|Plant Maintenance Resource Center
M-News Edition 42
Edition 42, January 2004
In this edition...
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Operations, Maintenance and Reliability Consulting from highly experienced consultants. Specialising in Maintenance and Reliability Audits/Reviews, Operations and Maintenance Improvement Planning, PM Optimisation, Stores and Procurement Improvement, Outsourcing and Contractor Management.
How does one "fix a machine so it doesn't break down again"? Answer: To prevent downtime from happening before it occurs, you must eliminate the basic stresses that cause the downtime. What is needed is a methodology for protecting computers, automation controllers, PLCs, CNC machines, etc. and protect their electronic and hydraulic control systems from the stresses that cause malfunctions and failures. Howard C. Cooper of Amemco has been applying this methodology and perfecting it since 1977. He calls it "Lean MaintenanceT for Lean Manufacturing." You will find his article at http://www.plant-maintenance.com/articles/lean_maintenance_for_lean_manufacturing.pdf. Note that you will require the free Adobe Acrobat reader to be able to view this file.
A CMMS worth its salt should treat Warranty & Policy Claims Receivable as just that, monies owed to your organization.
The system should provide conventions for recording Warranty & Policy Claims directly from a maintenance work order to Warranty & Policy Claims Receivable, and/or generating a debit memo to Accounts Payable, to the vendor's account. Read this article from Mark Goldstein at
Feature Article - Discoveries during Development of the next generation Ultrahigh Pressure Water Jetting Machines
This article argues that surface preparation before repainting will be much more effective in the future with the adjusted ultrahigh pressure water jetting method. In the past, water jetting equipment has been far too large and of course several times too expensive. New generation water jetting equipment may well will oust sand blasting and similar techniques because of their problems with dust, sand disposal etc. Read the article (contributed by Tron-Halvard Fladby of Speeder AS) at http://www.plant-maintenance.com/articles/high_pressure_cleaning.shtml.
Another vibration analysis case study contributed by Madhusudan.N This time, diagnosis is made of a Hydraulic Motor Test Bench, which is experiencing high levels of vibration. The case study can be read at http://www.plant-maintenance.com/articles/motor_test_bench_vibration.pdf. Yet again, note that you will require the free Adobe Acrobat reader to be able to view this file.
It's that time of year again - time for the 5th annual Plant Maintenance Resource Center maintenance salary survey. Find out how your salary compares with others in your country and your industry. Please visit http://www.plant-maintenance.com/survey.shtml to participate. It will only take 3 to 5 minutes of your time, and online live results will be displayed following submission of the form. The survey opened on January 15, and will remain open until March 15, 2004. Let all your colleagues and friends know so that they can participate also.
We have updated the Plant Maintenance Resource Center's Conferences and Events page with all the Maintenance-related conferences, training courses and events that we know about for 2004. Listing almost 300 events in places as far afield as the USA, Dubai, Chile, Australia, Venezuala, South Africa, the United Kingdom and more - could this be the most comprehensive list of Maintenance events on the web? Check it out for yourself at http://www.plant-maintenance.com/maintenance_conferences.shtml
In this sourcebook, Japanese consultant Hiroyuki Hirano describes the 5S's of Total Productive Maintenance: in Japanese they are seiri, seiton, seiso, seiketsu, and shitsuke (which translate as organization, orderliness, cleanliness, standardized cleanup, and discipline). Hirano discusses how the 5S's may be used as a rationalization process in all areas of the company, from the plant floor to the sales office. This book includes numerous examples, forms and checklists which many will find valuable.
To read our full review, visit http://www.plant-maintenance.com/books/1563270471.shtml
Here are ten Maintenance-related books that we have reviewed recently, and strongly recommend:
Get more information on these and other books at http://www.plant-maintenance.com/maintenance_books.shtml.
"Squawks" are problem listings that pilots generally leave for maintenance crews to fix before the next flight. Here are some "actual" squawks submitted by US Air Force pilots and the replies from the maintenance crews.
P. Left inside main tyre almost needs replacement
P. Test flight OK, except autoland very rough
P. #2 Propeller seeping prop fluid
P. Something loose in cockpit
P. The autopilot doesn't.
P. Evidence of leak on right main landing gear
P. DME volume unbelievably loud
P. Dead bugs on windshield
P. Autopilot in altitude hold mode produces a 200 fpm descent
P. IFF inoperative
P. Friction locks cause throttle levers to stick
P. Number three engine missing
P. Aircraft handles funny
P. Target Radar hums
P: Mouse in cockpit.
P. Suspected crack in windscreen.
P: Noise coming from under instrument panel. Sounds like a midget pounding on something with a hammer.
I hope you have enjoyed this newsletter. All feedback, comments and contributions to future editions are very welcome (as are enquiries about contributions to, and sponsorship of, this newsletter).
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