Miscon Assoc Mannheim Siemens Vibration Analysis

Siemens Solar Industries and Shell Solar Industries Wire Saws Improved

Productivity Through Vibration Analysis

A Case Study

M Miskus Director FM&E (2001-

2004)

Siemens SI and Shell SI

Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis A Case Study M Miskus Director FM&E (2001-2004)

Site Background on SSI

The increasing demand for renewable forms of energy is making photovoltaic

(PV) products an important part of the energy supply future.

The costs of producing photovoltaic modules have been significantly reduced

during the last 15 years as manufacturing costs per watt have dropped from

over $6 per peak watt to less than half of that value now.

Condition monitoring (vibration analysis) used in PV manufacturing has

contributed to this reduction.


Crystal growth improvements, both in yield and machine design, have reduced the PV manufacturing energy consumption by a factor of 3 and improved silicon utilization by 40%.

Wafer slicing process changes have resulted in 66% more wafers being produced for a given amount of silicon.

Cell production improvements in both automation and improved efficiency have reduced the labor cost contribution by over 40% per watt.


Larger modules and better materials have added another 10% reduction in the

cost to produce photovoltaics.

These improvements have contributed to a better energy payback time,

reducing it from over 5 years to approximately 3.

Reductions in cost and improvements in energy efficiency have made

photovoltaic products a commercially viable alternate energy source.


Why?

How?


Introduce Predictive Maintenance Practices

Subject Matter Expert – Miscon Associates

Mannheim

Identify high risk assets and failure modes

Correct application of sensors

Adequate data acquisition


Interpretation of data via report

Action to prevent breakdown


Identify Asset/Equipment for Pdm

Survey Asset/Equipment for sensor

Pre survey data for baseline

Install sensors, preliminary data

Review Data Collection Intervals


Review Data for Abnormalities

Review Baseline Data

Determine Asset Pre Failure

Run time to Failure


Scientific Maintenance

Life Cycle Cost Reduction

Increase Overall Equipment Effectivity

Operational Productivity Enhancement

Lean Manufacturing


Develop and manage five-year strategic plan

for equipment reliability through reliability

based maintenance. SOP review.

Implement predictive maintenance

technologies and interval based actions

Manage utility energy usage for Camarillo

Campus and Vancouver, WA


Manage long term utility energy use plan for

equipment

Manage routine review for ISO compliance

on all equipment preventive maintenance

procedures effectiveness


Manage performance based projects to

exceed PM/Downtime ratio for all areas –

measured 3.5/1

Establish OEE measurement for equipment

performance reviews


Develop Five-year strategic plan for

equipment reliability through reliability based

maintenance and introduction of sound

methods and systems

reduce $15MM expense budget by 15% per

year for 3 year period 2001-2003.


Integrate computerization with technical staff for on line equipment status.

Achieve uptime average of 96% from 60% in 2.5 years.

Administer review of all equipment preventive maintenance procedures

effectiveness. Manage ISO 9000 compliance for manufacturing support role.

Develop talent pool optimization for technical support of production areas.

Established OEE measurement for equipment performance reviews.

Exceeded PM/Downtime ratio for all areas – 3.5/1 from .5/1 in 2003.

Reduced redundant parts in maintenance stores and establish critical spares.


Developed talent pool optimization for technical support of production areas.

Established OEE measurement for equipment performance reviews.

Exceeded PM/Downtime ratio for all areas – 3.5/1 from .5/1 in 2003.

Reduced redundant parts in maintenance stores and establish critical spares.

Siemens Solar Industries Wire Saws Improved Productivity Through Vibration Analysis

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