4.0 Tools and Tactics General

A practical and efficient condition based maintenance (CBM) program is built of two fundamental elements-one for rotating and dynamic assets in the adopted term of a (PdM) or Predictive Maintenance program and one for static assets known as Risk Based Inspection (RBI) program. This presentation will highlight these NSPI asset management programs for monitoring the state and reporting condition based (CBM) deficiencies on our physical assets. The discussion will review the development, management, integration and day-to-day application of our PdM/RBI programs including tools and techniques for VA, IR, MCA, HEP/FAC inspections and more. Participants will also discuss the general journey to condition monitoring for equipment over the thermal fleet. NSPI consciously chose innovative vendors, technologies and techniques. The audience will learn what challenges it faced internally and externally. The differences between how the CBM programs are integrated into our business today as opposed to piecemeal prior to AM program implementation starting in 2012.

Reliability is a powerful concept that applied properly makes the difference between success and failure of installations, processes and systems; nevertheless, reliability does not need to be difficult, complex and overwhelming. Quite the opposite: reliability applications  are more likely to succeed if they are easily understood by the different levels of the organization from trades to CEO. This is achieved by explaining reliability concepts easily understood by everyone within the organization.The general objective of the workshop is to provide theory and practical guidelines to the audience for identifying and addressing reliability issues that are impacting the productivity and profitability the assets they are responsible for.The workshop will provide basic knowledge and understanding regarding the tools and methodologies available within the reliability discipline, for the design, analysis and implementation of equipment strategies to systematically improve the performance of assets.At the end of the training the assistants will be able to:- Understand the current Reliability Engineering terminology- Understand and apply reliability concepts at all levels of the organization- Understand and overcome the typical reliability paradigms- Collect the adequate data and calculate basic maintenance and reliability Metrics- Understand the different reliability methodologies and the right application framework for each one- Combine different reliability methodologies to create an effective reliability program- Understand the role that Reliability Engineering plays within the Asset Management FrameworkThe workshop is specifically designed for current or future reliability engineers, maintenance supervisors and planners with maintenance, engineering and/or operations background that desire to be involved in improving reliability, availability and maintainability of assets through the application of modern reliability methodologies and tools.

How can we be sure that our efforts to correct deficiencies are going to derive value for our organization? Do we fully understand that our area of focus is the right one? In this webcast we discuss how we often deal with symptoms and not the specific problem. We identify the tools that will help point us in the right direction and figure out how we can develop them. We examine the standard approaches to arriving at the root cause, discuss some that don't work, and identify systemic causes that seem to provide the best results. Learn how to understand the links in front of you when it comes to solving your problem.

The evolution of Preventive Maintenance (PM) is based on analyzing equipment operating conditions, its criticality to production and maintenance cost. In this case study, participants will see the journey starts with setting safe PM schedule and parts stock to sustain production. Then root causes of failures are analysed, and plans for improvement are launched. Learn how plans-in-action should be supported by motivating everyone to the expected achievement. Ahmed will share that implementation is not the end of journey - it is where we need to evaluate whether we landed on the right solution from all aspects. He will also show that sometimes, touch ups are needed. Participants will see the real journey of RajhiSteel, started with a greenfield mini mill 8 years ago. See real examples of doing more than PM in the harsh environment of steel melting Electric Arc Furnace (EAF) and its specific equipment as Water Cooled Cables (WCC).

"Uptime - Strategies for Excellence in Maintenance Management" has been a best-seller since 1995. It's 3rd edition includes a number of significant changes from the earlier editions reflecting changes in successful practices, the emerging field of Asset Management and the new imperative that any changes become sustainable. This workshop will provide an overview of the new Uptime "Model of Excellence," introduce the book's new material, explain how it all works and fits within the broader asset management framework.

Surprisingly rotating equipment operating under misaligned conditions still seems to be the most thorn in the side of many industrial maintenance managers. Again and again vibration analysts come back with diagnosis of misalignment on rotating equipment. How is it that after the industrial revolution misalignment is still the most common cause to premature failure and unscheduled downtime? In this presentation you will see how it can easily be avoided. We will discuss the benefits of having a proactive maintenance strategy and the necessary tools and skill sets for keeping machines in line and online. Questions from the participants will be welcome to get to the bottom of their own misalignment scenarios.