • Operator Performed Maintenance (OPM): This
maintenance is the growth of reliability-improvement term relates to maintenance tasks undertaken by

® 1-877-SKF NEWS
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OPERATOR RELIABILITY OPERATOR RELIABILITY OPERATOR RELIABILITY

Reliability on the Cutting Edge... (continued)

machine operators to increase machine availability. • What are the correct operating conditions, e.g.
Examples would include inspection, cleaning, minor temperature, pressure…
adjustments and repairs etc. • How does it fail? What can go wrong?
• When this goes wrong - How much does it matter?
History and rationale
(Costs/losses/risk)?
Given the complexity of modern production machinery
and associated support systems it would be unrealistic • What should be done?
to expect any one person to be fully conversant with all – When?
of the skills necessary for both operation and – How?
maintenance of a plant. Efficient production must – By Whom?
therefore involve a team of people who collectively
provide the necessary pool of skills and experience. To ‘qualify’ as a ‘dynamic business based process’,
Inevitably there must exist within the team specialists ODR must be directed by a thorough understanding of
in certain aspects of either operations or of ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
maintenance. Logically, the more sophisticated the
plant, the greater the need for these specialist skills. ODR can be a stand-alone
That said, the concept of operators participating in
maintenance activities is fundamentally not new. program, but is ideally part of
It is feasible and desirable for operators to accept
some involvement and responsibility for basic an overall Asset Efficiency
maintenance activities in a production plant, given
appropriate training. Some basic inspection activities
Optimization™ (AEO) program.
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
require the operator to be the person best equipped, by
virtue of experience, to perform the task. Routine the asset and the systemic interactions of’‘contributors’
surveillance is part of the plant operator’s day to day to get all members of the team aligned.
activities, and thus becomes sensitive to minor changes ODR can be a stand-alone program, but is ideally
in sounds, noises, vibrations, etc., that would not be part of an overall asset efficiency optimization (AEO)
apparent to someone lacking extensive front-line program. Other programs and initiatives may already
experience. Similarly, if the operator is empowered to be in place and ongoing at the facility. Ensure that
undertake simple adjustment / repair tasks, then minor ODR ‘complements’ where necessary, and ideally
defects can be corrected more quickly, avoiding delays ‘augments’ the’‘overall goal/mission’ at the facility.
while the maintenance counterpart is located and Various parties from different functional groups
summoned to the machine. It is essential to the within the organization may monitor the same plant
success of such a program that it is done within a machines/equipment. The essential difference lies in
culture of “ownership.” the ‘focus/specialization’ and the frequency of the
‘monitoring’ being conducted.
Program startup The ODR tasking is not limited to ‘more frequent
Operator Driven Reliability promotes ‘knowledge’ of condition monitoring’. The ODR task set is expanded
‘equipment function’ and increases the ‘awareness’ of to include performance/efficiency, condition and
‘consequence of loss of function.’ Therefore a integrity checks that are conducted by the operator as a
successful ODR program ‘implicitly and dynamically’ ‘complement’ to these other ‘core programs’.
asks and answers:
• What should it do? Operator activities in an ODR program
The first component of the operator monitoring and
• What does it actually do?
optimizing production capacity typically relies on
• How does it work?
• comparison of current operational trends and

® 1-877-SKF NEWS
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 OPERATOR RELIABILITY OPERATOR RELIABILITY OPERATOR RELIABILITY

Reliability on the Cutting Edge... (continued)

modifying/optimizing conditions on-the-spot, and evaluated based on statistical analysis in comparison

• recording changes in operating requirements as they to (a) known machine operating conditions and (b)
affect production. use of alert levels (either by gain/rate of increase,
The second component of the ODR program is the trending outside a normal operating envelope
acquisition and management of information in such a parameter, or becoming statistically anomalous (i.e.,
manner that plant operating condition and machinery 3£ deviation from operable ‘normal’ trend, etc.
risk assessment can be evaluated, and business These include dynamic measurements such as
decisions made in order to optimize plant production vibration, as well as static or static-variable
and machinery health. This second element, data parameters, such as temperature, pressure, flows, etc.,
acquisition and information management, is currently to name only a very few.
defined in simple terms of providing a model (most
typically vibration monitoring, lubrication analysis, Selection of equipment
temperature transient monitoring, etc.) of information Candidate systems are identified based on economic
management, from which more comprehensive (and and performance criteria, followed by an assessment
thus more sophisticated) models can be built and of what kind of data provides the best visual profile of
expanded. machinery performance in various operating
conditions. Industry standards and guidelines should
Capturing the right information at the right time be considered during this assessment, and from that,
One definition which applies to the process of machines are classified by criticality to production,
assimilating physical data is to determine what are risk management of potential catastrophic failures,
inspections, and what are PdM-type, or trendable, etc. Various guidelines are offered in both general
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ industrial terms, and in application-specific
categories. An example of general industrial
Various guidelines are offered in categorization of industrial machine is demonstrated
in an interpretation of the ISO10816-1 guideline
both general industrial terms, and in (10816 focuses on vibration assessment, which is
NOT the point in this context, however, the
application-specific categories. categorization method of the machinery being
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
measured is of interest).

data. In very general terms, an inspection is Inspection, process and vibration monitoring
conducted to assess the actual condition of a system In most cases, process variables frequency and
or asset. In most cases, these inspections are required parameters have been established based upon
conducted annually, semiannually, or quarterly, but do the history of production process. These are
NOT rely upon the ability to trend parameters or constantly scrutinized and adjusted, in order to most
perform statistical analysis to determine probability of effectively operate the production process. The
an anomaly. These inspections may include (but are results of this history can be categorized and the data
not exclusive to) belt inspections, image acquisition process be moved from a paper-type log
thermography, “remove/overhaul/replace” into the digital data acquisition (manual-digital and/or
maintenance items, ground strap inspections, fire automated data acquisition, depending on access,
extinguisher and safety asset inspections, etc. The safety exposure, and response requirements, as well
other category of data which is vital to plant as long term analysis of the process by production.
monitoring (both PdM/condition monitoring and Vibration, of course, is measured at key points in
process monitoring) is data which is collected with the machine train, so that trend and statistical analysis
reasonably repeatable cycle time (hourly, per shift, can indicate change in machinery dynamic
monthly, etc.), and that data is trended and/or performance. Selecting any single physical

® 1-877-SKF NEWS
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OPERATOR RELIABILITY OPERATOR RELIABILITY OPERATOR RELIABILITY

Reliability on the Cutting Edge... (continued)

measurement may provide mechanical insight into the of defense for any variable, which threatens the
physics of machine performance, however, current integrity of the production process
technology has allowed us to monitor multiple
parameters (e.g., in vibration, acceleration, velocity, Assessing results
enveloped acceleration, etc.) which are best suited to To assess the success of an Operator Driven
mechanical performance characteristics (enveloped Reliability program, all exceptions and actions must
acceleration is a primary indicator of bearing bring forward the details to allow the Program ROI -
performance; velocity is a typical identifier of Return On Investment to be produced, tracked and
primary mechanical condition, such as imbalance, reported upon. This can be done by means of a Key
misalignment, mechanical looseness, and advanced Performance Indicator- KPIs are in essence a list of
component wear in final stages of failure). This kind quantifiable objectives that spell out the desired
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ outcome for an ODR program. KPI’s are a ‘dynamic
entity’ that are reviewed regularly and adjusted, given
… the health of the machine the actual performance in key result areas. In best
practice company’s indices are added and deleted
can be optimized to support from the system, as needs dictate. Once the desired
level of performance is achieved it is considered
production requirements.. prudent to remove or change the initial selected KPI’s
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
used in the performance monitoring process.
of dynamic information coupled with component
temperature transients, lubrication pressures and Change Management
flows, process pressures, flows, temperatures and Successful implementation of an Operator based
differential pressures, give an experienced operator inspection program requires an understanding that
the ability to assess machine condition in both the activity ultimately benefits all parties, and
production and reliability. Taken a step further with requires management buy into the program from
management of database information showing the top down. It requires a clear business goal that
historical performance and trends, the health of the must be communicated, understood and owned by
machine can be optimized to support production the ODR team. Any major change agent/effort
requirements. requires proper training and communication
during the change process. Typically,
Route development implementing an ODR program requires changes
Routes are defined as the routine of acquiring various in the workflow process, implementation of new
process and condition assessment data based on: technology, enhanced communication and changes
• Operation/availability of machine or process to be in working relationships-from an individual and
monitored departmental standpoint. Management must
• Criticality of machine or process in terms of understand the change process and anticipate and
production and integration into sequenced facilitate change management as part of ODR
production implementation. Support of management in
• Geography, or footprint, of the machinery system facilitating this change is a key component of a
with relationship to operator access. successful program.
These are not exclusive criteria by any means, but SKF has recently introduced a range of data collectors
rather, illustrate variables to be considered when and personal data assistants to provide a convenient
designing a data acquisition process for the operator. and easy way for plants to implement an effective
Consideration must be given to the principle that the Operator Driven Reliability Program. Contact your
operator’s primary responsibility is to monitor and local SKF Representative for additional information
control the production process, and to be the first line on ODR or any of our MARLIN systems.

® 1-877-SKF NEWS
13
 NEW PRODUCTS NEW PRODUCTS NEW PRODUCTS

Hand-Held Data Collectors Suit Range

of Plant Requirements
SKF recently completed the Microlog , CMXA 50
®
range to 40,000 Hz and FFT
worldwide launch of a range of resolution at 12,800 lines, the
new hand-held data collectors and CMXA50 is great for optimum
accessories to accommodate a analysis and the earliest detection
multitude of customer needs. “As of bearing and gear mesh
organizations begin to understand problems.
the overall benefit of achieving
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ MARLIN Pro ®

These new products data manager,

include the latest CMDM5000
technology to provide
solutions for The Microlog CMXA50 is a robust
alternative for plants seeking to
maintenance, arm plant personnel with an easy
operations and to operate, feature-rich data
collection and analysis tool. For
engineering as well novice to advanced users, the “50”
bridges the gap between a high
as plant management. powered comprehensive analysis
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ solution such as the Microlog
CMVA60, and the simplified
their reliability goals, the need for MARLIN line of Data Assistants The MARLIN Pro is another of
instruments designed to meet a for operator use. The CMXA50’s SKF’s recent additions to its
variety of organizational structures price point and functionality make family of hand-held mobile
and operational requirements has it an essential addition to an computers for Operator Driven
emerged” says Marketing Director existing program, or the perfect Reliability. The MARLIN system
for SKF Reliability Systems, choice for starting out. is the quintessential frontline tool
Marty Herzog. “These new A two-channel, route-based for operators.
products include the latest instrument, the 50 is small, This fully rugged, high
technology to provide solutions for lightweight and rugged. It fits in performance data collector enables
maintenance, operations and one hand and weighs just 1.6 plant operations personnel to
engineering as well as plant pounds. It collects, stores and electronically collect, store and
management. Today, reliability is trends vibration and process data, analyze overall machine
a team effort and that reality has including enveloped acceleration- inspection, process and vibration
and will continue to influence our with 4 selectable input filters. data. The MARLIN Pro enables
product development efforts.” With a spurious-free dynamic in-the-field trending, comparison
Read on to learn more, or visit range of 90dB, and digital signal of baseline with previous readings,
our website at www.skfcm.com processing at 40kHz real time rate, alarm notification and more. User
for detailed information and the CMXA50 has an enhanced notes allow operators to record
datasheets. capacity for detecting and immediate impressions of
identifying problems quickly and troublesome machine conditions or
accurately. Maximum frequency measurements which may be

® 1-877-SKF NEWS
14 13
 NEW PRODUCTS NEW PRODUCTS NEW PRODUCTS

New Products... (continued)

uploaded to a host PC network for water jet protected), meeting the Microsoft Pocket Word, Pocket
team review. On-board software definition of “fully rugged”. The Excel and Internet Explore.
provides push button assistance, unit is designed to withstand the Additionally, because it uses an
offering users clear and specific most hostile and extreme industrial open “Pocket PC” platform, third
direction to enable the fastest and environments. The “Pro IS” has party or user-developed
most appropriate response to achieved the Intrinsic Safety rating applications may be loaded
changes in machine conditions. from the European regulatory directly onto the hand-held to
Companion software allows for agency, Cenelec, and is rated accommodate scheduling, tracking,
more in-depth analysis and the Group II (Petrochemical) Eex ia documentation, reference, storage,
sharing and communication of IIC T4 (ATEX directive). or communication requirements
machine data between operations, unique to your organization.
engineering, maintenance and
plant management. The MARLIN
MARLIN Pocket ®
The mobile, pocket-sized unit
has the user-friendly MARLIN
Pro has achieved the safety Pro data manager, graphical interface (GUI) that has
certification rating of Class 1, received industry-wide recognition
Division 2, Groups A, B, C, D. CMDM5000P and acceptance around the globe.
(“Non-Incendive”). The MARLIN Pocket Pro data
manager also works with the
MARLIN Pro-IS ®
popular Surveyor software for
analysis and sharing of important
data manager, machine information.
CMDM 5000-IS
for Hazardous MARLIN Condition®

Environments Detector Pro-IS,

CMVL3600-IS

The MARLIN Pocket Pro is

another tool for facilitating a team
approach to machine and process
availability. By combining the
Intel Strong Arm architecture in an
ergonomic, pocket-sized form
factor suitable for many industrial
environments, the MARLIN
Pocket Pro complements the fully The MARLIN Condition Detector
rugged MARLIN Pro line of Pro-IS is a Go/No Go monitoring
The MARLIN Pro-IS data mobile industrial computers for instrument designed for ease of use
manager brings the power of the Operator Driven Reliability. and convenience in monitoring
MARLIN Pro to hazardous This state-of-the-art data machine condition. The
environments. With all of the collector has the power to collect, instrument’s sensor affixes to a
functionality and benefits of the store, analyze and report on machine point via a MARLIN
MARLIN Pro, the “Pro-IS” has a important machine vibration, QuickConnect Stud (patent
multiple 6 foot drop test rating and inspection and process data, and pending) or magnetic base- for
is IP65 certified (dust-tight and also comes standard with automatic collection of vibration

® 1-877-SKF NEWS
15
 NEW PRODUCTS NEW PRODUCTS NEW PRODUCTS

and temperature data. Green, VibPak your MARLIN data manager via a
yellow and red LEDs provide small cable and is carried
easy to interpret indications of CMVL3700 comfortably in a shoulder pouch.
machine status, so operations or The MARLIN automatically
maintenance personnel can recognizes the module and
quickly identify the need for attachments, making its use easy
more in-depth analysis on a and hassle-free. Plant personnel
particular machine. The unit simply attach the desired
operates as a stand-alone device, instrument and proceed with
or as an integral component of collecting data via the MARLIN
the complete MARLIN system. system.
When performing
measurements, the MCD Pro-IS’ The VibPak is a MARLIN system SKF Machine
sensor input signal is processed accessory that connects to the
to produce two vibration MARLIN data manager. It enables Analyst Version 1.1
measurements for each MARLIN users to collect vibration
measurement POINT. Velocity velocity and enveloped
vibration identifies phenomena acceleration data from machinery SKF Machine
typically observable in the low in remote or hard-to-reach Analyst 1.1 is an
to mid-frequency range, and can locations. The collected data can enhancement
indicate such structural then be trended in the MARLIN release to the
problems as misalignment, data manager and/or PRISM4 existing
unbalance, mechanical looseness software. The compact, software. A range
and more. Events which occur lightweight unit is a cost-effective, of backend
in the higher frequency ranges safe solution for expanding your modifications have
such as bearing and gear vibration monitoring efforts improved the reliability and
problems, can also be detected without additional personnel. openness of the application to
by the MCD Pro IS with its The VibPak lets you take facilitate the integration of future
“acceleration enveloping” advantage of the systems you add-ons and third part plugs-ins. In
capability. This signal already have in place to facilitate addition, an Import/Export
processing technique enhances more comprehensive monitoring of functionality has been added which
the repetitious vibration signals plant equipment. The VibPak allows for the transfer of complete
that characterize such problems collects data from most standard or specified portions of the
as bearing or gear mesh faults. 100 mV/g industrial database between Machine Analyst
The new ruggedized MARLIN accelerometers. Its small size databases. And finally, a Notes
Condition Detector Pro-IS is affords an easy fit in locations not functionality now allows for the
now certified Intrinsically Safe easily reached with a standard introduction of SET specific notes
by the European regulatory vibration instrument. The VibPak from an easily accessible top-level
agency, Cenelec, and the North also collects vibration data from menu item or toolbar button.
American regulatory agency, permanently mounted SKF Machine Analyst is the
CSA. The MCD Pro-IS’ accelerometers in hard to reach data management and analysis
certifications make it an areas, or in remote locations via a software that provides the power
essential monitoring tool for BNC junction box or from SKF not only to manage, but to
use in hazardous environments Mechanical Condition Monitor optimize the efficiency of plant
typically found in the panels. machinery.
Petrochemical industry. The lightweight VibPak links to

® 1-877-SKF NEWS
16
Dan Bradley (continued)

Save on
implemented process find potential problems. Only 16%
Condition
improvements along with the
technology investment. This may
were using automated devices to
monitor and warn! In addition, the
Monitoring
seem obvious but clearly the
Reliability market suffers from the
tenet of any proper Reliability
Centered Maintenance program is
Products!
same obstacles. Operator involvement. This is
Second, proposals of hardware made even more essential by the From time to time, SKF
and software purchases must be continued downsizing of offers previously owned,
tied back into the companies engineering and maintenance staffs factory-refurbished equipment
business objectives and KPI’s (Key across all industries. Thus a at a substantial savings.
Performance Indicators). Looking reliability program augmented with The equipment has been
for a technology plan in isolation operator based inspection provides refurbished at our factory, or a
of the greater business objectives, a platform for achieving world factory-authorized service center,
process changes and required class benchmark performance. updated to the latest applicable
investment rarely results in release, completely tested and
achieving the desired results to the This issue of REVOLUTIONS fully calibrated.
bottom line. contains several articles on tools Units are covered under our
The points in the article are and services that can be used to standard Warranty Policy for a
particularly applicable to ODR - start and maintain such a program. period of ninety days.
Operator Driven Reliability. Our But success really starts prior to PRODUCT MODEL NO. QTY. AVAIL
experience has shown that two any requests for quotation or
sites within the same corporation purchase. It starts with a clear Microlog, Kit
can implement a “program” with program definition, commitment REFURB-CMVA60-K ................... 2
the same equipment but achieve and well-aligned program that ties
vastly different results. The to your particular business Marlin Kit
difference always turns out to be REFURB-CMVA4700-K ............... 4
objectives. SKF Reliability
how effectively the program is tied Systems is ready to help you get Microlog, Unit & Manual
to business objectives and to started along the path to REFURB-CMVA10 ....................... 2
changing the work flow process to productivity improvements and
achieve those business targets. ensure a return on your investment. I.S. Microlog, Unit & Manual
Customers who work with SKF REFURB-CMVA30 ....................... 3
Reliability Systems to implement Sources: Dual Channel Microlog,
their ODR program benefit from a Harvard Business Review. March 2002.
Unit & Manual
“The Real Source of the Productivity Boom”,
proven approach that combines REFURB-CMVA40 ....................... 1
Interview with Michael Nevens of McKinsey
new technology along with process & Company
changes. In addition, SKF offers Microlog, Unit & CD Manual
programs and training that help Managing Automation Magazine. November
REFURB-CMVA60 ....................... 3
2001. “On the Road to Integration”,
customers to achieve the necessary Stephanie Neil
cultural changes required to Hard Carrying Case, Gray
achieve results that are timely but Refurbished CMVA6133-HD ...... 6
long lasting.
Hard Carrying Case, Black
A recent survey in Managing
Refurbished CMVA6134-HD ...... 5
Automation magazine indicated
that 58% of respondents were *Note: Delivery times vary. Units on first
come, first serve basis. Above prices do not
utilizing operators to check include shipping charges. Please contact your
equipment on a periodic basis to local SKF representative for additional
information.

® 1-877-SKF NEWS
17
SKF Condition Monitoring ®
SKF Condition Monitoring Area Centers:
North & South America
4141 Ruffin Road
San Diego, CA 92123 USA
Tel: 858 496-3400
Fax: 858 496-3531
Europe - Middle East - Africa
Postbus 2091
5300 CB Zaltbommel
The Netherlands
Tel: (+31) 418-681818
Fax: (+31) 418-681800
Asia, Pacific
Kawasan Perindustrian Nilai
P.O. Box 26, 71807 Nilai
Negeri Sembilan Darul Khusus,Malaysia
Tel: (+60) 6-799-2713
Fax: (+60) 6-799-2407

Visit our web site at www.skfcm.com

REVOLUTIONS reports on topical issues, programs
and trends to educate on technology for plant reliability.
Please email your comments, suggestions and feature
requests to [email protected].
SKF is a registered trademark of SKF. All other trademarks
are the property of their respective owners.
Although care has been taken to assure the accuracy of the
information in this publication, SKF assumes no liability for
errors or omissions.
© 2002 SKF

CM5083

® 1-877-SKF NEWS