UPTIME MAGAZINE

dec/jan16
for maintenance reliability and asset management professionals

c m
R a m
P
E R
R EM L
DECEMBER/JANUARY 2016

The Pursuit of
Continuous
Improvement
in Asset Management
Lu Vib

M M Ut
AM W E AC

ro
uptimemagazine.com
M Pm
 Reliabilityweb.com® and Uptime® Magazine present

The The RELIABILITY Conference is designed

for those who lead, manage and contribute
to a reliability and asset management

Conference
program. Reliability leaders, asset managers,
maintenance managers and asset condition
management experts will deliver information

Las Vegas you can put to use immediately.

Topics Include
• Reliability Centered Maintenance • ISO55000 Asset Management
• Predictive Maintenance • Computerized Maintenance
• Work Execution Management Management Systems
• Asset Condition Management • Maintenance Planning & Scheduling
• Reliability Engineering for • Managing Maintenance
Maintenance • MRO Spare Parts Management
• Defect Elimination • Failure Mode and Effect Analysis
• Lubrication • Root Cause Analysis
• Key Performance Indicators • Leadership

888.575.1245 | 239.333.2500 | www.reliabilityconference.com

 machinery lubrication | Asset Condition Management

Lu

How a
New Reliability
Maintenance Program
Delivered a 705% ROI
Winery’s Spirits Inv
Gall
o es
E.
& J. tm
en
t
by Clay Calk
In 2012, E. & J. Gallo Winery’s spirits
making plant committed time and
resources to transition its current
asset management and lubrication
program to a world-class reliabil-
ity maintenance program uti-
lizing professional services and
enhanced lubricants. Plant man-
agement’s key objectives for the
Fin

new reliability maintenance pro-

an

gram were targeted to accom-

plish three plant goals: improve
cia

overall equipment effectiveness

lG

(OEE), reduce cost and increase

ain

plant profitability. Here’s how the

successful transition took place.

54 dec/jan 16
 Key objectives: Improve overall equipment effectiveness,
reduce cost and increase plant profitability

Preliminary Information 6. Improve the level of knowledge and education of Gallo’s maintenance
personnel to aid in changing the culture and drive lubrication and asset
In the strategic planning phase, six key areas were targeted for review reliability methodologies for continuous improvement.
and evaluation prior to the new program’s implementation.
Phase I – Program Evaluation
1. Understand current costs associated with the existing program, includ-
ing electrical energy usage, cost of unscheduled downtime, annual lu- In 2012, Phase I began with the performance of a comprehensive reliability
bricant expenditures, prevention of historic major failures, frequency of assessment and equipment and lubrication survey of all lubricated assets to
repairs/rebuilds and labor costs associated with reactive maintenance. understand the process, current lubricants and current practices in order to
2. Perform a comprehensive detailed asset inspection. List current lubri- establish the program’s baseline.
cants used, parts to lubricate, method of application, fill quantities, and
service and change interval. Verify whether or not current lubricants Macro overview of survey’s findings:
meet or exceed operations and maintenance (O&M) specifications for • Inspected and evaluated approximately 1,820 lubricated components.
each asset. • Discovered that:
3. Inspect each critical asset and identify the appropriate lubricant sam- • Twelve percent of the application points were being lubricated
pling hardware as part of a new condition-based program. Identify the with the wrong viscosity or wrong type of additive system per O&M
appropriate contamination control hardware required to protect the specifications.
asset and lubricant from particulate and moisture ingression so as to • Consolidation opportunities existed to reduce lubricant products
maximize each asset’s lifecycle. at Gallo by 31 percent.
4. Inspect current lubricant storage and handling conditions and deter- • Lubrication storage, handling and transfer facility required im-
mine if they comply with Gallo’s 5S system (sort/straighten/shine/sys- provement per 5S initiatives.
temize/sustain) for workplace organization initiatives. • Filtration, oil analysis monitoring and contamination control re-
5. Set up metrics for performing a gap analysis to document before and quired attention.
after program savings to justify the return on investment (ROI).

Figure 1: Reliability assessment

dec/jan 16 55
 machinery lubrication | Asset Condition Management

Lu
After

Figure 2: Before and after Figure 3: Before and after

lubricant storage room lubricant utility carts
Before
Before

Phase II – Program Transformation

Phase II of the program transformation was to focus efforts
on the lubrication storage and handling area to eliminate
contamination where it originates (new lubricants). Fur-
thermore, the existing lubricant storage and handling fa-
cility required improvement to Gallo’s 5S initiatives, making
this change a priority before moving the initiative down- After
stream. The plan would include adding proper lubricant
storage with three-way filtration and desiccant breathers,
lubricant product identification and color-coding to mit-
igate cross contamination and lubricant misapplications Lubricant Identification
Chart & Handling
on the plant floor. Organization and procedures for sus-
tainability also would be part of the plan.

Lubricant Storage Lubricant Handling

Lubricant Identification

Figure 4: Lubricant color mapping

for lubricant storage room

Phase III – Program Transformation

In the next phase of the transformation, Gallo’s 5S initiatives that began in the new lubrication storage and handling facility were applied
downstream to each asset on the plant floor, with proper lubricant identification and color mapping for both oils and greases.

Lubricant Mapping Grease Mapping

Get picture

Figure 5: Lubricant color mapping from lube room to application point (oils and greases)

56 dec/jan 16
 Phase IV – Program Transformation
After completing Gallo’s 5S initiatives downstream, Phase
IV centered on two critical areas that would extend the
lifecycle of each critical asset, as well as provide longer
oil life, reduce costs, increase overall equipment effec-
tiveness (OEE) and provide tangible and measurable
bottom-line returns.

First, moving from a time-based to a condition-based

lubrication program, Gallo installed lubricant sampling
valves in the primary sampling zone on all critical assets.
Desiccant breather, oil leveler, This provided Gallo technicians the capability to pull ac-
oil sampling valve curate, representative lubricant samples on the fly while
equipment was running to eliminate unnecessary down-
time. Second, the program had to address the contam-
Figure 6 (a-c): Reliability hardware asset ination control program for all critical equipment. This
modification step was crucial in order to mitigate the most destructive
particulates (e.g., dirt and water) that led to frequent oil
changes and reduced asset lifecycle.

Protecting these assets from these destructive particu-

lates, coupled with condition monitoring, ensured mul-
tiple benefits, including: 1) longer oil and asset life, 2) less
oil waste disposal, 3) reduced downtime, 4) less reactive
maintenance and 5) improved electrical, asset and over-
all equipment effectiveness. These benefits yielded mea-
surable cost savings that will continue to pay dividends
perpetually.
Single point lubricator

Sight glass

Phase V – Program Transformation

The number one reason new program transformations are unsuc-
cessful is the culture of the organization. Gallo’s strategy to drive
this culture change was by increasing the level of knowledge and
education of its people. The type of education and training body of
knowledge that would be required to support its culture change and
new reliability maintenance program initiatives included these six
topics: 1) Introduction to Reliability Centered Maintenance (RCM), 2) Oil
Analysis 101, 3) Lubrication Fundamentals, 4) Contamination Control:
Building Asset Reliability and Lubrication Excellence, 5) Understanding
Friction & Types of Wear Generation and 6) Understanding Filtration
and Filter Media. Furthermore, the training materials were the cata-
lyst for select Gallo personnel to obtain machinery lubrication tech-
nician (MLT) level I and II, and machinery lubrication analyst (MLA)
level I and II professional certifications.

Figure 7: On-site education and training

dec/jan 16 57
 machinery lubrication | Asset Condition Management

Lu
The number one reason new
program transformations are
unsuccessful is the culture of
the organization.

Credits: Special thanks to E. & J. Gallo Spirits Plant and Mr. Freddy
Delgado for the support and information documented over the past
two years to prepare this executive summary.

Clay Calk, Department Manager – Business Solutions,

has worked for Lubrication Engineers, Inc. for 16 years.
Figure 8: Program savings and variables measured Mr. Calk oversees all administrative and sales functions
in the Inside Sales Department, which encompass
order processing, customer service, inside sales, and
Phase VI – Program Documentation national strategic accounts. Clay is CLS, MLT II and MLA
II certified. www.LElubricants.com
The data in Figure 8 demonstrates the existing program and associated costs
for years 2011 and 2012 and compares this data to the new reliability main-
tenance program and associated costs for years 2013 and 2014. Overall plant
equipment effectiveness improved by nine percent.

Calculating ROI
In performing the ROI calculations, the amount of financial gain achieved
by Gallo was divided by its total program investment. The substantial and
perpetual savings yielded a return on investment of 705%.

705% ROI
Investment

Financial Gain

58 dec/jan 16
 TM
Uptime Elements

CRL
Workshops
Cre
LEA ate
D
in Y ERS
Org o
ani ur
zat
Leadership ion
Empower
Reliability

Reliability Leadership Institute | Fort Myers, Florida

Certified Reliability Leader

Workshops
The industry’s most advanced thinking in reliability

9 0 % ate
Included in your registration
4-Day Workshop Pass

s r Uptime Elements Passport Series plus Travel Guide -

pas the $150 value
on m
E xa g
CRL takin 30 - day free trial to the Uptime Elements Academy
ter ourse Learning Management System - $299 value
af
h is c
t CRL Exam - $299 value

reliabilityleadership.com | 239.333.2500 | 888.575.1245 | [email protected]

 New Releases!
2 New Additions to the Made Simple Series
FAILURE ANALYSIS
REM

MADE SIMPLE:

Neville W. Sachs, P.E.

BEARINGS AND GEARS
Neville W. Sachs, P.E.

Far too often we’ll see a group of people standing around a broken
part speculating as to the cause. Then a “person of authority,” whether
FAILURE ANALYSIS
MADE SIMPLE:

Failure Analysis Made Simple: Bearings and Gears

a manager, a senior mechanic or an engineer, comes along and, with-
out a careful inspection, sagely pronounces that the cause was “such

$19.99
and such.” The group agrees and then proceeds off on a witch hunt,

BEARINGS AND GEARS

frequently heading in the wrong direction.

This book is a guide to the basic failure analysis of bearings and gears
that can be used by almost everyone involved with machinery main-
tenance. It describes how the pieces function and the likely causes of
failure. Outlined steps are provided to show how the physical sources
Neville W. Sachs, P.E.
of most, certainly over 80%, of all mechanical failures in the field can be
solved with a careful inspection.

Failure Analysis Made Simple: Bearings and Gears is encouraged to be

used as a field handbook with the ultimate goal of making maintenance
more effective.

each 9 781941 872307

$39.99
ISBN 978-1-941872-30-7
53999>

REM

RCA Made Simple Failure Analysis

by Susan Lubell Made Simple
and Ricky Smith by Neville Sachs
LER ACM

The Relativity of
Continuous

Mary Jo Cherney
Dr. Klaus Blache

Robert Dapere
Improvement
刀攀氀椀愀戀椀氀椀琀礀ꀀ
Ramesh Gulati

Dr. Klaus Blache

䌀攀渀琀攀爀攀搀

THE VISUAL MANAGEMENT HANDBOOK

The Relativity of Continuous Improvement

䄀猀猀攀琀
Certified Reliability Leader Pocket Dictionary

VISUAL
Certified THE
text to come Reliability 䴀愀渀愀最攀洀攀渀琀
Leader Pocket 䈀礀 刀椀挀栀愀爀搀 伀瘀攀爀洀愀渀Ⰰ 䴀⸀匀⸀Ⰰ 䌀䴀刀倀Ⰰ 䌀刀䰀 MANAGEMENT
Dictionary HANDBOOK
Learning how to work on what matters

By Ramesh Gulati
Mary Jo Cherney
BARCODE BARCODE
and Robert Dapere
$19.99
ISBN 978-1-941872-32-1

LER ACM
51999>

LOCATION LOCATION
9 781941 872321

Certified Reliability Reliability Centered The Relativity of The Visual

Leader Pocket Dictionary Asset Management Continuous Improvement Management Handbook
by Ramesh Gulati by Richard Overman by Dr. Klaus Blache by Mary Jo Cherney
and Robert Dapere

BRAND NEW to the Reliabilityweb Library!

TRAP PRO
ACM

TRAP PRO [Mechanical Engineering]

ACM Robert C. Eisenmann, Sr., P.E. retired

MACHINERY MALFUNCTION
GUIDE Robert C. Eisenmann, Jr.

G DIAGNOSIS AND CORRECTION

Bill Holub

Vibration Analysis and Troubleshooting Robert C.

for the Process Industries Eisenmann,

U
“… very informative and useful source of information… has helped us
identify and correct a number of energy opportunities in the field. Robert C. Eisenmann, Sr., P.E. retired • Robert C. Eisenmann, Jr.
Sr., P.E. retired
I recommend this book for all who are involved with steam systems.” Robert C.

Trap Pro GuideS Machinery Malfunction

BERNIE SHEPARD, Sr. Director Engineering, Pilgrim’s Pride Corp. pecific, practical guidance for every individual involved
„ 7-point problem solving methodology
Eisenmann, Jr.
with solving process machinery problems. The single

I
based on the authors’ extensive field
source reference for explanations of fundamental ma-
“Straightforward, basic info with historical insight. Great job!” chinery behavior, static and dynamic measurements, plus
experience
DIAGNOSIS AND CORRECTION

MACHINERY
DALE LECKIE, Assets Specialist, Water Treatment, Suncor Energy data acquisition, processing and interpretation. A variety „ 52 detailed field case histories —
MACHINERY MALFUNCTION

of lateral and torsional analytical procedures, and physical problem definition through corrective
tests are presented and discussed. action

D
“Thanks for the books, they are a great guide – nicely done.” „ Extensive illustrations, sample
Successful machinery analysis requires the diagnostician to
MARK ROBERTSON, Reliability Specialist, Land O’ Lakes
calculations, and explicit physical

by Bill Holub Diagnosis and Correction

understand the mechanical equipment, the measurement of explanations

MALFUNCTION
vibration and other parameters, plus the underlying physical
„ Common malfunctions as well as
“Got your books and found them very to the point. No “fluff” – just principles that govern the rotor dynamics. This book cov-
unique machinery problems
ers all three areas, presenting explanations of machinery

E
straightforward explanations… good to see the insulation savings characteristics, and the use of vibration measurements and „ Proven techniques for extending
machinery life and minimizing
chart. Curious what the savings are for fiberglass insulation with PVC analytical models. It covers on exceptionally broad range

DIAGNOSIS AND
downtime
of process machinery, including industrial steam, gas and
jacketing. Enjoyed your book and will make it available here hydro turbines, centrifugal and reciprocating compressors, „ Addresses balancing, machinery
TRAP PRO GUIDE

to anyone interested.” expanders, gear boxes, pumps, motors, blowers plus vertical alignment, bearing characteristics
and more
TONY MEIER, Maintenance Lead, Cargill (Horizon Milling) and horizontal generators and drives.

by Robert Elsenmann, Sr.

ABOUT THE AUTHORS

CORRECTION
“Read your book. I must say it was jam-packed with useful ROBERT C. EISENMANN, Sr., P.E. retired is currently the President of Wilpat, Inc. in Missouri City, Texas.
information. Very well done.” He is affiliated with SULZER Rotating Equipment Services in La Porte, Texas with his primary responsibility as
training personnel about machinery diagnostics. A graduate of the Illinois Institute of Technology, Robert is a
BRIAN NAVLYT, Maintenance, Purina Animal Nutrition LLC member of the National Society of Professional Engineers and the American Society of Mechanical Engineers.

ROBERT C. EISENMANN, Jr., is currently the R&LT Machinery Advisor and Downstream Machinery
“Awesome job, well done.” SETA of BP PRODUCTS North America, Inc. in Missouri City, Texas. He is responsible for troubleshooting, Vibration Analysis and Troubleshooting for the Process Industries
TIM FARMER, Feed Mill Supervisor, Tyson Foods, Inc. repair, and refurbishment of process equipment. Robert is a graduate of Texas A&M University, a member
Steam Traps: Operation, of the America Society of Mechanical Engineers, the American Petroleum Institute and the Texas A&M

and Robert Elsenmann, Jr.

“Bill, the books are a big hit! I may be asking for a few more in the Testing and Solving Common Turbomachinery Symposium Advisory Committee.
ilityweb.
ab
future if they’re available.” Installation Problems $189.99
co
i

RW
Rel

ISBN 978-1-941872-33-8
m

DWAYNE BAGLEY, Maintenance Team Leader, CSM Bakery Products

59999>
s
Fo

rie

By Bill Holub
nd
ation Se ACM
u

$29.99 9 781941 872338

ISBN 978-1-941872-34-5
52999>

9 781941 872345
ACM

mro-zone.com | 239.333.2500 | 888.575.1245