So What`s the need for predictive maintenance

So What’s the Need for
Predictive Technology?
Terry L Haycraft
National Reliability Manager
Frito-Lay, Inc
May 2010
Frito-Lay, Inc. All Rights Reserved
Because…….
-Every .1 of Equipment DT reduction gets tougher to get each year
-Seasoned Mechanic Retirements - We can not afford a lengthy “learning
curve” for new mechanics
-No direct feedback on Corrective or PM Jobs
-Need a tool to transition from Time/Usage PM’s to Condition Based PdM
- The #1 reason for premature failure is Over Lubrication of equipment
Frito-Lay, Inc. All Rights Reserved
Equipment Demographic
61% of Plants
Were Above 2%
Equipment DT
Pulaski 0.89
Orlando 0.88
0 – 1.0%
FF East 1.85
Casa Grande 1.76
Brookhollow 1.74
Topeka 1.58
Kirkwood 1.46 Canton 1.71
FF Core 1.63
Perry 1.06
Fayetteville 1.01 Vancouver 1.63
Lethbridge 1.02 Beloit 1.61
1.1 – 1.5%
1.6 – 1.9%
Arlington 2.59
Williamsport 2.44
Modesto 2.37
Jonesboro 2.36
Irving 2.32
W Valley 2.12
Killingly 2.05
Lauzon 2.26
Tabor 2.39
2.0 – 2.5%
Charlotte 2.92
Wooster 2.79
York 2.70
Cambridge 2.69
Cucamonga 2.64
Kentville 2.86
2.6 – 2.9%
Equipment Down Time
Frito-Lay, Inc. All Rights Reserved
2005
Lynchburg 3.29
Aberdeen 3.23
Rosenberg 3.22
San Antonio 3.08
Kern 3.08
Denver 4.49
DBS 4.25
3.0 – 3.5%
3.6 and over
Equipment Demographic
Kirkwood .85
Perry .91
Pulaski 0.73
Orlando 0.65
Fayetteville .89
Casa Grande .88
Modesto .99
Williamsport .65
0 – 1.0%
FF Core 1.17
Topeka 1.47
West Valley 1.20
FF East 1.11
Beloit 1.20
Wooster 1.20
York 1.38
Canton 1.24
DBS 1.25
Denver 1.05
Killingly 1.42
Brookhollow 1.56
Lauzon 1.33
Lynchburg 1.70
Jonesboro 1.84
Aberdeen 1.67
San Antonio 1.92
Rosenberg 1.69
Cucamonga 1.96
Cambridge 1.87
Lethbridge 1.61
1.1 – 1.5%
1.6 – 1.9%
80% of Plants
Are Currently
Below 2%
Equipment DT
Vancouver 2.36
Irving 2.46
Charlotte 2.11
Tabor 2.51
2.0 – 2.5%
Arlington 2.81
Kern 2.84
Kentville 2.73
2.6 – 2.9%
Equipment Down Time
Frito-Lay, Inc. All Rights Reserved
2010
3.0 – 3.5%
3.6 and over
PREDICTIVE SOLUTIONS SAVE $$
COST & TIME FOR REPAIRS 
$$
$$
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COST OF DOING NOTHING
$ 100xTHOUSANDS
Replace machine
Major outage
Plant damage
$ 10xTHOUSANDS
TEMPERATURE
VIBRATION TECHNOLOGY
PARTICULATE MONITORING
STRESS WAVE ENERGY TECHNOLOGY
ULTRASOUND TECHNOLOGY
Turn shafts
Replace bearings
Replace gears
$ THOUSANDS
Align shafts
Replace bearings
Purge particulates
$ HUNDREDS
Change
lubricant
Pack bearings
“Predictive” Solutions we have Used
-Running PM’s: Observation based
-3rd Party Vibration Analysis-usually once a Quarter
-Lazer Alignment
-Temperature Reading
-Electrical Condition Monitoring
-Oil and Lube Analysis
-Precision Balancing
-Thermography Program
-Ultrasound-UE 2000-Rolled out as RC Tactic
Frito-Lay, Inc. All Rights Reserved
What about On-Line Systems?
$6,000 per Point vs. Average DT
Cost of $500 per Hour
Frito-Lay, Inc. All Rights Reserved
ADVANTAGES OF ULTRASOUND
•DIRECTIONAL
•LOCATABLE
•MULTIPLE APPLICATIONS FOR OUR SITES
•UTILIZABLE IN ALL ENVIRONMENTS
•EARLY WARNING FAILURE INDICATION
•SUPPORTS OUR OTHER TECHNOLOGIES
•Affordable……….
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Ultrasound Technology
Ultraprobe 10,000
•Records and analyzes sound samples
•Performs Condition Analysis
•Stores test data
•Trends Results
•Allows us to review inspection results
•Allows us to manage the test data colleted
Mechanical Inspection/Trending
•Bearing Condition
•Rubbing Conditions
•Cavitation
•Gears/Gear Boxes
•Pumps/Motors
•Lack of Lubrication
UE SYSTEMS INC. All Rights Reserved
Leak Detection/Energy Audits
•Compressed Air
•Compressed Gases (O2, NO, etc.)
•Vacuum Leaks
•Seals & Gaskets
•Condenser Tubes
•Hatches
•Boilers
•Heat Exchangers
•Valves
•Steam Traps
Electrical Inspection
•Arcing
•Tracking
•Corona
•Switchgear
•Transformers
•Insulators
•Relays
•Bus Bars
Ultrasound Technology
Ultraprobe 201 Grease Caddy
•The Ultraprobe 201 Grease Caddy
provides visual/audible indication for
controlling grease addition to bearings.
•Prevents Over Lubrication of bearings
•Audibly hear when grease is being applied
•Multiple mechanics have been trained to
successfully operate the grease caddy.
•Extremely helpful in dictating the amount
of grease needed to lube bearings
•Will be used as a separate PM in Avantis
•Recognize when to STOP greasing!!
“Over Lubrication is the #1 Cause for Premature Bearing Failure”!
UE SYSTEMS INC. All Rights Reserved
LEVELS OF SEVERITY
dB Levels over Baseline
8 dB LUBRICATION
12 dB MINOR DAMAGE-Microscopic faults
16 dB DAMAGE-Visual faults
35+ dB CATASTROPHIC FAILURE IMMINENT
UE SYSTEMS INC. All Rights Reserved
DBS Alpha Site
What they did…
• Baseline Overview of the technology
• Purchased / Set up the Ultraprobe 10000 and software
• Purchased Ultraprobe 201 Grease Caddy
• Developed routes for all processing lines
• Secured Level 1 Certification of Mechanic
• Performed Surveys for Mechanical, Electrical, & RC
• Secured job aids and tools
• Routes include 2x month on critical equipment and 1x for others
Frito-Lay, Inc. All Rights Reserved
Route Development Steps
• Walk line and identify equipment and parts to be measured
• Input points identified into DMS software
• Download route into gun
• Walk route and take initial baseline measurements
- Running PM’s with a Purpose
Frito-Lay, Inc. All Rights Reserved
DBS Routes
• Baked Cheetos
– Number of points (121)
– Time to develop and measure baseline (24 hrs)
– Time to execute route (1 hr)
• Baked Lays
– Number of points (319)
– Time to develop and measure baseline (36hrs)
– Time to execute route (3 hrs)
• Baked Doritos
– Number of points (247)
– Time to develop and measure baseline ( 30 hrs)
– Time to execute route (3 hrs)
• Pretzels Line 3
– Number of points (209)
– Time to develop and measure baseline (12 hrs)
– Time to execute route (1.5 hrs)
Frito-Lay, Inc. All Rights Reserved
Condition Based PdM Findings
Mechanical Inspection/Trending
Frito-Lay, Inc. All Rights Reserved
Condition Based Preventive Inspections
Baked Cheetos
–
Clextral Extruder shaft block bearings
–
The bearings seals had blown out leading to under-lubricated
condition of these critical bearings
–
Early detection saved a total of $5600 in parts and prevented
12 hours of unscheduled downtime
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Condition Based Preventive Inspections
Baked Cheetos
– Oven Exhaust Fan Motor
– During periodic route checks a significant sound change was noted.
Bearing on the motor was trending towards failure.
– The motor was replaced and prevented 1 hour of unscheduled
downtime
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Condition Based Preventive Inspections
Baked Doritos
– Sheeter Back Roll Motor
– Ultrasonic measurement indicated the motor bearings were
starting to fail
– The motor was replaced and prevented 1 hour of unscheduled
downtime
Frito-Lay, Inc. All Rights Reserved
Condition Based Preventive Inspections
Baked Lays
– Sheeter utilizes 10 Reggiani gearboxes
– Reggiani gearbox main bearing is prone to high wear and failure
– Routine ultrasound inspection is enabling proper lubrication to
prevent bearing/gearbox failure.
– 6 week lead time on replacement gearboxes
Frito-Lay, Inc. All Rights Reserved
Condition Based PdM Findings
Electrical Inspection
Frito-Lay, Inc. All Rights Reserved
Condition Based Preventive Inspections
Main Switch Gear
– Anomalies were heard during
ultrasound inspection
– A follow-up thermograph
inspection confirmed high heat
on 2 out of 3 phases
– Based upon ultrasonic and
thermo graphic information,
the plant was scheduled down
to replace the breaker
– Continued operation, without
the scheduled work, would
have likely resulted in a plantwide unscheduled downtime
event.
Frito-Lay, Inc. All Rights Reserved
Condition Based Preventive Inspections
Main Transformer
– Ultrasound Probe picked up
evidence of Tracking
– Transformer is 40 feet up on
utility pole
– Site contacted utility co.
– Utility Co. confirmed.
– They wanted to shut it down.
– Scheduled shutdown found that
the fuse holders had separated
and caused the tracking.
– DT Avoided est. at 2 days
Frito-Lay, Inc. All Rights Reserved
Condition Based PdM Findings
Leak Detection/Energy Audits
Frito-Lay, Inc. All Rights Reserved
Resource Conservation
• DBS had completed 104 air
leaks repairs since May 2009
• Most common types of leaks
found were fittings and
regulators
• Tags are tracked using works
orders and spreadsheet
Frito-Lay, Inc. All Rights Reserved
Copyright 2008 by UE Systems Inc. Patent Pending.
June 2009
Air Leaks Repaired
Record
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Argon Leaks Repaired
Helium Leaks Repaired
Hydrogen Leaks Repaired
Nitrogen Leaks Repaired
CFM
Cost
CFM
Cost
CFM
Cost
CFM
Cost
CFM
Cost
73.2
$7,592.72
0.0
$0.00
0.0
$0.00
0.0
$0.00
0.0
$0.00
Problem Description
CYLINDER LEAKING
REGULATOR LEAKING
COPPER LINE IS LEAKING
TRACKING REGULATOR IS LEAKING
TRACKING REGULATOR LINE HAS LEAK
TRACKING REGULATOR IS LEAKING
AIR INLET FITTING IS LEAKING
CYLINDER FOR WATER VLV FITTING
AIR INLET BY THE COOKER IS LEAKING
Repaired
(Y/N)
Y
Y
Y
Y
Y
Y
Y
Y
Y
Work Order
Schedule #
14704
14704
14704
14704
14704
14704
14704
14704
14704
TRACKING FILTER FITTING IS LEAKING
AIR INLET FITTING IS LEAKING
AIR INLET FITTING IS LEAKING
FL710 FILTER FITTING IS LEAKING
FL710 REGUALTOR FITTING IS LEAKING
FL710 REGUALTOR FITTING IS LEAKING
WATER VALVE AIR LINE HAS A HOLE
MAC VLV BY THE COOKER IS LEAKING
FITTING BY THE COOKER IS LEAKING
AMBIC DSC PUMP GAUGE IS BUSTED
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
14704
14704
14704
14704
14704
14704
14704
14704
14704
14704
Group Name
EXTRUDED
EXTRUDED
EXTRUDED
EXTRUDED
EXTRUDED
EXTRUDED
EXTRUDED
EXTRUDED
EXTRUDED
Location Name
L3 CYLINDER
L3 KLN REG
L3 KLN LINE
L3 TRK REG
L3 TRK LINE
L1 TRK REG
L1 AIR INLET
L1 COOKER
L1 PRF INLET
EXTRUDED
EXTRUDED
EXTRUDED
EXTRUDED
EXTRUDED
EXTRUDED
EXTRUDED
EXTRUDED
EXTRUDED
EXTRUDED
L3 TRK FITTING
L3 AIR INLET
L3 AIR FITTING
L3 FL710 FLTR
L3 FL710 REG
L3 FL710 REG
L3 COOKER
L3 PROOF BLT
L3 PROOF BLT
L1&3 AMBIC
Pressure at
Type of Gas
Leak
dB Reading
Air
75
63
Air
75
63
Air
75
53
Air
75
78
Air
75
85
Air
75
60
Air
75
75
Air
75
49
Air
75
55
Air
Air
Air
Air
Air
Air
Air
Air
Air
Air
75
75
75
75
75
75
75
75
75
75
55
42
33
63
26
38
71
61
58
102
CO2
Cost Avoidance
Identified
Repaired
$7,592.72 $7,592.72
% complete
100%
NO
SO2
Identified Identified Identified
179368
181
389
CO2
SO2
Identified
Energy
NO
leaks Cost Size of Leak Avoidance Avoidance Avoidance Avoidance
Avoidance
CFM
(kWh)
(lbs)
(lbs)
(lbs)
$421.57
4.1
7026
9959
10
22
$421.57
4.1
7026
9959
10
22
$325.41
3.1
5424
7687
8
17
$580.49
5.6
9675 13713
14
30
$660.24
6.4
11004 15597
16
34
$391.86
3.8
6531
9257
9
20
$547.37
5.3
9123 12931
13
28
$289.33
2.8
4822
6835
7
15
$343.98
3.3
5733
8126
8
18
$0.00
0.0
N/A
N/A
N/A
N/A
$0.00
0.0
N/A
N/A
N/A
N/A
$343.98
3.3
5733
8126
8
18
$229.68
2.2
3828
5426
5
12
$160.05
1.5
2667
3781
4
8
$421.57
4.1
7026
9959
10
22
$111.99
1.1
1866
2646
3
6
$197.70
1.9
3295
4671
5
10
$504.23
4.9
8404 11912
12
26
$401.68
3.9
6695
9489
10
21
$372.46
3.6
6208
8799
9
19
$867.56
8.4
14459 20495
21
44
Condition Based PdM Findings
“Saves” Impact Full Year
Location
Baked Cheetos
Baked Cheetos
Baked Doritos
Baked Doritos
Baked Lays
Main Switch Gear
Utility Pole
Equipment
Clextral Block Bearings
Exhaust Fan Motor
Sheeter Back Roll Motor
Lower Plenum Blower #3
Reggiani Gearboxes
Main Circuit Breaker
Transformer
Frito-Lay, Inc. All Rights Reserved
Issue
Seals blown
Bearings
Bearings
Bearings
Bearings
Tracking
Tracking
DT Hrs
12
1
1
2
1
144
288
449
% DT at
% DT
1/2 the
Avoidance Impact
2.28%
1.18%
DBS Best Practices
“Things we learned along the way”
Frito-Lay, Inc. All Rights Reserved
DBS Best Practices
• Notebooks/binders with pictures to identify routes and equipment in
order by name and number.
• Every point on a route is labeled to ensure consistency in
measurement location.
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DBS Best Practices
• Priority listing on what to check and not check on route development
• Items that are considered critical:
– Motors
– Gearboxes
– Drive bearings / Tail bearings / Pinch and Tension bearings
– Pumps
• Items that are less critical:
– Plastic housing bearings (hard to hear)
– Idle bearings (can prolong the route)
– Bearings that do not make a full rotation
Frito-Lay, Inc. All Rights Reserved
DBS Next Steps
• Optimize scheduling PM’s based on Ultrasound readings
to determine required lubrication and inspection
• Condition Based vs. Time/Usage
• Increase utilization and knowledge of sound signatures
to recognize impending failures
• Continue modifying machine guards to facilitate safe
ultrasonic measurements without guard removal.
• Increase Level 1 Certifications
Frito-Lay, Inc. All Rights Reserved
Observations / Recommendations
• Precision Based Equipment (i.e. modules, gun)
• Training on the UE 10,000 is critical to properly using the equipment.
If routes are developed, it should take no more than 2 full days to
bring a mechanic up to speed.
• Marking inspection points on parts has proven to be difficult as
bearings and motors are replaced.
• Some equipment may already be near failure and will affect the
initial baseline
• Air/Gas Leak finds will be large at first.
• The DBS Team Recommends moving to 3 Beta Sites with this
Technology.
Frito-Lay, Inc. All Rights Reserved
Beta Site Deliverables
• Diligent Selection of Ultrasound Point Person
• Set up and coordinate 2.5 Day Implementation
• Attendees to include: Point Person and MX BUL or Resource
• HQ is picking up the cost of the equipment and implementation. Site
picks up the labor costs.
• Insure equipment is secured and well maintained
• Development of Site wide game plan for PdM Routes
• Documentation
• Document findings and “saves”
• Record changes in PM set up-conversion to Condition Based PM’s
• Document before and after reading on equipment rebuilds
Frito-Lay, Inc. All Rights Reserved
Beta Site Roll-Out Success
Frito-Lay, Inc. All Rights Reserved
Condition Based Preventive Inspections
Muncho Department
– Muncho Pellet Belt
Drive
– Ultrasonic
measurement
indicated the
motor/gearbox was
starting to fail
– Prevented 1 hour of
unscheduled
downtime
Condition Based Preventive Inspections
Fritos Main Oil Circulation
Pump
– Ultra Sonic Identified
Bearing Failure
– Planned Motor
Change for Change
Over
– Prevented 4 hours
total downtime
Frito-Lay, Inc. All Rights Reserved
Condition Based Preventive Inspections
UTC Corn Cook Kettle
– Kettle Agitator
Gearbox
– During periodic route
checks a significant
sound change was
noted.
– Changed bevel gears
during shutdown
saved 6 hours of
unscheduled
downtime
Frito-Lay, Inc. All Rights Reserved
Resource Conservation
Copyright 2008 by UE Systems Inc. Patent
Pending.
Frito-Lay, Inc. All Rights Reserved
Air
Year to
Date
$14,834.14
Month
Identified
leaks Cost
Avoidance
Repaired
Leaks Cost
Avoidance
%
Comple
te
CFM
Cost
Dec-09
$2,684.75
$2,684.75
100%
25.9
$2,684.75
Nov-09
$5,839.94
$5,278.83
90%
50.9
$5,278.83
Oct-09
$6,309.45
$3,444.39
55%
33.2
$3,444.39
$11,407.97
81.5%
Leaks Repaired
Condition Based Preventive Inspections
PC #2
– Replaced coupling
on submerger motor
– $30 part, prevented
8 hrs of down time,
a hot rinse, and bent
paddles.
Frito-Lay, Inc. All Rights Reserved
–Early detection saved a total of $2020
in parts and prevented 8 hours of
unscheduled downtime.
Condition Based Preventive Inspections
PC #1
– Combustion Blower
– Found fan had dirt
buildup causing an
imbalance.
– Cleaned fan and
replaced motor.
Frito-Lay, Inc. All Rights Reserved
–Repaired motor for $650 saving $850
and prevented 3 hours of unscheduled
downtime.
Potential Reduction of PM / Labor Hours
Preventative to Predictive Shift
Hrs/pd reduced PM
6.8
5.75
4
7
23.55
4
4
4
4
5
8
8
6
2
0
45
68.55
Change
Running Corn Conveyor PMs
Running PC Conveyor PMs
FCC Thermographic PM
Warehouse Pickbelt Running PM's
Mechanic hours already reduced per period
changed to quarterly from every 6 weeks. 19 entities at 1 hr each
changed to quarterly from every 6 weeks. 16 entities at 1 hr each
Cancelled. It was set up biweekly for 2 hrs
Cancelled. 2 hrs every 8 weeks
PC PC back Allens Running Checklist
PC PC middle Allens Running Checklist
PC PC front Allens Running Checklist
PC 2 Running Checklist
PC 1 Running Checklist
TC 2 Running Checklist
TC 1 Running Checklist
FCC running Checklist
PC Thermographic PM
Kroma Sort routine idle end bearing replacement
Possible Mechanic hours reduced per period
Currently Monthly. 4 hrs
Currently Monthly. 4 hrs
Currently Monthly. 4 hrs
Currently Monthly. 4 hrs
Currently Monthly. 5 hrs
Currently biweekly. 4 hrs
Currently biweekly. 4 hrs
Currently biweekly. 3 hrs
Currently Monthly. 2 hrs
Currently set to trigger every 6 months.
Total Potential Reduction of hours identified
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Questions?
Thank You……
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