SKF Reliability Systems

The Guide to Asset Efficiency Optimizationfor Improved Profitability

“The most valuable assets of a 20th-century companywere its production equipment. The most valuableasset of a 21st-century institution, whether businessor non-business, will be its knowledgeable workersand their productivity.”

Peter Drucker

Management Challengesfor the 21st Century

Total Productive

Maintenance(TPM)

A conceptual representation of an industrial maintenance process.

OperatorDriven

Reliability(ODR)

DecisionSupportSystem(DSS)

Maintenance Automation

Correct / Improve / Optimize

FoundationStrategy/Organize/Systems/Manage

InformationReliability Centered

Maintenance (RCM)

StreamlinedReliability Centered

Maintenance (SRCM)

Quick StartReliability (QSR)

5–10 %

30 %

60 %

SKF Reliability Systems ..........................................................................2

Beyond the Bearing ................................................................................3

The Reliability Maintenance Challenge ....................................................4

Reliability Focused Maintenance ..............................................................5

Emerging Strategies ................................................................................6

Maintenance Maturity ..............................................................................7

The Financial Impact of Asset Efficiency Optimization (AEO) ................8–9

Critical Factors for Success ..................................................................10

Summary of Capabilities ........................................................................11

The AEO Process ......................................................................12–13

Assessment ..............................................................................14–15

Maintenance Strategy and Engineering ......................................16–17

Proactive Reliability Maintenance (PRM) ....................................18–19

Operator Driven Reliability (ODR) ..............................................20–21

Managing and Applying Knowledge ..........................................22–23

Advanced Decision Support ....................................................24–25

Machine Maintenance ..............................................................26–27

Machine Improvements ............................................................28–29

Supply Process ..............................................................................30

Training ..........................................................................................31

Integrated Maintenance Products ....................................................32–33

An Integrated Platform for AEO ........................................................34–35

e-maintenance ................................................................................36–37

AEO Technology Products

Condition Monitoring for Proactive Reliability Maintenance ........38–39

Reliability Tools ........................................................................40–41

SKF Technology Inside the Machine ..........................................42–43

Real Conditions, Real Solutions ........................................................44–45

Integrated Solutions for Complex Data Management ..................46–47

Maintenance Strategy ..............................................................48–49

Machine Reliability Assessment – A Fan Solution........................50–51

Operator Driven Reliability (ODR) ..............................................52–53

Integrated Maintenance Solution (IMS) ......................................54–55

SKF Reliability Systems – Global Locations ......................................56–57

2

SKF Reliability Systems

Achieving asset efficiency is a significant challengeOptimizing the efficiency of equipment has a significantimpact on profits – and shareholder value. It affectsproductivity and quality. In some cases, it may evendetermine a company’s ability to compete, or survive.Corporations that focus on overall equipment efficiencyfind that they can add capacity without large capitalinvestments.

Very often, management is aware of the significant benefitsthat can be achieved from a well run asset managementprogram. However, in some organizations, actuallyachieving asset efficiency can present a major challenge.Few companies have the resources or expertise toimplement the rapidly developing new technologies,processes, and cultural changes that are so important toachieving timely, long-term success. Many begin theprocess but are hindered by an incomplete strategy or insufficient planning or benchmarking. The result isinefficient utilization of capital and maintenance resources,and ultimately, failure to achieve efficiency objectives.

SKF can help you optimize asset efficiency to increase profitabilityTypically, machine and component manufacturers stand at the forefront in developing and implementing newtechnologies. SKF for example, has traditionally investedsignificantly in research and development, and iscommitted to the application of new technologies and materials to enhance the design and quality of ourproducts.

Today, reliance on supplier expertise is often recognized asone of the most practical and cost-effective means toenhance internal competencies. SKF enables customers tobenefit from nearly a century of experience in developingsolutions for optimizing machine and process performance.Through the business area called SKF Reliability Systems,SKF offers unique and highly effective methods to helpcorporations improve asset efficiency and managemaintenance costs more effectively.

Transforming asset management into a competitive edge

The Asset Efficiency Optimization conceptSKF’s Asset Efficiency Optimization (AEO) concept picksup where plant asset management programs typicallystop. AEO enables a plant to increase production whilemaintaining or even decreasing costs. It is a system oforganizing and applying assets – from personnel tomachinery – bringing knowledge and technology togetherto achieve the greatest return on investment. By applyingthe power of SKF’s technology and service solutions, youcan benefit from a program which assists in achieving yourorganization’s overall business objectives. These includereduced costs, greater productivity, better utilization ofresources, and as a result, increased bottom lineprofitability.

3

Beyond the BearingImproving machine and process performance

The bearing is the heart of the machineFrom huge rolling machines to the smallest motors, ifthere’s a potential problem with the equipment, the bearing“knows.” As the key interface between moving parts, thebearing is literally the diagnostic heart of the machine:misalignment, unbalance, looseness, and friction are alltelegraphed through the bearing. Understanding theinformation coming from this diagnostic pulse, and thenapplying the latest and best technologies to correct oravert a problem, is critical to raising machine productivityand lowering operating cost.

SKF expertise extends far beyond bearingsAs a world leader and innovator in bearing technologysince 1907, SKF has developed a unique understanding ofnot only how a bearing performs in an application but anintimate knowledge of machine components, systems andrelated processes – allowing us to create and providerealistic solutions for optimum machine and processreliability and productivity.

The evolution of SKF machine knowledge over nearly acentury has enabled the company to become a leadingsupplier of condition monitoring and maintenancediagnostic systems, hardware and software. These tools,and the knowledge of how to best use them, enable us to monitor operations and identify problems.

Our experience includes virtually every industryClose working partnerships with customers worldwidehave provided SKF with an extensive knowledge ofapplications in virtually every industry. As a result, we havelearned to apply the most relevant of today’s emergingtechnologies to industry-specific applications.

You can benefit from SKF’s advanced capabilities in manufacturing and researchSKF is taking the underlying competencies that have beenbehind our product success, and putting them ‘in front’ ofour customers. We view our manufacturing and researchcapabilities as ‘portable’ expertise that can be transferredto other manufacturing operations – enabling you tobenefit from our success.

SKF offers comprehensive solutionsSKF’s near-century tradition of excellence in bearings andmachine reliability has evolved in response to industryneed. Through SKF Reliability Systems we now provide asingle source for a complete productivity solution. Our goalis to help reduce total machine related costs, enhanceproductivity and strengthen profitability.

4

The Reliability Maintenance ChallengeCreating shareholder value through enhanced factory efficiency

To many, increasing productivity means building morefactories. Yet, one of the biggest opportunities today forcreating profits, positive cash flow and, ultimately,shareholder value is through improved factory efficiency.In fact, capitalizing on improved efficiency – as measuredby Overall Equipment Efficiency (OEE) – may reveal thebottom line equivalent of a new factory “hidden” withinmany companies today.

Achieving optimum reliability is essential to maximizingOEE – and maintenance plays a critical role in meetingreliability targets. Reaching these targets, however,requires a shift from traditional maintenance activity,which is reactive and functional, to a proactive processthat is fully integrated into overall plant activity.

SKF Reliability Systems is uniquely qualified to constructa comprehensive, customized change plan for themaintenance organization that is ready to be transformedfrom a cost center to a profit opportunity. Our seasonedasset management “pragmatists” work in true partnershipwith our clients, sharing risks as well as benefits in thequest to achieve optimum OEE. SKF works with clients todevelop effective maintenance and asset managementstrategies and helps companies transition to even higherlevels of efficiency. From streamlined analysis services tofactory floor automation tools, SKF Reliability Systemshas the breadth and depth to help its clients makepractical, lasting changes with significant financialbenefits.

In today’s economic environment, shareholders are takinga closer look at how companies manage asset efficiency.Wherever you stand, whatever your goals, SKF ReliabilitySystems can help you enhance productivity and value.The results could have a very positive effect on yourcompany’s financial spreadsheet.

Our experience in the area of Asset EfficiencyOptimization is not just limited to the successes we havehelped our customers achieve. As the leading bearingsupplier with 80 factories worldwide, we have learnedhow to optimize asset efficiencies to have an impact onour own bottom line – regardless of market conditions.The bearing industry is an extremely competitive marketdriven by the classic commodity supply model where thecost of production is one of the main determinants ofcompany profitability. The profitability and financialstability of SKF demonstrates that employing the AssetEfficiency Optimization process is a viable route toincreased shareholder value.

5

Minimum Efficiency

Reliability Focused MaintenanceShifting maintenance practices from reactive to proactive

Developing a reliability-focused maintenance programis an ongoing process that begins with determiningwhere your reliability and maintenance practices lie inthe range of reactive to proactive maintenance, andthen adjusting them to improve efficiency.

While in theory, this process is complete when youachieve optimum efficiency, in reality the process isnever finished. A successful program is dynamic innature, incorporating and retaining the most efficientmix of reactive, preventive, predictive, and proactivemaintenance, as well as measures enablingoperator driven reliability.

The goal, of course, is to optimize plant efficiency by shifting as much as possible from traditional,corrective activities to a fully integrated, proactiveapproach to reliability.

There are a wide range of scenarios to be considered,depending upon where your maintenance program isin the range, and what your business goals are.

The chart below illustrates the range of maintenancepractices. A business-supported dynamic blend of allof these will generate the best results.

Operator Driven Reliability (ODR)Front line operators are empowered to “own” theirmachinery. They identify, describe and communicatemachine information to the plantwide team to keepmachinery up and running.

Proactive Reliability Maintenance (PRM)Predictive maintenance is applied to help identify

the root causes of machine and process problems;machines operate with virtually no unplanned shutdowns;

Mean Time Between Failure (MTBF) on machines andcomponents is significantly increased.

Predictive Maintenance (PdM)Machine condition is assessed using condition monitoring

technologies; shutdowns are scheduled based upon machineproblems which are identified using sophisticated vibration and

condition monitoring equipment; unplanned shutdowns aresignificantly reduced.

Preventive Maintenance (PM)Unplanned and planned shutdowns are scheduled to overhaul equipment

at pre-determined intervals; maintenance efforts are not based upon anassessment of the machine’s condition while it operates.

Reactive/CorrectiveFix it when it breaks approach; unplanned shutdowns occur when the machinebreaks.

Maximum Efficiency

Our goal is to helpyour facility managethe evolution of your maintenanceprogram. A sus-tainable platform for efficiencyimprovement iseasily achieved byaddressing keyissues which mayinvolve a dynamicmix of programs.

Repair After Failure

Inspect, Lubricate

Preventive Maintenance

Systematic Planning & Scheduling

Predictive Maintenance

Root Cause Diagnostics

Reliability EngineeringReliability Centered Maintenance (RCM)

Operator Maintenance Total Productive Maintenance (TPM)

Concurrent Engineering Life Cycle Costing (LCC)

6

In the 1960’s, it was common practice to wait forequipment to fail, and then repair it – known today as“firefighting.” Generally speaking, management regardedmaintenance as a necessary cost of doing business.

Over the decades, this standard way of working – and thinking – began to change. During the 1970’s most plants had some kind of preventive maintenanceprogram. By the 1980’s, the best run facilities wereemploying predictive maintenance strategies and, by the1990’s, diagnostic tools and software were providingmaintenance personnel with machine conditioninformation that would have been unthinkable ageneration earlier.

Today, it is clear that maximizing the efficiency of a plantand its equipment requires a shift from traditional –or repair focused – maintenance activity, which is bothreactive and functional, into a proactive maintenance (orreliability and risk focused) process that is fully integratedinto overall plant activity.

The evolution of predictive to proactive and theintegration of industrial decision support systems canoften complete the transformation of maintenance from a cost center to a profit center.

Emerging StrategiesAligning your reliability maintenance strategy with your business goals

Mai

nten

ance

Eff

icie

ncy

Historic Development

7

Maintenance MaturityMoving through four phases to achieve world class efficiency optimization

Firefighting

DRIVER

PROGRAM

CHARACTERISTIC

MAINTENANCE

MATURITY

REWARD

BEHAVIOR

Overtime

Heroes

Responding

Breakdowns

MaintainingPromoting

Innovating

STABILIZING

OPTIMIZING

No Surprises

Planning

Avoid FailureCompetitiv

e

Advantage

Disciplined

Organization

Uptime WORLD CLASS

Efficiency O

ptimiza

tion

Organized Learning

Growth

In an ideal world, every plant could make use of all thebest new technologies for enhancing machine reliability.In reality, this is not possible.

Why? Because many techniques and technologies areappropriate only for plants that have reached a specificstage of maintenance maturity, and that have thenecessary culture and processes in place.

Other practices, ideal for facilities in the early stages ofmaturity, offer little additional value to plants that are inthe advanced phases of asset optimization.

The graphic above illustrates the drivers, rewardsand behaviors experienced by a plant as it movesthrough the four phases of maintenance maturity:firefighting, maintaining, promoting and innovating.

The first step toward the goal of improved assetefficiency optimization is to accurately identify your plant’s current situation and then constructand implement a program to achieve the optimum level of maintenance maturity.

8

The Financial Impact of AEOAdding shareholder value through Asset Efficiency Optimization

Improved asset efficiency and reliability can have a directimpact on a company Statement of Income in threedistinct areas:

(a) Cost of Goods Sold (b) Cost of Capital(c) Sales increase through improved

Operating Equipment Effectiveness (OEE)

(a) Increase in IncomeBecause the expense of maintenance is accounted for asa part of the cost of goods sold, it is often a temptingtarget for reduction. However, if the impact of assetreliability and risk are not properly recognized, history hasshown that short term savings will need to be repaidmultiple times in the following years to regain the ability toproduce.

The Wall Street Journal reported that for several hundredcompanies that engaged in cost cutting through layoffs ordownsizing over a period of about five years:

• Only 33 % showed profit improvement

• Only 50 % showed productivity improvement

• 88 % experienced a serious decline in morale

(b) Improved asset reliabilityreduces amount of capital needed.

A more sustainable reduction in cost of goods sold isachieved if maintenance processes are designed to takeinto account the entire life cycle costing of the asset. A maintenance process improvement can be targeted toreduce the level of unnecessary and preventable work andcan often mean doing less maintenance just as much as it could mean doing more. The key is to optimize theprocess so the right amount of maintenance is done at the right time and for the right reason. The result will be a measurable improvement in cost of goods sold.

(b) Reduction in CapitalEffective application of maintenance strategy andpractices has been shown to reduce the need for capitalby improving the reliability of existing assets andextending asset life. This reduces the amount of capitaltied up in assets overall including spare equipment andparts inventories and has a significant influence onEconomic Value Added (EVA). It also can have a verysignificant benefit of allowing the postponement ofinvestment of new capital due to improved utilization ofexisting assets.

Operations &Maintenance

Costs

OEE ProductionYield

SellingPrice

Cost of Goods Sold

OperatingIncome

Cost ofCapital

EconomicValue Added

(c) Asset reliability improvesevery aspect of OEE.

(a) O&M costs are calculated in the cost of goods sold. Improvements impact the operating profit component of EVA.

9

Theoretical Production Time

Equipment Failure

Excess CapacityPlanning

Availability

Performance

Quality

OVERALL EQUIPMENT EFFECTIVENESS = UPTIME X PRODUCTION RATE X SALABLE QUALITY

Benchmark: 85 % (Discrete Manufacturing), 95 % (Continuous Processes)

Planned Downtime

Setup & Adjustment

Idling & Minor Stops

Reduced Speed

Defects in Process

Start up Losses

Planned Production Time

Gross Operating Time

Net Operating Time

Planned Down Time

UnplannedDown Time

Losses

SpeedLosses

QualityLosses

ValuableOperating

Time

Overall Equipment Effectiveness (OEE)

OEE = %

(c) Increase in Sales Another direct contribution to profitability can come fromproducing more with the same assets or producing atthe same level with fewer assets. The most direct way to calculate this level of asset reliability is through themeasurement of Overall Equipment Effectiveness (OEE).Improvements in OEE are an indication of an increase inasset reliability. A more reliable asset will make moreproducts available for sale by:

• Being available to produce reliably when needed

• Producing at a higher run rate or for longer periods of time

• Producing more products within the requiredstandards for quality and consistency.

However, to simply “improve” the efficiency of an asset is an open-ended target and will at some pointbring a diminishing return. The term “Asset EfficiencyOptimization” means what it says: to achieve anoptimized level of asset efficiency. The decision aboutwhich level is correct for your firm should be driven bythe overall business strategy of your company. Linkingthis strategy to an appropriate maintenance strategy and supporting it with a suitable blend of maintenanceprocesses and practices can create profit opportunitiesthat would otherwise be overlooked.

10

Critical Factors for SuccessAchieving Asset Efficiency Optimization requires balance

Logically, each process connects to or has a relationship toothers, so the health of one area affects the overall system.

Our experience has shown that most companies have one or more maintenance programs in place. It is actually a rare situation where these are integrated into the overallplant activity, and thought of as a strategic component ofthe enterprise.

Viewing reliability maintenance from the asset managementstandpoint means that all improvements are important, andcan be made at any and all levels of the plant. Whatever

your current machine asset managementstrategy, SKF Reliability Systems

has the knowledge to help youidentify the areas that can

be improved to help youmeet your company’s

business objectives.

The chart on theopposite pagesummarizes the

capabilities of SKFReliability Systems –

from initial assessment to full Asset Efficiency

Optimization. Page numbersaccompanying each heading indicate where

you will find additional information about these subjects in this brochure.

The experience gained by SKF Reliability Systems in realworld conditions in a wide range of industries shows thatachieving competitive productivity and increased profit-ability through machine asset management depends on a balance of key factors:

• Corporate culture – It is important to have a culture that is willing to embrace change. With regard to improvingreliability, the required changes may involve the shifting of responsibilities among plant personnel. This means a company must be willing to invest the time and energy to re-train employees and bring them emotionally andintellectually into the culture.

• Technology – Successfulcompanies usetechnology as a tool to facilitateimprovements in products andproductivity. In addition, they commit the financial,educational, andpersonnel resourcesnecessary to make the bestuse of new and emergingtechnology initiatives.

• Processes – To be most effective and to achieve long-lasting results, technology must be supported by updatedand enhanced processes. In the case of machine assetmanagement, incorporating new technology into the datacollection, knowledge management, and decision makingprocesses is critical to achieving success.

Process

Success

TechnologyCulture

Assessment

Maintenance Strategy

Maintenance Engineering

11

Assets

SKF servicecapabilities areavailable in a varietyof forms to meet the most uniquerequirements. All ofthe capabilitiesshown in thissection are offeredto support the AEOprocess describedon the next page.

• Reliability-Centered Maintenance (RCM)• Streamlined Reliability-Center Maintenance (SRCM®)• Risk-Based Maintenance (RBM)• Criticality analysis• Quick Start Reliability

• Client Needs Analysis• Machine Reliability Assessment• Maintenance Strategy Review• Operating Unit Assessment

• Planned, predictive and proactive maintenance procedures• Process Documentation• CMMS structure and implementation• Spare Parts Alignment Rationalization

and Optimization (SPARO)

Summary of Capabilities

14-15

15-17

16-17

20-25

26-27

28-2930 31

• Predictive maintenance(PdM)

• Proactive ReliabilityMaintenance (PRM)

• Condition monitoringsystems:– Vibration analysis– Lubrication Analysis– Thermography– Operating Deflection

Shape Analysis• Operator Driven

Reliability• Machine diagnostics• Knowledge

management• Decision Support

System

• Precision alignment• Precision balancing• Lubrication

management• Bearing failure

analysis• Bearing installation,

maintenance andrepair

• Maintenance tools

• Trouble-free supply• e-supply• e-commerce• Spare Parts Alignment

Rationalization andOptimization (SPARO)

• Machine upgrade,rebuild and re-design

• Design engineering• Technology upgrade

– Components– Systems

• Refurbishment andrepairs

• Post-maintenancetesting

• Machine Reliability– Condition monitoring– Vibration analysis– Application specific

training– Lubrication

management– Bearing application– Bearing maintenance

• Asset managementRefer to page 31

The Asset EfficiencyOptimization (AEO)process

See pages 12–13.

AssetKnowledge

MachineMaintenance

Logistics and Supply

ProcessMachine

ImprovementsTraining

12

The AEO ProcessA process for translating asset knowledge into bottom-line value

A key aspect of any world-class asset managementprogram is a proactive, efficient work managementprocess, designed to ensure the effective performance of maintenance on critical assets. To achieve maximumreturn on investment and maintain the greatest degree ofproductivity, it is pivotal that organizations have a processthat effectively translates asset information to knowledge,and ultimately gain value from that knowledge.

To help organizations achieve these goals, SKF offers Asset Efficiency Optimization (AEO), amanagement process designed to achieve maximumefficiency and effectiveness from work managementactivities focused on business goals for the facility.

The AEO process encompasses four key elements:Strategy, Identification, Control and Execution. Within eachof these elements, the coordination and participation ofthree essential factors within the organization – process,culture, and technology – is paramount to the overallsuccess of the AEO process.

Maintenance Strategy involves the evaluation of workactivities in relationship to a facility’s business objectives, a procedure that creates the documented basis for themaintenance program.

Work Identification is where “work” is identified from theevaluation of a comprehensive flow of data in conjunctionwith an integrated decision-making process. Key to thesuccess of Identification is a comprehensive CMMS(Computerized Maintenance Management System).

Work Control involves establishing procedures forplanning and scheduling the work identified by the CMMS.Tasks are organized based on several parameters,including time and condition; job plans or procedures;man-hours required; data feedback; special requirements;and many other factors.

Work Execution is where identified, planned andscheduled work is performed. Once work is completed,feedback from the field plays a key role in measuring theoverall effectiveness of the AEO process and makingrefinements for even greater efficiency in the future.

The AEO process transforms conceptual assetmanagement to tangible competitive edge. SKF can helpplan a course of action to align your reliability and riskfocused maintenance strategy with your organization’sbusiness objectives. Our team will help correct knownproblems, and will then work with you to assess andidentify additional opportunities for improvement in theareas of production, safety and environment.

13

WorkExecution

WorkControl

WorkIdentification

MaintenanceStrategy

Asset Efficiency Optimization –Work Flow Process

Maintenance Strategy Project

Reliability Issues (Design)

PRM/ODR Collection and Analysis

Work Order Generation

Planning

Rolling Schedule

Work Execution

Post Maintenance Testing

Update Living Program

Standard Job Plansand Procedures

Spare Parts Alignment

Information Integrationand Decision Making

Plant Asset Management and Maintenance Program (Living Program)

PM PRM ODR RTF

RCFA

Pre-Defined Priorities

Business Goals

CorrectiveMaintenance

Operators Initiators

PM = Preventive Maintenance (time based)

PRM = Proactive ReliabilityMaintenance (predictive and corrective)

ODR = Operator Driven Reliability (observations)

RTF = Run to Failure (reactivemaintenance)

RCFA = Root Cause Failure Analysis

Maximum return is achieved when all parts of the process are implemented; however,customers can focus on first one area then another in progressive stages.

14

Assessment

The most common reason for the failure of an assetmanagement change initiative is the failure to establish ifthere really is a problem – and when, why and how itmatters. Planning a shift to an integrated reliability andrisk-based asset management strategy starts with a deepunderstanding of where you have been, where you trulyare today and where you really need to go.

The purpose of an assessment is to gain thisunderstanding and then to use it to put together adetailed, structured improvement plan that includesrealistic, achievable, and necessary actions. To achieveand measure success, there must be clear and objectivedocumentation of what the AEO process is intended toaccomplish.

Identifying the problems – when, where and how they matter

Every assessment is uniqueWe make sure that we clearly understand a client’s needsbefore recommending the type, depth and complexity ofthe assessment.

Assessments vary from a three-hour facilitated ClientNeeds Analysis to situations where we deploy multiplesubject matter experts at the client’s site for periods offour to five days.

The Client Needs Analysis can be completed in just a fewhours and asks 10 assessment questions for each of thefour main facets of the AEO process: maintenancestrategy, work identification, work control, and workexecution. These 40 questions are designed toinvestigate, quantify, and visualize the situation at yourfacility. Results are displayed in a graphical “spider chart”format which provides a visual footprint of a particularplant’s assessment in accordance with internationalstandards/models of business excellence.

Innovating

Promoting

Maintaining

Fire Fighting

WorkIdentification

MaintenanceStrategy

WorkExecution

Work Control

Innovating

Promoting

Maintaining

Fire FightingThis is the assessment result.

15

The Quick Start Reliability Program

Each assessment is conducted via a standardized andproven process that uses our detailed AEO model as a baseline from which to work. At a practical level,assessments can use purely quantitative(discrete/numerical approach), purely qualitative(descriptive/questioning/interview approach) or a composite approach.

Skilled assessment teamsOur assessment teams are made up of specialists selectedfor their knowledge and understanding of your specificindustry, type of plant, and the equipment it uses. Their jobis to interview plant personnel to collect information thatwill be used to pinpoint problem areas, and serve as abenchmark for improvements. They will also providerecommendations for streamlining processes andimplementing the most cost effective practices.

SKF typically offers the Quick Start Reliability program to facilities that are organized in a classically reactivestructure or hierarchy, and so often have absent or sub-optimized maintenance/reliability engineering capabilities.The program can provide a basic first step in theevolution towards using the complete AEO process. The Quick Start Reliability program is:

■ Targeted to those clients that are in the lower maturityphase (firefighting) in the maturity pyramid.

■ Designed to establish a maintenance process wherenone exists or is sub-standard.

■ Focused on the first 90 days of the overall changemanagement plan for maintenance.

■ Geared to quickly put a performance managementculture or process in place.

■ An 8-step process that identifies a plant’s best “earlywins” and implements a program to achieve them.

■ Built around performing the right work at the right timein the right way – on equipment that is business critical.

■ The best course of action when a plant has neither thetime nor the funding to conduct a comprehensivemaintenance strategy review.

16

Maintenance Strategy and Engineering

Maximizing the efficiency of a plant and its machineassets requires a shift from discrete maintenanceactivities to a strategic process that is embracedcompany-wide.

Properly structured and implemented, a well thought-outmaintenance strategy transforms maintenance from acost to a profit center.

A comprehensive maintenance strategy is likely to employa number of techniques working to support each other.Choosing the right technology tool, or combination oftools, requires a sound understanding of the plant andthe relative data that may or may not be available.

SKF Reliability Systems has assembled a formidablebody of expertise in the field of maintenance engineeringand employs seasoned asset management pragmatistswho are skilled at developing and executing strategiesbased on their knowledge and a real world understandingof all current maintenance techniques.

In addition to more than 15 years in the business ofreliability maintenance, SKF Reliability Systems also has acquired several firms recognized in the field ofmaintenance engineering to complement our capabilitieswith in-depth first-hand knowledge and understanding of reliability issues.

With this knowledge and experience, we are able toidentify what is truly needed for each client and thencreate a maintenance strategy which most effectivelycombines the right technologies to meet those needs.

The following is a brief discussion of the most commonlyapplied maintenance techniques:

RCM – Reliability-Centered MaintenanceThis is often recommended for equipment wherecriticality is high and confidence in existing maintenanceis low. The role of RCM in most cases is to provide adefensible base for specific equipment where there islimited knowledge and history. While RCM can be quiteeffective for reliability improvements in specific areas, ingeneral it is inappropriate for the rest of the plant. Thisaspect of RCM has led to the development of othersimilar maintenance techniques which are moreappropriate on a plant-wide basis.

SRCM® – Streamlined Reliability-Centered MaintenanceThis enhanced version of RCM focuses on the dominantfailure modes of equipment and the significant effects ofthose failures such as production losses, personnelsafety, environmental releases, etc. A key benefit of anSRCM program is developing the understanding of plantpersonnel on the value of a modern-based maintenancestrategy. As such, SRCM is particularly appropriate wherea major change in the maintenance culture within theenterprise needs to be made, which also makes it a goodoption for new builds.

RBM – Risk-Based MaintenanceThis is a financially based analysis technique whichfocuses on establishing the relative worth of mainten-ance. It was originally developed as a means of reviewingexisting maintenance programs, and in this mode it workswell as a continuous improvement tool. RBM definesopportunities for incremental improvement through theelimination of tasks of low value and the introduction oftasks which address high commercial risk areas. As such,RBM is also valuable in transferring knowledge fromexisting installations to provide a baseline for new builds.

Setting a course for success

17

Business Goals

Select System

Typical Maintenance Strategy Model

Boundaries

System Function Non-ImportantFunction

SystemComponents

Failure Causes

DefineAppropriate PM* Tasks

PerformNon-CriticalEvaluation

Define SimpleTasks

CompareExisting PM

Program

Implement Decisions

Execute LivingProgram

Continuousimprovement process

* Planned Maintenance** Run to Failure

Recommended RTF

Yes

Yes

No

No

Failure ModesFailure Effects

FMEA(Criticality Analysis)

ComponentCritical?

Define whatPM’s should

be done

Identitywhat is

important

Change PM Program

RTF**

Important Function

Proactive Reliability Maintenance(PRM)

SKF Proactive Reliability Maintenance addresses failures andimplements the processes necessary to prevent recurrence. At thefoundation of the process is a systematic method to benchmarkasset productivity and implement corrective actions that willreduce total life cycle costs. In short, it enables an organization totake complete control over what is happening on the plant floor.

While traditional Predictive Maintenance (PdM) processes form asustained maintenance loop, the PRM process forms a continuousimprovement loop.

The SKF Proactive Reliability Maintenance process is based onfour key steps:

1. Predictive MaintenancePredictive Maintenance (PdM) is a process aimed at detectinga machine condition that will eventually lead to failure and thenestimating the amount of time before failure occurs. To do this,sophisticated condition monitoring technology is used to gatherdata such as machine vibration, thermography, lubricant condition,motor current analysis, process parameters, etc.

While most PdM programs stop at detecting a problem andmaking a residual life prediction, SKF uses this information as thebasis to diagnose the problem with the objective to determinewhich proactive tasks are necessary to achieve an extension ofmachine life.

A process to achieve the best possible return on plant assets

18

Proactive ReliabilityMaintenance

PredictiveMaintenance

Failure DetectionCondition Repairing (e.g.

Redesign, Correction)Chain-ReactionFailure

Root CauseFailure Analysis

Life ExtensionOriented

Residual LifePrediction

Lube Oil AnalysisVibration AnalysisThermographyMotor Current Analysis

Contaminant MonitoringAlignmentBalanceDesign Engineering

ProactiveMaintenance

19

2. Diagnostics and Root Cause Failure Analysis (RCFA)SKF Reliability Engineers use applied knowledge and its accumulated experience to diagnosecollected data. This may lead to the recom-mendation for actions such as precisionalignment, precision balancing, alterations inlubrication management, redesign of machineor critical components, etc.

To complement the knowledge derived from thediagnosis of data, detailed machine and componentdiagnostics are conducted on site, or at a centralizedSKF Reliability Systems center. Damaged or failedcomponents undergo a thorough Root Cause FailureAnalysis (RCFA). This information is used to prevent arecurrence of the problem or, if required, to assist our OEM partners in a redesign of the machine.

3. Key Performance IndicatorsKey Performance Indicators (KPIs) are performanceimprovement targets established jointly between plantmanagement and SKF. They can cover a range of factors,such as unplanned mechanical downtime, quantity ofproduct manufactured, plant efficiency, maintenance costs,and bearing performance. KPIs are also used to determinethe number of personnel needed to maintain assetperformance, and what qualifications those individualsneed in terms of specific skills (e.g. lubrication, mounting,alignment). Where possible, once a KPI is achieved, a newtarget is set to facilitate continuous improvement.

4. Operational ReviewAchievement of Key Performance Indicators is monitoredthrough a periodic review of the total PRM program.Results are documented and presented at performancereview meetings between plant management and SKFReliability Systems. These meetings also help to assurethat the process is continually refined to achieve the bestasset performance and PRM process activity cost.

An effective decision support system further enhances thePRM process, allowing for information and data that iscaptured throughout PRM to be fully utilized in decision-making processes. The decision support system facilitatesefficient organization and presentation of data, interpretsdata based on user-defined parameters, and then providesrecommended actions for maintenance and operations.

A well-implemented and managed Proactive ReliabilityMaintenance process is the most effective method ofmanaging risk, increasing reliability and ensuring the bestpossible return on plant assets. Depending on your needs,SKF can design, implement and manage the process foryour entire plant or specific sectors, and supply allnecessary hardware, software and technical resources. For those who wish to run the process on their own, wecan provide consulting services and the technologiesnecessary to initiate and manage the process.

Predictive Maintenance PdM

Operational Review

PRM

Diagnostics and Root CauseFailure Analysis (RCFA)

Corrections KPI’S

Operator Driven Reliability (ODR)Making operations part of your reliability maintenance strategy

Process Availability

Maintenance delivers equipmentreliability

Operationsdelivers processreliability

The relationship between operations and maintenance isan under-exploited opportunity in most companies today.The reasons for this are usually organizational, cultural orhistoric. Even in firms where a healthy relationship exists,the interaction process between the two departments canbe improved. Trend-setting firms have realized this and areembracing a strategy called Operator Driven Reliability(ODR). ODR is built upon the following main concepts:

Operators are critical to asset reliabilityBeing in close proximity to the machines – 24 hours a day,7 days a week – operators are often the first to notice eventhe smallest changes in machine condition. What they dowith this information can mean the difference betweenmachine failure and failure avoidance. ODR provides aprocess to turn early detection of developing problems intoprompt corrective actions.

Shared ownership of assetsMost companies are being asked to produce morewith fewer personnel. ODR creates a culture of sharedownership that leads to a greater contribution and ahigher level of job satisfaction for operations personnel.Operations is responsible for process reliability.Maintenance is responsible for asset reliability. Togetherthey can generate improvements in process availability.

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Facilitates total productive maintenanceThe most competitive companies in any industry have longago accepted the concept of Total Productive Maintenance(TPM). ODR augments the TPM process and extends thecultural benefit by enhancing liaison between maintenanceand operations. In companies where TPM does not exist,an Operator Driven Reliability program can be the stimulusfor adopting it.

Automates data collectionManual data collection by an operator is often inefficientand prone to error. The increase of dependable handheldcomputers in the industrial workplace makes it possible toautomate most data collection tasks. Clear benefits inefficiency, accuracy and job satisfaction are the result.

Builds teamworkRecent advancements in the IT world do not solvethe problem alone: silos of information still exist in mostorganizations. By linking the two worlds of operations andmaintenance, ODR increases cross-functional awarenesswith direct benefits to both.

Fulfills Maintenance Strategy Work PlansOne of the key outputs of the maintenance strategy process is a recommended work plan and task list for each asset and process. Building an Operator Driven Reliability program around these requirements has the benefit of linking daily activities directly to the overall strategy.

The MARLIN® system for Operator Driven ReliabilityRecognizing this developing trend towards ODR in themid-1990s, SKF developed a technology solution that fullysupports the concept: The MARLIN system consists of acustomized rugged handheld computer and specificallydeveloped application software, allowing operators to easilycollect three main types of data:

■ Process Data (pressures, flow rates,temperatures, etc.)

■ Machine Inspection Data (visual observations of machine condition)

■ Machine Condition (level of vibration andtemperature)

As operators make their rounds and collect data,the MARLIN system makes specific recommendationswhen certain machine conditions are detected. Therecommendations are pre-determined by themaintenance staff and allow the operator to takeimmediate corrective action.

Collecting and trending each type of data in anaccurate, repeatable and objective manner has its owndirect benefit. And linking operational data to themechanical condition monitoring data collected bymaintenance personnel yields a more complete pictureof asset and process condition.

Developing a decision from the merged data brings theultimate benefit. The SKF @ptitude® Industrial DecisionSupport system automates this process and capturesthe knowledge derived from it for future use.

ODR implementationSKF has also developed a complete implementationprocess to facilitate rapid and successful deploymentof the technology. The ODR implementation addressesthe many cultural and process changes that are neededto succeed. Let our experience and success in thisfield help your company benefit from using OperatorDriven Reliability.

Managing and Applying Knowledge

As organizations compete in the global arena and seekways to reduce costs while increasing efficiencies, theability to gather, store and instantly access essentialknowledge is increasingly urgent for maintaining andimproving plant productivity.

SKF Reliability Systems has recognized the importanceof cultivating and retaining knowledge andcompetencies to ensure the ongoing stability,effectiveness and continuous improvement of yourprogram. Today’s technology makes it possible toamass and provide immediate access to essentialinternal and external knowledge from an array ofsources, enabling your team to effectively and efficientlyapply it to address your plant’s unique reliability andproductivity issues.

The Factory of the Future is heree-business has revolutionized the way today’s plantsoperate. Plant assets (people and machines) are nowgoverned and directed by information networks such asplanning systems and are linked to an even smallernumber of suppliers (Figure 1). As e-business continuesto evolve, the majority of transactions – those which aretypical and repetitive in nature, and require no humaninteraction – will occur automatically. As workers focusonly on the exceptions, and suppliers take on the role ofmanaging customer inventories, transaction costs aresignificantly reduced.

Similarly, today’s advanced decision support systemsprovide a significant operational and financial benefit toplants that implement them. As predictable eventsoccur at regular intervals between the assets andproductivity systems in an enterprise – such as a motorfailing every six months – the system automaticallyaddresses the occurrence. This typically consists of aseries of actions ranging from identifying the problem toproviding the specific steps to take to correct it.

An enterprise-wide approach yields optimum results

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80 % Normal

Transactions

80 % Normal Events

DecisionSupport System

@ptitude®

20 % Abnormal

20 % Abnormal

Analyze / Corrections

Analyze / CorrectionsE-Commerce

Endorsia.com®

ptplace.com®

Exceptions

Exceptions

Suppliers

Planning Systems (CMMS / ERP)

Assets

Figure 1

As exceptions occur, they are analyzed, corrected,resolved and incorporated into the Decision SupportSystem (DSS) information base. A series of rules aredefined based upon information and knowledge derivedfrom subject matter experts and knowledgeable workerswho have provided input to the system. As such, aprocess for identifying and addressing such problems isestablished for future occurrences.

Each new occurrence provides an opportunity to add to the decision support information base so thatpredictable events are automatically addressed if orwhen they recur. Therefore, the knowledge in theinformation base is continually updated, then shared toimplement consistent resolutions to common problemswithin a single enterprise or at multiple sites throughoutthe country or around globe.

Users of decision support systems dramatically improveasset efficiency and integrity while maintaining andenhancing results over the long term. The impact ontime, cost savings and enhanced productivity aresignificant.

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Advanced Decision Support

The system is built upon Asset Knowledge Science (Figure 1), which goes beyond traditional failure analysismodels like Failure Modes and Effects Analysis (FMEA),Fault Tree Analysis (FTA), Reliability Centered Maintenance(RCM) and others to embody a fundamental understandingof the predominant failure modes of machinery, themeasurements required to effectively monitor equipmenthealth, and the consequences of failure. The essence ofthis capability is knowledge of an asset’s components, how they are assembled and how the asset is designed to perform, allowing for fault detection and resolution priorto failure.

The @ptitude® Industrial Decision Support system fromSKF is an advanced, multi-faceted asset managementsolution which automates the industrial reliabilitymaintenance decision making process. The system makesit possible for users to efficiently and effectively utilize thedata made available through plant systems, providing adynamic resource for machine and process diagnosis,analysis, reporting and corrective actions.

The @ptitude system integrates SKF’s range ofcompetencies with data from other systems such ascondition monitoring systems, distributed control systems,computerized maintenance management systems (CMMS),and internet/intranet websites, with your own organization’sinternal knowledge. It incorporates the best of the world’smost widely used failure analysis methodologies withSKF’s extensive practical knowledge of components andmachinery, and fuses this knowledge with live dataanalyzed through the @ptitude system software.

Asset Knowledge Science “Tree”

Figure 1

Asset

Reactive

ProactiveFusion

Mea

sure

men

t Cen

tric

Asse

t Cen

tric

PdM

• P

RM •

ODR

Mai

nten

ance

St

rate

gy

Components

Failures

Faults

Symptoms

Key Features

Measurements

Knowledge is power

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Reliability expertise at your fingertipsThe @ptitude system also includes an online web-enabledknowledge portal known as @ptitudeXchange that allowsinstant access to reliability maintenance knowledge 24/7.Through @ptitudeXchange, customers gain access andshare in the wealth of knowledge and experience of SKF,and SKF’s alliance partners as well. Website contentincludes papers, application notes, best practices,benchmarking information and more. @ptitudeXchangecomplements the knowledge of your reliabilityprofessionals and provides immediate access toknowledge which can be instantly applied to support orenhance your team’s reliability efforts.

By integrating data from multiple sources into one easy-to-use software application, the @ptitude system applies astructured approach to facilitate consistent and reliabledecision making – enabling personnel to act quickly basedon meaningful data and a predetermined set of proceduresand priorities. The system replaces labor-intensive datacollection and analysis with automatic analysis, faultresolution and even work order notification.

Accurate, consistent and reliable decision makingThe @ptitude® Industrial Decision Support system includesan expert environment where a diagnostic systemmanages the decisions for rotating machines. Based on arule set made of asset systems and key features, the@ptitude system triggers notifications to plant personneland recommends appropriate action. Should a part needreplacement or if a failure analysis is required, the systemadvises on appropriate procedures and optimization, evenlinking actions with the plant’s specific asset managementstrategy. This helps to ensure accuracy and consistency inperforming such tasks anywhere in the plant or around theworld.

Asset management databank combines assethistory and worker knowledgeTo facilitate the incorporation of local or enterprise-specificknowledge, processes and procedures, the @ptitudesystem also includes the ability to add physical informationabout plant assets including lists of faults and symptoms,activity history and document management folders. Theinformation is organized and readily accessible accordingto its criticality – specifically relative to production, safetyor environment.

www.aptitudeXchange.com

Machine Maintenance

The bearing is at the heart of all rotating equipmentAs the key interface between moving parts, the conditionof the bearing often reflects how well a machine is running.Problems such as misalignment, unbalance, looseness andfriction are all telegraphed through the bearing.

With its expertise in bearings, SKF has the unique capabilityto develop the most comprehensive service programs forrotating equipment. We’ll help you to combine an asset-aware maintenance strategy, structured competence andcapabilities – including the best mix of internal resourcesand external specialists – to drive machine maintenance inthe most cost effective ways.

■ Precision alignmentMisalignment is one of the major causes of machinecomponent failure. SKF has the competencies toconduct precision alignment of machines.Comprehensive engineering services – combined with the application of products that quickly andcorrectly accomplish critical alignment and machinerymounting – can contribute significantly to the reduction of machine failure.

■ Precision balancingUnbalanced components in machinery cause an increase in load on bearings and on the entire machinestructure – all evidenced by high vibration levels.Precision balancing will reduce vibration, lowermaintenance costs and optimize machine running time.SKF Reliability Engineers, using state-of-the-artinstrumentation, will accurately diagnose machineconditions and, if needed, provide on-site precisionbalancing services.

■ Lubrication managementA concentrated effort to evaluate and improvelubrication issues in your plant will improve returns onplant assets and lower consumption and supply costs.SKF can provide a complete management process thatwill focus on improving lubrication conditions in theplant, and lower the associated supply and logisticcosts.

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Comprehensive service programs for rotating machinery

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■ Bearing failure analysisThe process of bearing analysis offers an importantmechanism for identifying and addressing machineperformance issues. SKF provides a Failure Analysisservice with the most comprehensive analysis report in the industry. Each report includes a complete written account of why the failure occurred, plusrecommendations for corrective actions needed to eliminate repetitive failures.

■ Technology advice and machine upgradesUpgrading machines and processes with the latesttechnologies can play a significant role in improvingprofitability. SKF engineers are experts at evaluatingapplications and initiating improvements to extendmachine life.

■ Bearing installationAlignment of the machine, precision balancing and avibration baseline analysis at start up can be included as part of the mounting process.

Machine Improvements

To remain competitive, plants must keep pace with new machine technologiesIncreased production targets for your existing machinesand competition with global companies equipped withnewer machines make it hard to keep pace using yourexisting assets. SKF Reliability Systems can help – withoutthe need to invest in completely new equipment.

Our engineers apply the latest design solutions, which are built on a solid foundation of reliability engineering.Their recommendations can include one, or a combinationof actions:

Upgrade, rebuild and re-designA pragmatic review of current operating conditions andmachine history combined with information derived from a thorough Root Cause Failure Analysis (RCFA) can lead to a recommendation for an upgrade of key components or a re-design of entire sub-assemblies. These actions can extend asset life or result in an improvement ofproduction capability – or a combination of both –generating significant value at the bottom line. Projectsmight include:

■ Post-maintenance testing■ Optimization of paper machine press and dryer section

for speed increase■ Conversions of continuous casters or chocks for the

metals industry■ Upgrade of machine tool spindle design for high run

rates■ Modernization of printing press cylinder systems for

improved quality■ Re-engineering of lubrication and sealing systems

for new operating conditions

Design engineeringSKF can also provide an extensive range of designservices,including:

■ Design review using finite element modeling■ CAD/CAM design and consulting ■ Prototype design and production■ Structural modeling with modal analysis/operating

deflection shape

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Run it faster, run it better

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Refurbishment of bearings and assembliesAnother way of maximizing your existing asset investmentsis through refurbishment and repair. Professionalrefurbishment procedures are used for large or specializedbearings that have been in operation or stored for sometime. These can often be returned to an “as new” conditionfor a fraction of the cost of a new bearing.

A skilled technician inspects each bearing, then issues a comprehensive Bearing Failure Analysis Report. Inaddition to providing detailed information about thebearing, this report also contains a wealth of informationabout the operating environment and how it might beimproved to maximize service life.

■ Large size bearings and their housings■ Industry-specific repair and services■ Continuous caster bearings and assemblies■ Backup and work roll bearings for metal rolling mills■ Housings, rolls, and complete units such as printing

cylinders and water-cooled housings for continuouscasters

Supply Process

Reducing costs associated with purchasing, supply and inventory management is an integral part of increasing profitability. SKF Reliability Systems works in close partnership with our SKFAuthorized Distributor Network – or your currently contractedsupplier – to reduce transaction costs, release capital tied up inspares inventories, and assure that spares are available anddelivered when needed. SKF can also assist you in taking fulladvantage of electronic purchasing systems.

Trouble-free supplySKF maintains the world’s widest network of authorizeddistributors who can provide you with supply arrangements forbearings and other industrial components through a single buyingchannel.

Through trouble-free supply, the management of inventory andsupply is handled by the SKF distributor network. Our distributorswill determine with you, the precise requirements for eachmachine so that dedicated inventories are available to meetdemand. This eliminates the need to invest in inventory, ormanage the supply process, and contributes to reduced costs.

Electronic supplySKF has developed electronic supply processes to facilitateefficient, reliable and cost effective inventory management.

SKF Authorized Distributors are connected to a centralwarehouse and logistics support center, so you can link directlyto this system for quick and easy access to the latest inventoryand shipping information.

Many distributors are also joining two web based industrialmarketplaces: Endorsia.com® and PTplace.com.® Endorsed byleading manufacturers, these all-in-one service networks aredynamic electronic marketplaces for branded industrial goodsand services. Distributors, manufacturers and MRO users benefitfrom an efficient, streamlined system for buying and selling.

Websites: www.ptplace.com (USA) and www.endorsia.com

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Partnership and technology for reduced costs, greater efficiency

Training

SKF Reliability Systems offers machine reliability and assetmanagement training – from the shop floor to the highestlevels of management. Courses focus on the skills andknowledge your team needs to work toward achievingmaximum reliability and productivity. Our trainers areexperts with years of experience in industry, many of whom also teach at universities or trade organizations.

Machine Reliability■ Condition monitoring■ Maintenance management■ Mechanical maintenance skills■ Lubrication management■ Bearing maintenance and service

Asset Management■ Proactive Reliability Maintenance skills■ Assessment techniques■ Equipment criticality analysis■ Maintenance strategy■ Reliability and Risk Based Maintenance■ Key Performance Indicators■ CMMS population and optimization■ Operator Driven Reliability■ Predictive Maintenance program setup and management■ Planning and scheduling■ Continuous improvement process “living” program

management■ Spare Parts Optimization

Classes are held around the globe, or may be customizedand taught on-site to meet your plant’s specific needs.Many courses are offered via e-learning and tutor-ledinteractive web tutorials. Or, your team can learn at theirown pace or enhance their existing knowledge as timepermits with a subscription to @ptitudeXchange, SKF’sreliability knowledge website.

Contact your local SKF office for availability and schedulingin your area.

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Building and enhancing competence

The Integrated Maintenance Solutions (IMS) agreementoffers industry a new alternative to current maintenancepractices or full outsourcing.

With an IMS agreement, SKF Reliability Systems willmanage every key component of a machine assetmanagement strategy, providing a total system forachieving Asset Efficiency Optimization.

An IMS contract brings together all areas of expertiseoffered by SKF, establishing a continuous process ofmaintenance monitoring, analysis and improvement. Itprovides a planned skills transfer program for maintenanceand operations personnel, and technology upgrades whererequired. The services and support best suited to optimizeasset efficiency and integrity (safety and environment) areall included under one fixed fee performance basedagreement.

Each agreement is customized to specific business needs.You can choose which areas you want included, based oninternal resources and current supplier contracts.

With an IMS contract, SKF plays a significant part inincreasing the reliability and integrity of your plant. Weshare some of the risk as well as the savings, while youreceive agreed upon financial returns and technologyupgrades without capital investment.

(See Case History on pages 54–55.)

Integrated Maintenance Solutions

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Guaranteed return without capital investment

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M a i n t a i n a n d M o d i f yAll data collected is used to achieve optimum machine performance and to establish effective maintenance practices.

W o r k C o n t r o lProactive Reliability Maintenance (PRM) addresses repetitive failures andimplements processes to prevent reoccurrences. It is a strategy that enables yourorganization to take complete control over what is happening on the plant floor.

B e n c h m a r kThe first step in the process is a detailed assessment of your existing supply,maintenance and predictive maintenance procedures.

P l a nIdentifying key strategic problem areas in the plant is critical. This makes it possible to prioritize actions based on the relative importance of each asset.

PRM

Maintenance Strategy

Operat ional Review

Diagnost ic & Root CauseFai lure Analysis (RCFA)

Maintenance Engineer ing

Machine Maintenance Technology Upgrades

Supply Process

Correct ion KPI ’sPredict ive

Maintenance (PdM)

A s s e s s m e n t

Training

D e v e l o pThe skills of plant personnel must be developed to make the most effectiveuse of new technologies and evolve asset management culture.

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An integrated platformSKF’s range of products and services – from conditionmonitoring and decision support systems to bearings andseals – are all designed to provide the solutions that willultimately lead to increased bottom line profitability for SKF customers. Our focus on technology and seamlessinterface with plantwide systems supports four key areas in an effective maintenance process.

Distribution and E-Commerce Platform Endorsia.com® and PTPlace.com®

@ptitude® Industrial Decision Support System

SKF Machine Analyst or ProConData Management and Analysis Software

Mechanical Maintenance

BalancingLubricationAlignmentProtectionSystems

TransientAnalysis

On-line Surveillance

VibrationAnalysis

SinglePoint

Monitors

OperatorTools

■ Decision support: The ability to facilitate consistent,accurate and effective decisions on plant equipment and processes is a crucial component of a world classprogram. SKF has made a commitment to assistingcustomers in the retention, storage and utilization ofcrucial information with its decision support software.

■ Condition monitoring: As a leading supplier ofcondition monitoring products, SKF offers a completerange – from hand-held data collectors/analyzers toonline surveillance and machinery protection systems.These products offer a seamless interface to conditionmonitoring analysis software, CMMS, ERP, and otherplantwide systems.

Proactive Reliability MaintenanceOperator DrivenReliability

An Integrated Platform for AEOProducts and services for bottom line results

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TechnologyUpgrades

ProcessControl

ERP / CMMS

TechnologyBearings

MaintenanceTools

SystemInstallation

and Management

Services

ConsultingServices

ReliabilityServices

MaintenanceServices

■ Tools and lubricants: Safe and proper machinemaintenance is critical when the goal is to optimizeequipment running time. The development of SKF toolsand lubricants is based upon our own experience in fieldwork and includes the latest technologies.

■ Component innovations: New component innovationsare needed to achieve productivity goals that were neverintended by original equipment manufacturers. SKFcontinues to develop bearing products designed to runfaster, longer, cooler and maintenance-free in manydifficult applications.

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e-maintenanceEnabling Proactive Maintenance Reliability via the Internet

Management of a predictive maintenance program can be a challenging task due to the amount of data acquiredand the time required to reduce it into meaningfulinformation. In some facilities, the personnel who collectmachine data are also required to perform the analysis.This leaves little time to focus on corrective actions andwork order follow-up. It then becomes impractical toevolve from PdM into a full Proactive ReliabilityMaintenance program.

SKF has developed a solution for this dilemma called e-maintenance, which uses web-enabled technology andintegrates SKF Machine Analyst data management andanalysis software; the @ptitude® Industrial DecisionSupport system; and the Microlog® portable vibrationdata collector. The entire process is managed by a groupof experienced SKF reliability engineers. The result is acomplete analysis process built upon proven techniquesthat support your existing infrastructure. And your PdMprogram begins to evolve into a true PRM program.

For companies that do not have a PdM program or havehad trouble in maintaining one due to lost expertise orinvestment limitations, the SKF e-maintenance processcan be used to run your PdM program at one facility. Or, it can also be used to standardize on PdM processesacross multiple facilities. SKF can manage the entire e-maintenance program for you or put together theinfrastructure as a turnkey system for your company torun itself.

Benefits of an Internet-enabled e-maintenance solution from SKF:

■ Remote monitoring 24/7Data collected via portable or on-line surveillancedevices at remote locations can be uploaded to theSKF Diagnostics Center for analysis and reporting.

■ Centralized data repositoryHistorical data from all locations is easily accessed byall responsible personnel. Reports are generatedcentrally and distributed to local workstationselectronically.

■ Better informed field techniciansMaintenance and operations have access to morecomplete and timely data.

■ Efficiency and consistencyData is managed more efficiently, and in a consistentmanner throughout an organization.

■ Minimized investmentA centralized location eliminates the need forredundant analysis centers, saving on hardware,software and manpower.

■ Savings through outsourcingUsers may choose to use the SKF Diagnostics Center;supported by SKF reliability experts and a dedicatedweb server.

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(1) From a central SKF Diagnostics Center, a datacollection route is sent electronically to the laptopcomputer of a technician in a remote location.

(2) The information is downloaded to a Micrologportable data collector. (3) Once collected,machine vibration or process data is (4) uploadedinto the remote PC and then (5) sent electronicallyback to the SKF Diagnostics Center where it isdisplayed, analyzed and stored in SKF MachineAnalyst software.

(6) Using the @ptitude system, an SKF analystgenerates reports or work order requests which are sent to the customer along with the supportivedata. This information is also posted to a webserver for future reference by the customer. The SKF Diagnostics Center provides the datarepository.

An example of e-maintenance at work

Diagnostics Center

Certified Maintenance Technician

Plant

Data

Routes

Reports

AEO Technology ProductsCondition monitoring for Proactive Reliability Maintenance (PRM)

Portable vibration analysis for predictive maintenance programsThe Microlog® family of vibration analyzers and data collectors incorporate acomprehensive range of features ideal for walk around condition monitoring. Selectedproducts include on-board smart diagnostic wizards, single or two channel capability,color screens and intrinsic safety for industries with hazardous/gaseous environments.All Micrologs are supported by the SKF Machine Analyst Data Management andAnalysis software and seamlessly integrate with the @ptitude® Industrial DecisionSupport system.

Portable systems for Operator Driven Reliability The MARLIN® system automates the machine inspection process and builds atechnology and communications bridge between the operations and maintenancefunctions. MARLIN collects, stores, analyzes and reports on vibration, process andinspection data, providing information needed to take proactive measures to improvemachine and process reliability. The MARLIN family includes a range of rugged PDAsthat operate with Microsoft® Pocket PC, is supported by SKF Machine Analyst Suiteand integrates with the @ptitude system.

Surveillance systems for 24/7 on-line machinery monitoring Continuous monitoring systems alert operations personnel to important changes inmachine condition before they result in unexpected downtime. They also enablevibration analysts to spend less time collecting data and more time identifying the root causes of machine problems. SKF’s surveillance family includes the Multilog®

and MasCon lines – each designed for specific applications and supported by datamanagement and analysis software including SKF Machine Analyst and ProCon. Both integrate with the @ptitude system.

Critical machine protection and diagnosisThe SKF range of API compliant machinery protection systems can be easily extendedto include condition and performance monitoring capabilities. They monitor bothmechanical condition and process variables. Versatile and open, the systems operatesin standalone modes or as parts of a comprehensive network linked to plant-wideinformation systems, and can be integrated with the @ptitude system.

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Accurately interpreting what data means is more effective when the hardware and software used can also analyze, then seamlessly blend it with other systems. As the world’s largest supplier of condition monitoring products, SKF offers everything from simple hand-held devices to plant-wide protection systems.

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Accelerometers, Eddy Probe Systems and accessoriesSKF offers a broad range of high quality industrial sensors, accelerometers, velocitytransducers, eddy probes and mounting accessories to suit a range of applications fromgeneral purpose to those in the harshest environments. SKF’s experience in everyaspect of on-line condition monitoring and machine protection systems means that wehave the expertise to identify and apply the appropriate product for the best result.

Integrated software platformSKF Machine Analyst software manages, manipulates and analyzes machine conditiondata, and forms the core platform in SKF’s family of reliability software applications calledSKF Machine Suite. The software may be customized for maximum efficiency and easeof use. Open architecture enables easy access to data within the Oracle® relationaldatabase as well as easy integration with the SKF @ptitude® system and other plant-widesystems.

Human machine interface softwareThe SKF Machine Analyst/HMI enables an effective and timely response to changes inmachine condition by showing a graphical representation of the machine. Data from theon-line system is displayed “live”, enabling an operator or analyst to identify not only thesymptoms of an alarm condition but the potential cause.

Specialty Applications – Wind turbine monitoringThe SKF WindCon system helps to extend maintenance intervals by continuallymonitoring the operational parameters and the key mechanical components of a windturbine. This allows potential maintenance needs to be identified early and incorporatedin scheduled maintenance stops. As a consequence, the time between maintenanceintervals increases and costly emergency stops can be significantly reduced. Togetherthese benefits result in less downtime, which increases the performance and costefficiency of the turbine.

The products shown here are only samples from the range SKF has to offer. For information about other products, or more information about the ones shown, contact your local SKF representative or go to www.skf.com/reliability.

AEO Technology ProductsReliability tools for mechanical machine maintenance

SKF shaft alignment toolsShaft misalignment in rotating equipment can cause frequent breakdowns. It generatesadditional loads and vibration which can cause premature damage to bearings, sealsand couplings. And, it can significantly increase energy consumption. Shaft alignmenttools from SKF use the latest laser technology to provide a more accurate way ofdetecting and correcting shaft misalignment. The display unit provides ‘live’ values ofthe nature and degree of misalignment, allowing easy and quick correction of shaftmisalignment.

Vibracon® SM elementVibracon is a universal, adjustable steel chock that eliminates the need for rigid steelchocks, shims or epoxy resin chocks. For generators, compressors, turbine and pumpsets, Vibracon chocks eliminate a number of problems common to traditional methodssuch as parallel and angular soft foot and it is not necessary to machine the base frameor foundation. And there are no on-site problems related to arranging or installing shims.When used in combination with laser alignment equipment, alignment time can bereduced by 50 percent.

SKF BeltAlign: belt alignment toolPulley misalignment can result in frequent breakdowns, additional noise and vibration,and higher energy consumption. Therefore, accurate pulley alignment is an essentialelement in reducing maintenance costs. While traditional methods align the face of thepulley, BeltAlign provides fine-tuning of alignment where it counts most: in the groovesof the pulley.

Personal Digital Assistants (PDAs) for vibration monitoringSKF’s most powerful palm-sized vibration meters are made to fit the expansion slot of a standard PDA. The unit collects acceleration, velocity, displacement, HighFrequency Detection (HFD) and enveloped acceleration – then automatically evaluatesresults. It stores overall vibration signals, FFT spectrum and time waveform data for later recall. The PDA easily fits into a shirt pocket and is the perfect starter for beginnersor a spot-check tool for technicians.

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Safe and damage-free machine maintenance is critical when the goal is to optimize running time. The development ofSKF tools and lubricants is based on our own experience in field work, and includes the latest technologies for effectivebearing maintenance and extended productivity.

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Vibration PenPlusThe Vibration PenPlus is a pocket-sized vibration monitoring tool which measuresoverall vibration caused by rotational and structural problems like imbalance,misalignment, and looseness. It can also take enveloped acceleration measurements of vibration in higher frequencies, such as those caused by rolling element bearings orgear mesh problems. The LCD simultaneously displays both overall and envelopedacceleration measurement values, providing useful fault detection data.

SYSTEM 24® automatic lubricatorThe System 24 automatic lubricator delivers greases or oil continuously for up to 12 months. The System Multipoint keeps up to eight lubrication points simultaneouslyand automatically lubricated. Simply use SKF’s DialSet re-lubrication calculationprogram for the correct grease dispense rate. The interactive LubeSelect available onthe @ptitudeXchange website helps you to identify the appropriate lubricant for yourapplication.

SensorMount®

SensorMount is designed to prevent errors when mounting large-size bearings bymeasuring the bearing inner ring expansion during drive-up on a tapered shaft seating.The system includes a bearing with sensor and a hand-held indicator. The signal fromthe sensor is picked up by the indicator, which displays a value representing the internalclearance reduction (mm) divided by the bore diameter (m).

Induction heatersForcing a bearing into place can damage bearings and compromise employee safety. By heating the bearing before mounting, larger bearings can easily be mounted onto a shaft. SKF induction heaters quickly heat bearings to the optimum mountingtemperature, enabling a fast, easy and accurate installation. SKF offers induction heaters for a wide variety of bearings and other components including gears, pulleys,shrink rings, couplings, belt wheels, pistons and sleeves.

The products shown here are only samples from the range SKF has to offer. For information about other products, or more information about the ones shown, contact your local SKF representative or go to www.skf.com/reliability.

AEO Technology ProductsSKF technology inside the machine

CARB® for non-locating bearing arrangements The CARB® bearing from SKF, is a toroidal roller design exclusively for use as a non-locating bearing. In addition to accommodating shaft deflection, CARB bearingsallow axial freedom not possible with traditional locating and non-locating bearingarrangements that use self-aligning bearings in both positions. The CARB bearing findsthe best position to carry the load, no matter how the shaft moves.

SKF Explorer spherical roller bearings provide endurance and performanceAfter years of intensive efforts by an international team of SKF scientists and engineers,Explorer bearings have been reengineered at the micro and molecular levels for superiorlife and performance. Field tests confirm that Explorer bearings last longer in real-worldconditions than any other brand of bearing, including previous generations of SKFbearings. Explorer designs have been introduced for spherical roller, angular contactball, cylindrical roller, taper and spherical roller thrust bearing product lines.

INSOCOAT® electrically insulated bearingsINSOCOAT® bearings are insulated to protect against flashover damage in electricmotors and generators. They are designed with an outer ring coated with a thin layer of aluminum oxide of uniform thickness, which is further treated to make it virtuallyimpervious. The SKF plasma spray coating technique used on INSOCOAT bearingsprovides significantly better adhesion than is possible using other methods. At just 100 microns thick, the INSOCOAT bearing insulation layer can withstand 1 000 volts.

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The world’s largest manufacturer of high quality rolling bearings, SKF is also a leading innovator of new bearingtechnologies. Beyond our line of standard bearing products, SKF has developed new, technologically advanced bearingsdesigned to solve problems related to extreme operating conditions and specialized machine applications.

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Sensorized Rotostat SealSKF has a strong capability in providing customized sealing solutions. A good exampleof this is the sensorized ROTOSTAT® seal design which integrates a speed sensor andPTFE seal in a custom designed metal frame to form a single, integrated assembly for use on the crankshaft of a passenger vehicle. SKF has extensive experience in providingall types of radial shaft seals, as well as a unique capability in bonding elastomerics and metal.

SKF Hybrid Ceramic bearings surpass extreme conditionsThe silicon nitride ceramic balls used in hybrid bearings make them an excellent choicefor applications that require high speed, high stiffness, high temperature, low noise, and intrinsic electrical insulation. The lower density of ceramic material enables higher speeds and more rapid acceleration. A low coefficient of friction enhances wearresistance, so bearings run cooler.

NoWear® bearings for increased lifetime in difficult conditionsNoWear® bearings are made of steel, but the rolling elements are coated with a newtype of diamond-like-carbon which is only a few microns thick. This coating can beapplied to most bearings and other components such as gears and bushings. Steelcoated in this way has all the resilience of steel, plus the hardness and low frictioncoefficient of NoWear bearings. Ideal for demanding environments, NoWear helps toincrease component lifetime, improve machine performance, and reduce risk ofunplanned downtime.

SKF Magnetic bearingsThe SKF line of magnetic bearings is non-contact and lubrication-free, providing cleaner,faster and more efficient performance. They operate at extremely high rotational speeds,unaffected by harsh environments, corrosive fluids, and even cryogenic temperatures.Recent advancements in electronics, software and motion control systems make themsuitable for applications ranging from compressors to machine tools. SKF hasdeveloped magnetic bearing solutions for industries as diverse as petroleum,semiconductor fabrication, HVAC, machine tools and pulp and paper.

The products shown here are only samples from the range SKF has to offer. For information about other products, or more information about the ones shown, contact your local SKF representative or go to www.skf.com/reliability.

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On the following pages are examples of how SKF Reliability Systems has combined its knowledge,services and products to provide solutions to real-lifeapplication conditions. The applications described are onlysamples from the multitude of industries in which SKF isinvolved.

For information about how SKF can help increaseprofitability in your type of business, talk to your SKF representative or visit www.skf.com/reliability.

Real Conditions. Real Solutions.For machine and plant productivity

REAL CONDITIONS. REAL SOLUTIONS.

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Real Conditions. Real Solutions.Integrated solutions for complex data management

In modern process plants, growing demands upon theavailability and reliability of critical rotating machineryhave lead to requirements for more complex machinecondition data in automated monitoring systems.

The machine’s monitoring function must be integratedwith the plant’s control and safety functions. In addition,vital machinery health data must be available for manualor automated analysis over the plant LAN (Local AreaNetwork) and over a corporate WAN (Wide Area Network)for enterprise-wide analysis. A successful examplefollows:

Application:Gas-turbine-driven power generation.

Condition:A series of remote power stations – some 500 km apart– each relied upon aeroderivative gas turbines as theprime mover for the generation plant. The availability ofthe turbines had been adversely affected by compressorsection problems, which manifested themselves asspecific sub-synchronous vibrations.

The existing vibration monitoring system was unable to react to these vibrations in order to provide adequateearly warning for corrective action. A more complexapproach was required, that would be reliable, usableand accessible over a WAN.

Solution:An integrated system combining machinery protection,condition monitoring and transient analysis was installedat each site. The protection hardware was programmedto track and, through voting logic, automatically trip onthe occurrence of the dangerous sub-synchronousvibrations. The condition monitoring system acquiredcomplete FFT data continuously to gather a full scope ofdiagnostic information for analysis by dedicated trending,analysis and data management software. A vital factorwas bandwidth limitations of the WAN for transfer and/oraccess of data from a remote location.

Additional options were expansion of the data into theplant control system by modern open protocol such asOPC, Object Linking and Embedding (OLE) for ProcessControl, and interfacing into a decision support system(@ptitude® from SKF).

Station 2

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SKF Reliability Systems implemented an advanced on-line monitoring system for a critical power generation plant distributed over a remote region. The system supports WAN operations, and provides machinery protectionand continuous condition monitoring – capturing and archiving critical rotating machinery condition parameters,including steady state vibration data and run-up/coast-down transient events, for early warning of mechanicalproblems that could lead to costly machine failure.

REAL CONDITIONS. REAL SOLUTIONS.

Integrated Condition Based Maintenance System

Results:The modern digital monitoring system has provided live information to machineryreliability experts at remote locations in a cost effective and timely manner. Theprotection system provides insuranceagainst the known compressor problems,and the condition monitoring analysissoftware has given early warning of anengine bolt problem, avoiding multi-milliondollar unplanned downtime.

Balance of PlantEquipment

Condition MonitoringSurveillance System

Machine Protection System integrated withCondition Monitoring and Transient Analysis

Gas Turbine Generators

WAN

Ethernet LAN

32 channels

32 channels

32 channels• @ptitude• OPC Data

To/from DCS

Stat

ion

1

Station 2

Display Station

Fire

wal

l

Remote Access

DataAcquisitionTrending &Analysis

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Real Conditions. Real Solutions.Maintenance strategy

Improving reliability does not necessarily mean addingmaintenance tasks. Sometimes the opposite is true. Thekey to optimizing plant operations and assets, therefore, is to develop a strategic plan that increases value-addingactivities and decreases non-value adding activities. Thisis the core of Reliability Centered Maintenance (RCM),which demonstrates that the best overall maintenancestrategy improves reliability while meeting business goals.

With unique expertise in RCM, SKF partners withcompanies to develop a maintenance strategy thatdefines:• the right equipment on which to spend preventive

maintenance dollars• performing the right maintenance tasks at the right time.

With RCM, recommendations are developed in concertwith the business objectives of the organization. Theresults speak for themselves.

HPI installation decreases unplannedmaintenance, saves $2.4 million per year

Application:Inlet gas compressor/engine system at a major refinery

Condition: In the field, gas compressor intercoolers were cleanedinfrequently and poorly, as were engines within the ignitercooling system. In addition, there was no chemicaltreatment or operating parameters established for one ofthe cooling towers. In the inlet gas system, the currentbatch operation caused daily variations. Plus, the currentflows and conditions failed to adequately remove H2S.

Solution:RCM was applied to all processes and utility units. SKFran two studies concurrently. The studies took 24 monthsto complete. Implementation included:• Reducing intrusive-type maintenance tasks• Increasing condition-monitoring tasks• Improving compressor/engine reliability• Reducing lost production time

Results:Savings are conservatively estimated at 5 cents perbarrel of crude oil processed. This equates tosustainable savings of $2,430,000 per year.

Task Type Metrics for Two SystemsWhere Total Task Decreased

After RCM AnalysisRCM OLD

Program Program

Task Type Average Average Average Average

# % # %

Time Directed Intrusive 10 23 39 53

Time Directed Non-Int. 7 15 29 40

Condition Directed 13 29 1 1

Failure Finding 19 33 3 6

Totals 49 100 72 100

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Power utility decreases high priority correctivework by up to 40 %

Application:Twenty-seven operating units at 15 power plants.

Condition:After several years of cost-cutting measures, the utilitywas experiencing reliability and performance problems.There was a clear need to improve performance bydecreasing equipment failure while ensuring properlyfocused maintenance resources.

Solution:RCM was applied to all key systems. SKF studied thesystems over a 30-month period. Implementationincluded: • Development of documentation for the maintenance

program• Focusing planned maintenance on critical equipment

and dominant failure mechanisms• Emphasizing condition-based tasks• Eliminating unnecessary routine and outage tasks• Reducing maintenance costs• Improving availability and reliability

Results:• 30 % reduction in equivalent forced outage rate (EFOR)• 7 % increase in peak period reliability• 30–40 % reduction in high priority corrective work

Petrochemical plant – potential savings of up to $400,000 per year

Application:Pilot program at one of the company’s five chemicalprocessing plants.

Condition: The company was seeking to increase profitability byreducing costs from equipment failures and shutdowns atthe five plants.

Solution:RCM was applied during a five-month period. SKFanalyzed seven processes within the pilot plant.Implementation included:• Utilizing SRCM® software to unify data collection and

analysis• Training team on RCM and software• Verifying equipment IDs and updating process and

instrumentation diagrams• Establishing a methodology to standardize the

company’s maintenance practices from plant to plant

Results:The pilot program demonstrated that each of the fiveplants could achieve estimated sustainable maintenancesavings from $40,000 to $150,000 per year, for apotential company-wide maintenance savings of$400,000 per year.

REAL CONDITIONS. REAL SOLUTIONS.

Real Conditions. Real Solutions.Machine reliability assessment – A fan solution

Industrial fans are an integral part of most plant installations.Often, the very nature of their work creates process bottlenecks.Heat, dust, dirt, gasses and paint are daily environmental factorsthat can cause impeller imbalance and contribute to reliabilityproblems.

Application: Primary dust control fan, cement plant

Condition:Repeated fan failure was shutting down the process every sixmonths. It took maintenance crews six hours to restore the fanback to operation and one hour to restart the process. Revenuelosses were approximately $10,000 an hour, and the problem hadbeen occurring for three years – ever since the new fan wasinstalled. Plant engineers had tried to solve the problem bythemselves, with the help of the fan OEM and three consultantgroups, all with no success.

Solution:An SKF Machine Reliability Assessment was carried out on the fan:■ A complete asset history was developed■ Maintenance technicians, engineers and operators were

interviewed for opinions■ A detailed vibration analysis was performed■ The lubrication system and lubricant type were examined■ The bearing arrangement and L10 design life were reviewed

SKF Reliability Systems then conducted an analysis of the fanbase structure using a vibration analyzer and OperatingDeflection Shape (ODS) Software. It was determined that thestructure was deflecting considerably. This caused the fanpedestal to twist, and the bearings to become misaligned duringoperation. The result was higher than calculated bearing loadsand excessive seal stresses.

SKF strengthened the base structure; changed the bearing setupfrom two spherical roller bearings to a CARB® bearing on thewheel side of the fan and an SKF Explorer spherical rollerbearing on the sheave end; and permanently installed an SKFMachine Condition Transmitter system to alert the plant DCS to higher than normal vibrations. The lubricant type and delivery system were also upgraded.

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It was also determined that periodic dust build-up occurredon the fan blades, causing an imbalance condition in thefan. With the introduction of the low cost SKF MachineCondition Transmitter vibration monitoring, the operatorscould detect the problem as it began to reoccur and takenecessary proactive steps during a convenient shutdownperiod.

Fan life improved dramatically. The fan easily surpassedthe old MTBF (mean time between failure) and ran for threemore years until it was shut down during a major outage,when the bearings were replaced and analyzed as part of a design assessment. All showed normal wear withsignificant residual life remaining.

Results:Approximately $420,000 in production gain and asustainable maintenance cost reduction of $50,000.

Benefit/Cost = more than 20:1

Based on the success of this project, the customer optedfor a complete Proactive Reliability Maintenance (PRM)contract for all plant fans.

Products and Services provided■ Machine Reliability Assessment■ Condition Monitoring■ Lubrication analysis■ Application engineering■ ODS (Operation Deflection Shape) analysis■ Machine Condition Transmitter■ Root Cause Failure Analysis■ Bearing, Seal and Lubricant Technology upgrade

REAL CONDITIONS. REAL SOLUTIONS.

SKFExplorer Bearing

Electric Motor

Fan

VibrationAnalysis

Microlog®

CMXA50

SKFMachine Condition

Transmitter

ImpellerBalancing

Microlog®

CMVA60

SKF Shaft AlignmentTool

PrecisionAlignment

SYSTEM 24® forLubrication

CARB®

Bearing

Real Conditions. Real Solutions.Operator Driven Reliability (ODR)

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In the hydrocarbon processing and chemical industries, centrifugal pumps are a key asset in the plant infrastructure. They are of vital importance to production processes, yet they operate in a harsh environment with demanding duty cycles that can easily lead to reliability problems. Highmaintenance competencies are required to maximize pumpreliability.

Application: Centrifugal pump, Oil Refinery

Condition:The operator of a large refinery, concerned about theeffectiveness of the existing plant maintenance strategy and predictive maintenance program, was interested in improvingthe performance of pump assets in relation to actual pump maintenance and operating costs. SKF Reliability Systems was called in to assess the current strategy and make recommendations for improvement.

Solution:SKF conducted a detailed plant-wide pump audit in conjunctionwith the customer’s mechanical seal supplier. The assessmentexamined all facets of pump performance, maintenance activitiesand component supply logistics, focusing on improvementopportunities that would have the most impact on maximizingasset efficiency.

A key component of the SKF recommendation included therefocusing of critical maintenance activities, including theimplementation of a Proactive Reliability Maintenance(PRM) strategy aimed at eliminating repetitive componentfailures.

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REAL CONDITIONS. REAL SOLUTIONS.

Another major improvement opportunity was to involveoperations personnel as the first line of defense in themaintenance program. The use of the MARLIN® datacollection process was suggested, along with training forplant operators in using the MARLIN to collect strategicprocess and condition information. An ongoingmaintenance skills training program related to bearings andmechanical seals was suggested for all mechanics.SKF also recommended that we join the mechanical seal supplier in a reliability maintenance partnership withthe goal of reducing bearings and mechanical sealsconsumption.

Products and Services provided■ Assessment■ Proactive Reliability Maintenance■ Operator Driven Reliability■ MARLIN and Microlog® data collectors■ SKF Database, analysis and reporting software■ Seal partnership■ Bearing supply

Result:All recommendations were accepted and SKF assistedwith the integration of Proactive Reliability Maintenanceand Operator Driven Reliability into the customers’maintenance practices. This included support of thenecessary cultural changes so that the use of technologyand necessary work process changes would be accepted

Key Performance Indicator Base Year 1st Year 2nd Year

Overall Machinery Maintenance Cost 100 % 66 % 62 %

Centrifugal Pump Maintenance Cost 100 % 83 % 74 %

Pump MTBF years 3.01 3.75 4.18

Mechanical Seal MTBF, years 8.5 11.6 13.9

Mechanical Seal Costs 100 % 69 % 52 %

Real Conditions. Real Solutions.Integrated Maintenance Solution (IMS)

SKF Reliability Systems introduced the Integrated MaintenanceSolution (IMS) concept to show how our range of technologiesand know-how provides the strategic framework and imple-mentation capabilities for processes, systems, practices andtechnology. This performance-based approach to a long term customer relationship allows SKF to apply its core competence so that a customer is free to focus on their true competence.

Application: Paper mill

Condition:Improve plant-wide asset reliability, reduce bearing and lubricant consumption, reduce unplanned downtime and total maintenance costs.

Over 100 hours of unplanned downtime in one year was incentiveenough to prompt the management of a large integrated papermill to recognize the value behind the IMS promise.

Solution:The mill agreed that SKF should first conduct a detailed mill-wideassessment. The result was the identification of a long list ofopportunities to optimize asset effectiveness, reduce theunplanned mechanical downtime and increase overall productivity– and a five year performance-based contract including:

■ Supply and installation of an on- and off-line conditionmonitoring system. Because the cost is spread over five yearsno capital funds were necessary to upgrade to the latesttechnology. This was very important, since it released funds toinvest in urgently needed production equipment.

■ A staff of reliability engineers and maintenance technicians tomanage the condition monitoring and lubrication program andmake the necessary improvements.

■ Specialist diagnostic support from two SKF support centers.■ Application engineering support for mechanical and lubrication

redesign, as needed.■ Support on precision alignment and balancing.■ Training of the customer’s maintenance staff.■ 100 % bearing supply per a declining annual fixed price level.■ Bearing stock management, in partnership with an SKF

Authorized Distributor.

Included in the terms is a guarantee that SKF will pay backpart of the contracted fee if agreed goals are not met along withperformance incentive if they are.

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Result:In one year, the contract generated tangible savings for themill, which gave the customer pay-back on theirinvestment in less than one year. Additional progress inmeeting the Key Performance Indicators led to a contractextension in the middle of the original 5 year contract.

Customer Competitive Advantages:■ Fixed costs on bearing and lubrication products■ Integration of lubrication and vibration programs■ Root Cause Failure Analysis for ALL bearing failures■ Continuous improvement studies in critical areas■ Technology upgrades provided as part of contract■ Ongoing training and skills tracking

Products and Services provided■ Mill-wide Reliability Assessment■ On and off-line Condition Monitoring■ Decision Support System■ Proactive Reliability Maintenance ■ Precision alignment and balancing■ Bearing and Lubrication Supply

REAL CONDITIONS. REAL SOLUTIONS.

Key Performance Indicator Base Year 1st Year 2nd Year 3rd Year

Equipment in Alarm 10 % 7 5 3

Root Cause Failure Analysis – 375 300 160

Bearing & LubricantConsumption 100 % 110 % 82 % 71 %

UnscheduledShutdown, hours 120 47 0.7 0

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SKF Reliability SystemsGlobal service and product/technology centers

Key

Country Headquarters

Product/Technology Centers

Global Headquarters

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© Copyright SKF 2004The contents of this publication are thecopyright of the publisher and may not be reproduced (even extracts) unlesspermission is granted. Every care hasbeen taken to ensure the accuracy ofthe information contained in this publi-cation but no liability can be acceptedfor any loss or damage whether direct,indirect or consequential arising out ofthe use of the information containedherein.

Publication 5160/I E

Printed in Denmark

@ptitude, CARB, INSOCOAT, MARLIN,MICROLOG, MULTILOG, NoWear,SensorMount, SRCM, SYSTEM 24, Vibracon,ROTOSTAT and SKF are registeredtrademarks of the SKF Group.

ENDORSIA.COM is a registered trademark of Endorsia.com International AB.

*Oracle is a registered trademark of Oracle Inc.*Microsoft, Windows and Windows NT areregistered trademarks of Microsoft Corp.