Machinery Lubrication magazine published by Noria Corporation
Issue link: https://www.e-digitaleditions.com/i/229047
Maintenance and Reliability AS I SEE IT JIM FITCH NORIA CORPORATION Demand 'RELIABILITY READINESS' from Equipment BUILDERS When it comes to modern concepts in the field of lubrication and applied tribology, many users these days are far more sophisticated than those who are designing and building the machines they operate. This lack of sophistication by original equipment manufacturers (OEMs) is very evident when you see what's not included with the sale of new machinery. One could assume that what's missing from the machine and its documentation is functionally missing from the knowledge and awareness of the engineers and builders of this equipment. Ignorance is not bliss. The same is true for complacency. Reliability needs to have shared responsibility. It must be fixed in the DNA of the machine as well as in the minds of operators and maintainers. It's like a reliability chain; every link in the chain must be equally strong in order for the chain's full length to bear the load. Machinery Lubrication magazine is primarily devoted to advanced concepts in lubrication from a user's perspective, more specifically lubrication-enabled reliability. MAINTAINABILITY MACHINE DESIGN FEATURES Users not only have a significant influence on machine reliability during operation but also by what is being done (or not done) by equipment builders to "ready" machines for optimum reliability. They want the machine's design to have an implanted genetic code that enables reliability. Users define what's expected from OEMs and the machines they deliver. Of course, meeting the minimum required operating performance is a basic need of every machine, but prolonged sustainability of that performance is also important. This is not simply a matter of quality manufacturing to a design specification in order to avoid defects. From the standpoint of reliability, it's more about including design features that have little to do with the machine's functional performance. At first, this may seem unnecessary and wasteful, but when viewed over a timespan of several years, these "extra features" could translate to huge financial benefits. In sum, OEMs can achieve machine reliability in the following ways (used collectively): • Design for functional robustness (functional design, material selection, lab and field testing) • Design for optimum maintainability by the user (ease and effectiveness) • Quality manufacturing to reduce defects and other anomalies (e.g., Six Sigma) • Provide a documented equipment maintenance plan (EMP) (see sidebar on page 3) • Training and education of field-service technicians, operators and maintainers to execute the EMP Developing Reliability Readiness Investments in machine reliability should be purposeful. Certainly, there will be costs and even risks associated with reliability initiatives. You aren't trying to maximize reliability but rather optimize it in the context of the user organization. OEMs must be keenly aware of how their machines will be deployed, the operating environment and the minimum needs for reliability. Ideally, they should follow these steps: STABILIZED LUBRICANT HEALTH CONTAMINATION CONTROL N/A Avoids lubricant distress from contamination and low lubricant levels Reduces the severity of contaminant ingression (dirt, water, process chemicals, etc.) Reduces leakage-induced starvation N/A Reduces excessive heat, churning and contaminant-induced grease degradation Reduces the ingress of certain contaminants including heat, water and dirt May reduce leakage, starvation and overlubrication issues CORRECT LUBRICANT ADEQUATE AND SUSTAINED LUBRICANT SUPPLY Seals and Leakage Use of labyrinth and other premium seal technologies Proper selection and installation of bearing seals and shields 2| November - December 2013 | www.machinerylubrication.com