Reliability-Focused Lubrication Management & Best Practices - Bemas - Training
Programme:
Reliability-focused Lubrication Management & Best Practices
25 & 26 April 2012 – Antwerp
lectured by Martin Williamson, expert on lubrication active around the world…
Martin Williamson is a brand-independant expert. You are guaranteed to receive
unbiased advice on lubrication.
Introduction
With ever increasing demands for profitability and a drive to reduce costs, maintenance & reliability managers are facing tougher challenges. This is especially so with lubrication, with rising costs of lubricants and reduced manpower levels. Blue chip companies like Cargill have taken up the challenge and overcome the problems. These companies put lubrication at the top of their reliability strategy as a proactive and essential part of their maintenance & reliability management. This results in reduced failures, greater reliability, and consequently improved uptime and OEE figures. Just as importantly, their health and safety, and environmental performance also benefits. This course is designed to introduce engineers on how to achieve this success in their own companies by sharing theory and best practices in reliability focused lubrication.
Program
1.The role of lubrication in a maintenance and reliability strategy
2.Lubrication theory and fundamentals
a.- Understanding the Lubricant technical data sheet
b.- Criteria for selecting machine specific lubricants
3.Managing a proactive oil analysis programme
a.Oil sampling best practices
b.Interpreting oil analysis reports for root cause information
4.Lubricant and machine contamination control best practices
a.Lubricant storage and management
b.Lubrication handling and dispensing
c.Machinery contamination control
d.Filtration theory and fundamentals
5.Developing a Lubrication programme management strategy
a.Lubrication Key Performance Indicators (KPIs)
b.When to use subject matter expert team
c.Common barriers to implementation and how to get buy-in from all levels
d.Designing a best practice focused lubrication scheduling and management programme
After the course you will have acquired the necessary skills to…
1.understand the fundamentals of lubrication and oil analysis
2.define a correct lubrication strategy and get more out of it
3.work with lubricant suppliers and OEMs to get the optimum lubricant choice from a technical and cost perspective
4.work with your oil analysis laboratory to avoid commercial conflicts and get machine specific testing for improved analysis accuracy
5.interpret oil analysis reports for root cause information to take your programme from a predictive to a proactive focus and avoid failure before it begins
6.design an optimum contamination control strategy encompassing all aspects of lubricant handling from storage to disposal
7.design a proactive lubrication scheduling programme that eliminates unnecessary PMs
8.set lubricant based KPIs for improved lubrication cost management and environmental gain
9.sell the benefits to senior management to gain approval for the project.
Your company will benefit from:
1.increased reliability
2.increased profits and turnover
3.improved quality
4.improved health & safety success
5.reduced environmental impact
6.ensured compliance with ISO9001,etc…
About the lecturer
Martin Williamson is a graduate Mechanical Engineer from the University of Cape Town and began his maintenance career working in the mining industry in South Africa. This experience included condition monitoring with a focus on oil analysis and Tribology. In 1994, Martin joined Pall Filtration in the UK and provided technical support on their contamination monitoring instruments to clients in a variety of industries.
He later joined Entek IRD to work in product management of their oil analysis tools, as well as providing a technical support role including training on oil analysis to international clients. For the last 10 years, he has been presenting training classes and undertaking consulting projects on an international level on behalf of Noria Corp and other key clients such as BP, Dow Corning, Marathon Oil and Cargill. He attained his CMRP (Certified Maintenance & Reliability Professional) status with SMRP (Society for Maintenance & Reliability Professionals) and has been involved with ICML (International Council for Machinery Lubrication), as well as working on various related ISO working groups. Martin is currently managing director of KEW Engineering Ltd, a company he formed in 2005.
Personal story from Martin Williamson
“This last month I returned to Australia to undertake several public lubrication training courses on behalf of Noria Corp. It has been a few years since my last visit ‘down under’ and I was surprised at how expensive the cost of living appeared to be, especially now with a much stronger Australian dollar. The employment market is very buoyant, with excellent salaries being offered, particularly in the coal and iron ore mining sector. This is not surprising given the demand from China. But how long can this last? Some sources suggest that by 2020 the Chinese growth will have levelled out and that we will once again see a downturn in the demand for these mineral resources. What will happen then?
Which got me thinking about my early career as a maintenance engineer in South Africa when I was fortunate enough to get a post on an iron ore mine in the Northern Cape. This was just after the recession of the 1980s when many iron and steel businesses had suffered as a result. The Japanese had survived by implementing a number of strategies that helped them ride out this period. As an example, companies like Nippon Steel and Kawasaki Steel had implemented best practices in the form of contamination control. This resulted in significant savings for both, with instances of up to 80% reduction in lubricant usage, 50% reduction in bearing purchases, a 75% reduction in hydraulic failures and 80% reduction in pump repairs. In addition, both companies claimed various other non-quantifiable benefits, namely; improvements in health & safety and other tribological related issues. 25 years on we could add more benefits; reduced impact on the environment and improvements in staff morale.
I mentioned that I was fortunate to get a post on the iron ore mine. I use the word fortunate as I was able to witness and be closely involved in the same best practice implementation process at the mine. The results of this were such that I have basically devoted my career since then to helping others achieve the same benefits. The process plant on our mine was originally designed for 18 million tons of ore per year and although it was running at around 21 million tons, the equipment was not reliable enough, with a typical breakdown strategy of maintenance and much pressure from the mine management. By implementing best practices aimed addressing the root causes of failure, the plant subsequently achieved 27 million tons per year, and I believe is now running around 30 million tons per year. Amazingly, this 50% increase in productivity came with a similar level of savings. Admittedly there was an initial investment in rectifying root cause issues, but after two years there was a noticeable drop in the maintenance budget, which by the 5th year had risen to a 50% saving over the original maintenance costs.
So how can one prepare for the slowdown in the economy and be better able to ride out the recession periods in the future? Best practices make sense. Focus on the root causes and eliminate the failures. The trouble is promoting the technical benefits of best practices to senior managers and showing the return on investments. This need not be an issue. One of the areas I focus on in my work is translating the technical benefits into financial benefits, a language that senior management understand. I hope you will join me on the forthcoming course in Brussels and learn how you can turn your reliability issues into your own success stories.
Date and time 25 & 26 April 2012. Welcome at 8:30 am. Start at 9:00 am. Course ends at around 6 pm. Location: Radisson Blu Astrid Hotel Antwerp Koningin Astridplein 7 2018 Antwerp BELGIUM
Reliability-Focused Lubrication Management & Best Practices - Bemas - Training
Programme:
Reliability-focused Lubrication Management & Best Practices
25 & 26 April 2012 – Antwerp
lectured by Martin Williamson, expert on lubrication active around the world…
Martin Williamson is a brand-independant expert. You are guaranteed to receive
unbiased advice on lubrication.
Introduction
With ever increasing demands for profitability and a drive to reduce costs, maintenance & reliability managers are facing tougher challenges. This is especially so with lubrication, with rising costs of lubricants and reduced manpower levels. Blue chip companies like Cargill have taken up the challenge and overcome the problems. These companies put lubrication at the top of their reliability strategy as a proactive and essential part of their maintenance & reliability management. This results in reduced failures, greater reliability, and consequently improved uptime and OEE figures. Just as importantly, their health and safety, and environmental performance also benefits. This course is designed to introduce engineers on how to achieve this success in their own companies by sharing theory and best practices in reliability focused lubrication.
Program
1.The role of lubrication in a maintenance and reliability strategy
2.Lubrication theory and fundamentals
a.- Understanding the Lubricant technical data sheet
b.- Criteria for selecting machine specific lubricants
3.Managing a proactive oil analysis programme
a.Oil sampling best practices
b.Interpreting oil analysis reports for root cause information
4.Lubricant and machine contamination control best practices
a.Lubricant storage and management
b.Lubrication handling and dispensing
c.Machinery contamination control
d.Filtration theory and fundamentals
5.Developing a Lubrication programme management strategy
a.Lubrication Key Performance Indicators (KPIs)
b.When to use subject matter expert team
c.Common barriers to implementation and how to get buy-in from all levels
d.Designing a best practice focused lubrication scheduling and management programme
After the course you will have acquired the necessary skills to…
1.understand the fundamentals of lubrication and oil analysis
2.define a correct lubrication strategy and get more out of it
3.work with lubricant suppliers and OEMs to get the optimum lubricant choice from a technical and cost perspective
4.work with your oil analysis laboratory to avoid commercial conflicts and get machine specific testing for improved analysis accuracy
5.interpret oil analysis reports for root cause information to take your programme from a predictive to a proactive focus and avoid failure before it begins
6.design an optimum contamination control strategy encompassing all aspects of lubricant handling from storage to disposal
7.design a proactive lubrication scheduling programme that eliminates unnecessary PMs
8.set lubricant based KPIs for improved lubrication cost management and environmental gain
9.sell the benefits to senior management to gain approval for the project.
Your company will benefit from:
1.increased reliability
2.increased profits and turnover
3.improved quality
4.improved health & safety success
5.reduced environmental impact
6.ensured compliance with ISO9001,etc…
About the lecturer
Martin Williamson is a graduate Mechanical Engineer from the University of Cape Town and began his maintenance career working in the mining industry in South Africa. This experience included condition monitoring with a focus on oil analysis and Tribology. In 1994, Martin joined Pall Filtration in the UK and provided technical support on their contamination monitoring instruments to clients in a variety of industries.
He later joined Entek IRD to work in product management of their oil analysis tools, as well as providing a technical support role including training on oil analysis to international clients. For the last 10 years, he has been presenting training classes and undertaking consulting projects on an international level on behalf of Noria Corp and other key clients such as BP, Dow Corning, Marathon Oil and Cargill. He attained his CMRP (Certified Maintenance & Reliability Professional) status with SMRP (Society for Maintenance & Reliability Professionals) and has been involved with ICML (International Council for Machinery Lubrication), as well as working on various related ISO working groups. Martin is currently managing director of KEW Engineering Ltd, a company he formed in 2005.
Personal story from Martin Williamson
“This last month I returned to Australia to undertake several public lubrication training courses on behalf of Noria Corp. It has been a few years since my last visit ‘down under’ and I was surprised at how expensive the cost of living appeared to be, especially now with a much stronger Australian dollar. The employment market is very buoyant, with excellent salaries being offered, particularly in the coal and iron ore mining sector. This is not surprising given the demand from China. But how long can this last? Some sources suggest that by 2020 the Chinese growth will have levelled out and that we will once again see a downturn in the demand for these mineral resources. What will happen then?
Which got me thinking about my early career as a maintenance engineer in South Africa when I was fortunate enough to get a post on an iron ore mine in the Northern Cape. This was just after the recession of the 1980s when many iron and steel businesses had suffered as a result. The Japanese had survived by implementing a number of strategies that helped them ride out this period. As an example, companies like Nippon Steel and Kawasaki Steel had implemented best practices in the form of contamination control. This resulted in significant savings for both, with instances of up to 80% reduction in lubricant usage, 50% reduction in bearing purchases, a 75% reduction in hydraulic failures and 80% reduction in pump repairs. In addition, both companies claimed various other non-quantifiable benefits, namely; improvements in health & safety and other tribological related issues. 25 years on we could add more benefits; reduced impact on the environment and improvements in staff morale.
I mentioned that I was fortunate to get a post on the iron ore mine. I use the word fortunate as I was able to witness and be closely involved in the same best practice implementation process at the mine. The results of this were such that I have basically devoted my career since then to helping others achieve the same benefits. The process plant on our mine was originally designed for 18 million tons of ore per year and although it was running at around 21 million tons, the equipment was not reliable enough, with a typical breakdown strategy of maintenance and much pressure from the mine management. By implementing best practices aimed addressing the root causes of failure, the plant subsequently achieved 27 million tons per year, and I believe is now running around 30 million tons per year. Amazingly, this 50% increase in productivity came with a similar level of savings. Admittedly there was an initial investment in rectifying root cause issues, but after two years there was a noticeable drop in the maintenance budget, which by the 5th year had risen to a 50% saving over the original maintenance costs.
So how can one prepare for the slowdown in the economy and be better able to ride out the recession periods in the future? Best practices make sense. Focus on the root causes and eliminate the failures. The trouble is promoting the technical benefits of best practices to senior managers and showing the return on investments. This need not be an issue. One of the areas I focus on in my work is translating the technical benefits into financial benefits, a language that senior management understand. I hope you will join me on the forthcoming course in Brussels and learn how you can turn your reliability issues into your own success stories.
Date and time 25 & 26 April 2012. Welcome at 8:30 am. Start at 9:00 am. Course ends at around 6 pm. Location: Radisson Blu Astrid Hotel Antwerp Koningin Astridplein 7 2018 Antwerp BELGIUM
