Terry Haycraft FritoLay RW
So What’s the Need for Predictive Maintenance? Terry L Haycraft National Reliability Manager Frito-Lay Inc Inc. RELIABLE PLANT 2010 ©Frito-Lay, Inc. All Rights Reserved
Because……. -Every .1 of equipment downtime reduction gets tougher to get each year
-Seasoned mechanic retirements: We can’t afford a lengthy “learning curve”” ffor new mechanics h i
-No direct feedback on corrective or PM jobs
-Need a tool to transition from time/usage PMs to condition-based PdM
- The No. 1 reason for premature failure is over-lubrication of equipment ©Frito-Lay, Inc. All Rights Reserved
E i Equipment t Demographic D hi 61% of Plants Were Above 2% Equipment DT
Pulaski 0.89 Orlando 0.88
0 – 1.0%
FF East 1.85 Casa Grande 1.76 Brookhollow 1.74 Topeka 1.58 Kirkwood 1.46 Canton 1.71 FF Core 1.63 Perry 1.06 Fayetteville 1.01 Vancouver 1.63 Lethbridge 1.02 Beloit 1.61 1.1 – 1.5%
1.6 – 1.9%
Arlington 2.59 2 59 Williamsport 2.44 Modesto 2.37 Jonesboro 2.36 Irving 2.32 W Valley 2.12 Killingly 2.05 Lauzon 2.26 Tabor 2.39
2.0 – 2.5%
Charlotte 2.92 Wooster 2.79 York k 22.70 0 Cambridge 2.69 Cucamonga 2.64 Kentville 2.86
2.6 – 2.9%
Equipment q p Down Time
©Frito-Lay, Inc. All Rights Reserved
2005
Lynchburg 33.29 29 Aberdeen 3.23 Rosenberg 3.22 San Antonio 3.08 Kern 3.08
Denver 4.49 DBS 4.25
3.0 – 3.5%
3.6 and over
E i Equipment t Demographic D hi
Kirkwood .85 Perry .91 Pulaski 0.73 Orlando 0.65 Fayetteville .89 Casa Grande .88 88 Modesto .99 Williamsport .65
0 – 1.0%
FF Core 1.17 Topeka 1.47 West Valley 1.20 FF East 1.11 Beloit 1.20 Wooster 1.20 York 1.38 Canton 1.24 DBS 1.25 Denver 1.05 Killingly 1.42 1 42 Brookhollow 1.56 Lauzon 1.33
Lynchburg 1.70 J Jonesboro b 11.84 84 Aberdeen 1.67 San Antonio 1.92 Rosenberg 1.69 Cucamonga 1.96 Cambridge 1.87 Lethbridge 1.61
1.1 – 1.5%
1.6 – 1.9%
80% of Plants Are Currently Below 2% Equipment DT
Vancouver 2.36 Irving 2.46 2 46 Charlotte 2.11 Tabor 2.51
2.0 – 2.5%
Arlington 2.81 Kern 2.84 Kentville 2.73
2.6 – 2.9%
Equipment Down Time
©Frito-Lay, Inc. All Rights Reserved
2010
3.0 – 3.5%
3.6 and over
PREDICTIVE SOLUTIONS SAVE $$
COST T & TIME FO OR REP PAIRS SÆ
$$
$$
©Frito-Lay, Inc. All Rights Reserved
COST OF DOING NOTHING
$ 100xTHOUSANDS Replace machine Major outage Plant damage $ 10xTHOUSANDS
TEMPERATURE
VIBRATION TECHNOLOGY
PARTICULATE MONITORING
STRESS WAVE ENERGY TECHNOLOGY
ULTRASOUND TECHNOLOGY
Turn shafts Replace bearings Replace gears
$ THOUSANDS Align shafts Replace bearings Purge particulates
$ HUNDREDS Change lubricant Pack bearings
“Predictive” Solutions we have Used -Running PMs: Observation based -Third-Party Vibration Analysis: Usually once a quarter -Laser Alignment -Temperature Reading -Electrical Condition Monitoring -Oil and Lube Analysis g -Precision Balancing -Thermography Program Ultrasound: UE 2000 rolled out as RC tactic -Ultrasound: ©Frito-Lay, Inc. All Rights Reserved
What About On-Line Systems? $6,000 per Point vs. Average Downtime Cost of $500 per Hour
©Frito-Lay, Inc. All Rights Reserved
ADVANTAGES OF ULTRASOUND •DIRECTIONAL •LOCATABLE LOCATABLE •MULTIPLE APPLICATIONS FOR OUR SITES •UTILIZABLE IN ALL ENVIRONMENTS •EARLY WARNING FAILURE INDICATION •SUPPORTS SUPPORTS OUR OTHER TECHNOLOGIES •Affordable …
©Frito-Lay, Inc. All Rights Reserved
What is ULTRASOUND? LOW FREQUENCY SOUND WAVES RANGE IN SIZE FROM 3/4” (1.88 CM) TO 56’ (16.9 M) (assuming the average hearing is 16.5 kHz)
HIGH FREQUENCY (ULTRASOUND) SOUND WAVES RANGE IN SIZE FROM 1/8 1/8” (0.34 (0 34 CM) TO 5/8” (1.7 CM) (assuming ultrasound range from 20 kHz-100kHz) kHz 100kHz) ©UE SYSTEMS INC. All Rights Reserved
Ultrasound Technology Ultraprobe 10,000 •Records and analyzes sound samples •Performs Condition Analysis •Stores test data •Trends results •Allows us to review inspection results •Allows us to manage test data collected Mechanical Inspection/Trending •Bearing Condition •Rubbing Conditions •Cavitation •Gears/Gearboxes •Pumps/Motors P /M t •Lack of Lubrication
©UE SYSTEMS INC. All Rights Reserved
Leak Detection/Energy Audits •Compressed Air •Compressed Gases (O2, NO, etc.) •Vacuum Leaks •Seals & Gaskets •Condenser C d T Tubes b •Hatches •Boilers •Heat Exchangers •Valves •Steam Traps
Electrical Inspection •Arcing •Tracking •Corona •Switchgear •Transformers T f •Insulators •Relays •Bus Bars
Ultrasound Technology Ult Ultraprobe b 201 G Grease C Caddy dd •The Ultraprobe 201 Grease Caddy provides visual/audible indication for p controlling grease addition to bearings. •Prevents over-lubrication of bearings. •Audibly A dibl hear when hen grease is being applied. •Multiple mechanics have been trained to successfully operate the caddy caddy. •Extremely helpful in dictating the amount of grease needed to lube bearings. •Will be used as a separate PM in Avantis. •Recognize when to STOP greasing!!
“Over-lubrication is the No. 1 Cause for premature bearing failure!” ©UE SYSTEMS INC. All Rights Reserved
LEVELS OF SEVERITY dB L Levels l over B Baseline li 8 dB LUBRICATION 12 dB MINOR DAMAGEDAMAGE-Microscopic faults 16 dB DAMAGEDAMAGE-Visual faults 35+ dB CATASTROPHIC FAILURE IMMINENT
©UE SYSTEMS INC. All Rights Reserved
DBS Alpha Site: What They Did • Baseline overview of the technology • Purchased / set up the Ultraprobe 10 10,000 000 and software • Purchased Ultraprobe 201 Grease Caddy • Developed routes for all processing lines • Secured Level 1 certification of mechanic • Performed surveys y for mechanical,, electrical & RC • Secured job aids and tools • Routes include 2x month on critical equipment and 1x for others ©Frito-Lay, Inc. All Rights Reserved
Route Development Steps • Walk line and identify equipment and parts to be measured • Input points identified into DMS software • Download route into gun • Walk route and take initial baseline measurements - Running PMs with a purpose
©Frito-Lay, Inc. All Rights Reserved
DBS Routes • Baked Cheetos – Number of points (121) – Time to develop and measure baseline (24 hours) – Time to execute route (1 hr) • Baked Lays – Number of points (319) – Time to develop and measure baseline (36 hrs) – Time to execute route (3 hrs) • Baked Doritos – Number of points (247) – Time to develop and measure baseline (30 hrs) – Time to execute route ((3 hrs)) • Pretzels Line 3 – Number of points (209) – Time to develop and measure baseline (12 hrs) – Time to execute route (1.5 hrs) ©Frito-Lay, Inc. All Rights Reserved
Condition-Based PdM Findings Mechanical Inspection/Trending
©Frito-Lay, Inc. All Rights Reserved
Condition-Based Preventive Inspections Baked Cheetos – Clextral Extruder shaft block bearings – The bearings seals had blown out, leading to under-lubricated condition of these critical bearings – Early detection saved a total of $5,600 in parts and prevented 12 hours of unscheduled downtime
©Frito-Lay, Inc. All Rights Reserved
Condition-Based Preventive Inspections Baked Cheetos – Oven exhaust fan motor – During g periodic route checks, a significant g sound change g was noted. Bearing on the motor was trending toward failure. – The motor was replaced and prevented 1 hour of unscheduled downtime
©Frito-Lay, Inc. All Rights Reserved
Condition-Based Preventive Inspections Baked B k dD Doritos i – Sheeter Back Roll Motor – Ultrasonic measurement indicated the motor bearings were starting to fail – The motor was replaced and prevented 1 hour of unscheduled d downtime ti
©Frito-Lay, Inc. All Rights Reserved
Condition-Based Preventive Inspections Baked B k dL Lays – Sheeter utilizes 10 Reggiani gearboxes – Reggiani gg g gearbox main bearing g is p prone to high g wear and failure – Routine ultrasound inspection is enabling proper lubrication to prevent bearing/gearbox failure – 6 week lead time on replacement gearboxes
©Frito-Lay, Inc. All Rights Reserved
Condition-Based PdM Findings Electrical Inspection
©Frito-Lay, Inc. All Rights Reserved
Condition-Based Preventive Inspections Main Switch Gear – Anomalies were heard during ultrasound lt d inspection i ti – A follow-up thermograph inspection confirmed high heat on 2 outt off 3 phases h – Based upon ultrasonic and thermographic information, the plant was scheduled down to replace the breaker – Continued operation, without the scheduled work, would have likely resulted in a plantwide unscheduled downtime eventt ©Frito-Lay, Inc. All Rights Reserved
Condition-Based Preventive Inspections Main M i Transformer T f – Ultrasound Probe picked up evidence of tracking g – Transformer is 40 feet up on utility pole – Site Sit contacted t t d utility tilit company – Utility company confirmed – They wanted to shut it down – Scheduled shutdown found that the fuse holders had separated and d caused d th the ttracking ki – Downtime avoided estimated at y 2 days ©Frito-Lay, Inc. All Rights Reserved
Condition-Based PdM Findings Leak Detection/Energy Audits
©Frito-Lay, Inc. All Rights Reserved
Resource Conservation • DBS had completed 104 air leak repairs since May 2009 • Most common types of leaks found were fittings and regulators • Tags are tracked using work orders and spreadsheets
©Frito-Lay, Inc. All Rights Reserved
Copyright 2008 by UE Systems Inc. Patent Pending.
June 2009 Air Leaks Repaired
Record NNumber b 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Argon Leaks Repaired
Helium Leaks Repaired
Hydrogen Leaks Repaired
Nitrogen Leaks Repaired
CFM
Cost
CFM
Cost
CFM
Cost
CFM
Cost
CFM
Cost
73.2
$7,592.72
0.0
$0.00
0.0
$0.00
0.0
$0.00
0.0
$0.00
GGroup Name N EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED
EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED
LLocation ti NName Type T off Gas G L3 CYLINDER Air L3 KLN REG Air L3 KLN LINE Air L3 TRK REG Air L3 TRK LINE Air L1 TRK REG Air L1 AIR INLET Air L1 COOKER Air L1 PRF INLET Air
L3 TRK FITTING L3 AIR INLET L3 AIR FITTING L3 FL710 FLTR L3 FL710 REG L3 FL710 REG L3 COOKER L3 PROOF BLT L3 PROOF BLT L1&3 AMBIC
Air Ai Air Air Air Air Air Air Air Air Air
Pressure at L k Leak dB RReading di 75 63 75 63 75 53 75 78 75 85 75 60 75 75 75 49 75 55
75 75 75 75 75 75 75 75 75 75
55 42 33 63 26 38 71 61 58 102
PProblem bl DDescription i ti CYLINDER LEAKING REGULATOR LEAKING COPPER LINE IS LEAKING TRACKING REGULATOR IS LEAKING TRACKING REGULATOR LINE HAS LEAK TRACKING REGULATOR IS LEAKING AIR INLET FITTING IS LEAKING CYLINDER FOR WATER VLV FITTING AIR INLET BY THE COOKER IS LEAKING
Repaired (Y/N) Y Y Y Y Y Y Y Y Y
Work Order Shdl # Schedule 14704 14704 14704 14704 14704 14704 14704 14704 14704
TRACKING FILTER FITTING IS LEAKING AIR INLET FITTING IS LEAKING AIR INLET FITTING IS LEAKING FL710 FILTER FITTING IS LEAKING FL710 REGUALTOR FITTING IS LEAKING FL710 REGUALTOR FITTING IS LEAKING WATER VALVE AIR LINE HAS A HOLE MAC VLV BY THE COOKER IS LEAKING FITTING BY THE COOKER IS LEAKING AMBIC DSC PUMP GAUGE IS BUSTED
Y Y Y Y Y Y Y Y Y Y
14704 14704 14704 14704 14704 14704 14704 14704 14704 14704
CO2
Cost Avoidance Identified
Repaired
$7,592.72 $7,592.72
% complete
100%
NO
SO2
Identified Identified Identified 179368
181
389
CO2 SO2 Identified Energy NO leaks Cost Size of Leak Avoidance Avoidance Avoidance Avoidance A id Avoidance CFM (kWh) (lb ) (lbs) (lb ) (lbs) (lb ) (lbs) $421.57 4.1 7026 9959 10 22 $421.57 4.1 7026 9959 10 22 $325.41 3.1 5424 7687 8 17 $580.49 5.6 9675 13713 14 30 $660.24 6.4 11004 15597 16 34 $391.86 3.8 6531 9257 9 20 $547.37 5.3 9123 12931 13 28 $289.33 2.8 4822 6835 7 15 $343.98 3.3 5733 8126 8 18 $0.00 0.0 N/A N/A N/A N/A $0.00 0.0 N/A N/A N/A N/A $343.98 3.3 5733 8126 8 18 $229 68 $229.68 22 2.2 3828 5426 5 12 $160.05 1.5 2667 3781 4 8 $421.57 4.1 7026 9959 10 22 $111.99 1.1 1866 2646 3 6 $197.70 1.9 3295 4671 5 10 $504.23 4.9 8404 11912 12 26 $401.68 3.9 6695 9489 10 21 $372.46 3.6 6208 8799 9 19 $867.56 8.4 14459 20495 21 44
Condition-Based PdM Findings “Saves” Saves Impact Full Year
Location Baked Cheetos Baked Cheetos Baked Doritos Baked Doritos Baked Lays Main Switch Gear Utilit Pole Utility Pl
Equipment Clextral Block Bearings g Exhaust Fan Motor Sheeter Back Roll Motor Lower Plenum Blower #3 Reggiani Gearboxes Main Circuit Breaker T f Transformer
©Frito-Lay, Inc. All Rights Reserved
Issue Seals blown Bearings Bearings Bearings Bearings Tracking T ki Tracking
DT Hrs 12 1 1 2 1 144 288 449
% DT at % DT 1/2 the Avoidance Impact
2.28%
1.18%
DBS Best Practices “Things we learned along the way”
©Frito-Lay, Inc. All Rights Reserved
DBS Best Practices • N Notebooks/binders b k /bi d with i h pictures i to id identify if routes and d equipment i iin order by name and number. • Every point on a route is labeled to ensure consistency in measurement location.
©Frito-Lay, Inc. All Rights Reserved
DBS Best Practices • Priority listing on what to check and not check on route development • Items that are considered critical: – Motors – Gearboxes – Drive bearings / tail bearings / pinch and tension bearings – Pumps • Items that are less critical: – Plastic housing g bearings g ((hard to hear)) – Idle bearings (can prolong the route) – Bearings that do not make a full rotation
©Frito-Lay, Inc. All Rights Reserved
DBS Next Steps • Optimize scheduling PMs based on ultrasound readings to determine required lubrication and inspection • Condition C diti b based d vs. ti time/usage /
• IIncrease utilization tili ti and d kknowledge l d off sound d signatures i t to recognize impending failures • Continue modifying machine guards to facilitate safe ultrasonic measurements without guard removal removal. • Increase Level 1 certifications ©Frito-Lay, Inc. All Rights Reserved
Observations / Recommendations • Precision-based equipment (i.e. modules, gun) • Training on the UE 10,000 is critical to properly using the equipment. If routes are developed, it should take no more than 2 full days to bring a mechanic up to speed. • Marking inspection points on parts has proved to be difficult as bearings and motors are replaced. • Some equipment may already be near failure and will affect the initial baseline. • Air/gas leak finds will be large at first. • The DBS team recommends moving to 3 beta sites with this technology. ©Frito-Lay, Inc. All Rights Reserved
Beta Site Deliverables • Diligent selection of ultrasound point person • Set up and coordinate 2.5-day implementation • Attendees to include: point person and MX BUL or resource • Headquarters is picking up the cost of the equipment and implementation. Site picks up the labor costs costs. • Insure equipment is secured and well maintained • Development of site-wide game plan for PdM routes • Documentation • Document findings and “saves” • Record changes g in PM set-up p conversion to condition-based PMs • Document before and after reading on equipment rebuilds ©Frito-Lay, Inc. All Rights Reserved
Beta Site Roll-Out Roll Out Success
©Frito-Lay, Inc. All Rights Reserved
Condition-Based Preventive Inspections Muncho Department – Muncho M h P Pellet ll t B Belt lt Drive – Ultrasonic measurement indicated the motor/gearbox was starting to fail – Prevented 1 hour of unscheduled d downtime ti
Condition-Based Preventive Inspections Fritos Main Oil Circulation Pump – Ultrasonic identified bearing failure – Planned motor change for change over – Prevented 4 hours total downtime
©Frito-Lay, Inc. All Rights Reserved
Condition-Based Preventive Inspections UTC Corn C Cook C k Kettle K ttl – Kettle Agitator Gearbox – During periodic route checks, a significant g sound change was noted. – Changed bevel gears during shutdown and saved 6 hours of unscheduled downtime
©Frito-Lay, Inc. All Rights Reserved
Resource Conservation Copyright 2008 by UE Systems Inc. Patent Pending.
©Frito-Lay, Inc. All Rights Reserved
Air
Year to Date
$14,834.14
Month
Identified leaks Cost Avoidance
Repaired Leaks Cost Avoidance
% Comple te
CFM
Cost
Dec-09
$2,684.75
$2,684.75
100%
25.9
$2,684.75
Nov-09
$5,839.94
$5,278.83
90%
50.9
$5,278.83
Oct-09
$6,309.45
$3,444.39
55%
33.2
$3,444.39
$11,407.97
81.5% L k Repaired Leaks R i d
Condition-Based Preventive Inspections PC #2 – R Replaced l d coupling li on submerger motor – $30 pa part, t, p prevented e e ted 8 hours of downtime, a hot rinse and bent paddles.
©Frito-Lay, Inc. All Rights Reserved
–Early detection saved a total of $2,020 in parts and prevented 8 hours of unscheduled downtime.
Condition-Based Preventive Inspections PC #1 – Combustion Blower – Found fan had dirt buildup, causing an imbalance – Cleaned fan and replaced motor
©Frito-Lay, Inc. All Rights Reserved
–Repaired motor for $650, saving $850, and prevented 3 hours of unscheduled d downtime. ti
Potential Reduction of PM / Labor Hours Preventative to Predictive Shift Hrs/pd reduced PM 6.8 5.75 4 7 23.55
4 4 4 4 5 8 8 6 2 0 45
68.55
Change
Running Corn Conveyor PMs Running PC Conveyor PMs FCC Th Thermographic hi PM Warehouse Pickbelt Running PM's Mechanic hours already reduced per period
changed to quarterly from every 6 weeks. 19 entities at 1 hr each changed to quarterly from every 6 weeks. 16 entities at 1 hr each C Cancelled. ll d It was sett up bi biweekly kl ffor 2 hhrs Cancelled. 2 hrs every 8 weeks
PC PC back Allens Running Checklist PC PC middle Allens Running Checklist PC PC front Allens Running Checklist PC 2 Running Checklist PC 1 Running Checklist TC 2 Running Checklist TC 1 Running Checklist FCC running Checklist PC Thermographic PM Kroma Sort routine idle end bearing replacement Possible Mechanic hours reduced per period
Currently Monthly. 4 hrs Currently Monthly. 4 hrs Currently Monthly. 4 hrs Currently Monthly. 4 hrs Currently Monthly. 5 hrs Currently biweekly. 4 hrs Currently biweekly. 4 hrs Currently biweekly. 3 hrs Currently Monthly Monthly. 2 hrs Currently set to trigger every 6 months.
Total Potential Reduction of hours identified
©Frito-Lay, Inc. All Rights Reserved
Questions? Th k You! Thank Y !
©Frito-Lay, Inc. All Rights Reserved
Because……. -Every .1 of equipment downtime reduction gets tougher to get each year
-Seasoned mechanic retirements: We can’t afford a lengthy “learning curve”” ffor new mechanics h i
-No direct feedback on corrective or PM jobs
-Need a tool to transition from time/usage PMs to condition-based PdM
- The No. 1 reason for premature failure is over-lubrication of equipment ©Frito-Lay, Inc. All Rights Reserved
E i Equipment t Demographic D hi 61% of Plants Were Above 2% Equipment DT
Pulaski 0.89 Orlando 0.88
0 – 1.0%
FF East 1.85 Casa Grande 1.76 Brookhollow 1.74 Topeka 1.58 Kirkwood 1.46 Canton 1.71 FF Core 1.63 Perry 1.06 Fayetteville 1.01 Vancouver 1.63 Lethbridge 1.02 Beloit 1.61 1.1 – 1.5%
1.6 – 1.9%
Arlington 2.59 2 59 Williamsport 2.44 Modesto 2.37 Jonesboro 2.36 Irving 2.32 W Valley 2.12 Killingly 2.05 Lauzon 2.26 Tabor 2.39
2.0 – 2.5%
Charlotte 2.92 Wooster 2.79 York k 22.70 0 Cambridge 2.69 Cucamonga 2.64 Kentville 2.86
2.6 – 2.9%
Equipment q p Down Time
©Frito-Lay, Inc. All Rights Reserved
2005
Lynchburg 33.29 29 Aberdeen 3.23 Rosenberg 3.22 San Antonio 3.08 Kern 3.08
Denver 4.49 DBS 4.25
3.0 – 3.5%
3.6 and over
E i Equipment t Demographic D hi
Kirkwood .85 Perry .91 Pulaski 0.73 Orlando 0.65 Fayetteville .89 Casa Grande .88 88 Modesto .99 Williamsport .65
0 – 1.0%
FF Core 1.17 Topeka 1.47 West Valley 1.20 FF East 1.11 Beloit 1.20 Wooster 1.20 York 1.38 Canton 1.24 DBS 1.25 Denver 1.05 Killingly 1.42 1 42 Brookhollow 1.56 Lauzon 1.33
Lynchburg 1.70 J Jonesboro b 11.84 84 Aberdeen 1.67 San Antonio 1.92 Rosenberg 1.69 Cucamonga 1.96 Cambridge 1.87 Lethbridge 1.61
1.1 – 1.5%
1.6 – 1.9%
80% of Plants Are Currently Below 2% Equipment DT
Vancouver 2.36 Irving 2.46 2 46 Charlotte 2.11 Tabor 2.51
2.0 – 2.5%
Arlington 2.81 Kern 2.84 Kentville 2.73
2.6 – 2.9%
Equipment Down Time
©Frito-Lay, Inc. All Rights Reserved
2010
3.0 – 3.5%
3.6 and over
PREDICTIVE SOLUTIONS SAVE $$
COST T & TIME FO OR REP PAIRS SÆ
$$
$$
©Frito-Lay, Inc. All Rights Reserved
COST OF DOING NOTHING
$ 100xTHOUSANDS Replace machine Major outage Plant damage $ 10xTHOUSANDS
TEMPERATURE
VIBRATION TECHNOLOGY
PARTICULATE MONITORING
STRESS WAVE ENERGY TECHNOLOGY
ULTRASOUND TECHNOLOGY
Turn shafts Replace bearings Replace gears
$ THOUSANDS Align shafts Replace bearings Purge particulates
$ HUNDREDS Change lubricant Pack bearings
“Predictive” Solutions we have Used -Running PMs: Observation based -Third-Party Vibration Analysis: Usually once a quarter -Laser Alignment -Temperature Reading -Electrical Condition Monitoring -Oil and Lube Analysis g -Precision Balancing -Thermography Program Ultrasound: UE 2000 rolled out as RC tactic -Ultrasound: ©Frito-Lay, Inc. All Rights Reserved
What About On-Line Systems? $6,000 per Point vs. Average Downtime Cost of $500 per Hour
©Frito-Lay, Inc. All Rights Reserved
ADVANTAGES OF ULTRASOUND •DIRECTIONAL •LOCATABLE LOCATABLE •MULTIPLE APPLICATIONS FOR OUR SITES •UTILIZABLE IN ALL ENVIRONMENTS •EARLY WARNING FAILURE INDICATION •SUPPORTS SUPPORTS OUR OTHER TECHNOLOGIES •Affordable …
©Frito-Lay, Inc. All Rights Reserved
What is ULTRASOUND? LOW FREQUENCY SOUND WAVES RANGE IN SIZE FROM 3/4” (1.88 CM) TO 56’ (16.9 M) (assuming the average hearing is 16.5 kHz)
HIGH FREQUENCY (ULTRASOUND) SOUND WAVES RANGE IN SIZE FROM 1/8 1/8” (0.34 (0 34 CM) TO 5/8” (1.7 CM) (assuming ultrasound range from 20 kHz-100kHz) kHz 100kHz) ©UE SYSTEMS INC. All Rights Reserved
Ultrasound Technology Ultraprobe 10,000 •Records and analyzes sound samples •Performs Condition Analysis •Stores test data •Trends results •Allows us to review inspection results •Allows us to manage test data collected Mechanical Inspection/Trending •Bearing Condition •Rubbing Conditions •Cavitation •Gears/Gearboxes •Pumps/Motors P /M t •Lack of Lubrication
©UE SYSTEMS INC. All Rights Reserved
Leak Detection/Energy Audits •Compressed Air •Compressed Gases (O2, NO, etc.) •Vacuum Leaks •Seals & Gaskets •Condenser C d T Tubes b •Hatches •Boilers •Heat Exchangers •Valves •Steam Traps
Electrical Inspection •Arcing •Tracking •Corona •Switchgear •Transformers T f •Insulators •Relays •Bus Bars
Ultrasound Technology Ult Ultraprobe b 201 G Grease C Caddy dd •The Ultraprobe 201 Grease Caddy provides visual/audible indication for p controlling grease addition to bearings. •Prevents over-lubrication of bearings. •Audibly A dibl hear when hen grease is being applied. •Multiple mechanics have been trained to successfully operate the caddy caddy. •Extremely helpful in dictating the amount of grease needed to lube bearings. •Will be used as a separate PM in Avantis. •Recognize when to STOP greasing!!
“Over-lubrication is the No. 1 Cause for premature bearing failure!” ©UE SYSTEMS INC. All Rights Reserved
LEVELS OF SEVERITY dB L Levels l over B Baseline li 8 dB LUBRICATION 12 dB MINOR DAMAGEDAMAGE-Microscopic faults 16 dB DAMAGEDAMAGE-Visual faults 35+ dB CATASTROPHIC FAILURE IMMINENT
©UE SYSTEMS INC. All Rights Reserved
DBS Alpha Site: What They Did • Baseline overview of the technology • Purchased / set up the Ultraprobe 10 10,000 000 and software • Purchased Ultraprobe 201 Grease Caddy • Developed routes for all processing lines • Secured Level 1 certification of mechanic • Performed surveys y for mechanical,, electrical & RC • Secured job aids and tools • Routes include 2x month on critical equipment and 1x for others ©Frito-Lay, Inc. All Rights Reserved
Route Development Steps • Walk line and identify equipment and parts to be measured • Input points identified into DMS software • Download route into gun • Walk route and take initial baseline measurements - Running PMs with a purpose
©Frito-Lay, Inc. All Rights Reserved
DBS Routes • Baked Cheetos – Number of points (121) – Time to develop and measure baseline (24 hours) – Time to execute route (1 hr) • Baked Lays – Number of points (319) – Time to develop and measure baseline (36 hrs) – Time to execute route (3 hrs) • Baked Doritos – Number of points (247) – Time to develop and measure baseline (30 hrs) – Time to execute route ((3 hrs)) • Pretzels Line 3 – Number of points (209) – Time to develop and measure baseline (12 hrs) – Time to execute route (1.5 hrs) ©Frito-Lay, Inc. All Rights Reserved
Condition-Based PdM Findings Mechanical Inspection/Trending
©Frito-Lay, Inc. All Rights Reserved
Condition-Based Preventive Inspections Baked Cheetos – Clextral Extruder shaft block bearings – The bearings seals had blown out, leading to under-lubricated condition of these critical bearings – Early detection saved a total of $5,600 in parts and prevented 12 hours of unscheduled downtime
©Frito-Lay, Inc. All Rights Reserved
Condition-Based Preventive Inspections Baked Cheetos – Oven exhaust fan motor – During g periodic route checks, a significant g sound change g was noted. Bearing on the motor was trending toward failure. – The motor was replaced and prevented 1 hour of unscheduled downtime
©Frito-Lay, Inc. All Rights Reserved
Condition-Based Preventive Inspections Baked B k dD Doritos i – Sheeter Back Roll Motor – Ultrasonic measurement indicated the motor bearings were starting to fail – The motor was replaced and prevented 1 hour of unscheduled d downtime ti
©Frito-Lay, Inc. All Rights Reserved
Condition-Based Preventive Inspections Baked B k dL Lays – Sheeter utilizes 10 Reggiani gearboxes – Reggiani gg g gearbox main bearing g is p prone to high g wear and failure – Routine ultrasound inspection is enabling proper lubrication to prevent bearing/gearbox failure – 6 week lead time on replacement gearboxes
©Frito-Lay, Inc. All Rights Reserved
Condition-Based PdM Findings Electrical Inspection
©Frito-Lay, Inc. All Rights Reserved
Condition-Based Preventive Inspections Main Switch Gear – Anomalies were heard during ultrasound lt d inspection i ti – A follow-up thermograph inspection confirmed high heat on 2 outt off 3 phases h – Based upon ultrasonic and thermographic information, the plant was scheduled down to replace the breaker – Continued operation, without the scheduled work, would have likely resulted in a plantwide unscheduled downtime eventt ©Frito-Lay, Inc. All Rights Reserved
Condition-Based Preventive Inspections Main M i Transformer T f – Ultrasound Probe picked up evidence of tracking g – Transformer is 40 feet up on utility pole – Site Sit contacted t t d utility tilit company – Utility company confirmed – They wanted to shut it down – Scheduled shutdown found that the fuse holders had separated and d caused d th the ttracking ki – Downtime avoided estimated at y 2 days ©Frito-Lay, Inc. All Rights Reserved
Condition-Based PdM Findings Leak Detection/Energy Audits
©Frito-Lay, Inc. All Rights Reserved
Resource Conservation • DBS had completed 104 air leak repairs since May 2009 • Most common types of leaks found were fittings and regulators • Tags are tracked using work orders and spreadsheets
©Frito-Lay, Inc. All Rights Reserved
Copyright 2008 by UE Systems Inc. Patent Pending.
June 2009 Air Leaks Repaired
Record NNumber b 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Argon Leaks Repaired
Helium Leaks Repaired
Hydrogen Leaks Repaired
Nitrogen Leaks Repaired
CFM
Cost
CFM
Cost
CFM
Cost
CFM
Cost
CFM
Cost
73.2
$7,592.72
0.0
$0.00
0.0
$0.00
0.0
$0.00
0.0
$0.00
GGroup Name N EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED
EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED EXTRUDED
LLocation ti NName Type T off Gas G L3 CYLINDER Air L3 KLN REG Air L3 KLN LINE Air L3 TRK REG Air L3 TRK LINE Air L1 TRK REG Air L1 AIR INLET Air L1 COOKER Air L1 PRF INLET Air
L3 TRK FITTING L3 AIR INLET L3 AIR FITTING L3 FL710 FLTR L3 FL710 REG L3 FL710 REG L3 COOKER L3 PROOF BLT L3 PROOF BLT L1&3 AMBIC
Air Ai Air Air Air Air Air Air Air Air Air
Pressure at L k Leak dB RReading di 75 63 75 63 75 53 75 78 75 85 75 60 75 75 75 49 75 55
75 75 75 75 75 75 75 75 75 75
55 42 33 63 26 38 71 61 58 102
PProblem bl DDescription i ti CYLINDER LEAKING REGULATOR LEAKING COPPER LINE IS LEAKING TRACKING REGULATOR IS LEAKING TRACKING REGULATOR LINE HAS LEAK TRACKING REGULATOR IS LEAKING AIR INLET FITTING IS LEAKING CYLINDER FOR WATER VLV FITTING AIR INLET BY THE COOKER IS LEAKING
Repaired (Y/N) Y Y Y Y Y Y Y Y Y
Work Order Shdl # Schedule 14704 14704 14704 14704 14704 14704 14704 14704 14704
TRACKING FILTER FITTING IS LEAKING AIR INLET FITTING IS LEAKING AIR INLET FITTING IS LEAKING FL710 FILTER FITTING IS LEAKING FL710 REGUALTOR FITTING IS LEAKING FL710 REGUALTOR FITTING IS LEAKING WATER VALVE AIR LINE HAS A HOLE MAC VLV BY THE COOKER IS LEAKING FITTING BY THE COOKER IS LEAKING AMBIC DSC PUMP GAUGE IS BUSTED
Y Y Y Y Y Y Y Y Y Y
14704 14704 14704 14704 14704 14704 14704 14704 14704 14704
CO2
Cost Avoidance Identified
Repaired
$7,592.72 $7,592.72
% complete
100%
NO
SO2
Identified Identified Identified 179368
181
389
CO2 SO2 Identified Energy NO leaks Cost Size of Leak Avoidance Avoidance Avoidance Avoidance A id Avoidance CFM (kWh) (lb ) (lbs) (lb ) (lbs) (lb ) (lbs) $421.57 4.1 7026 9959 10 22 $421.57 4.1 7026 9959 10 22 $325.41 3.1 5424 7687 8 17 $580.49 5.6 9675 13713 14 30 $660.24 6.4 11004 15597 16 34 $391.86 3.8 6531 9257 9 20 $547.37 5.3 9123 12931 13 28 $289.33 2.8 4822 6835 7 15 $343.98 3.3 5733 8126 8 18 $0.00 0.0 N/A N/A N/A N/A $0.00 0.0 N/A N/A N/A N/A $343.98 3.3 5733 8126 8 18 $229 68 $229.68 22 2.2 3828 5426 5 12 $160.05 1.5 2667 3781 4 8 $421.57 4.1 7026 9959 10 22 $111.99 1.1 1866 2646 3 6 $197.70 1.9 3295 4671 5 10 $504.23 4.9 8404 11912 12 26 $401.68 3.9 6695 9489 10 21 $372.46 3.6 6208 8799 9 19 $867.56 8.4 14459 20495 21 44
Condition-Based PdM Findings “Saves” Saves Impact Full Year
Location Baked Cheetos Baked Cheetos Baked Doritos Baked Doritos Baked Lays Main Switch Gear Utilit Pole Utility Pl
Equipment Clextral Block Bearings g Exhaust Fan Motor Sheeter Back Roll Motor Lower Plenum Blower #3 Reggiani Gearboxes Main Circuit Breaker T f Transformer
©Frito-Lay, Inc. All Rights Reserved
Issue Seals blown Bearings Bearings Bearings Bearings Tracking T ki Tracking
DT Hrs 12 1 1 2 1 144 288 449
% DT at % DT 1/2 the Avoidance Impact
2.28%
1.18%
DBS Best Practices “Things we learned along the way”
©Frito-Lay, Inc. All Rights Reserved
DBS Best Practices • N Notebooks/binders b k /bi d with i h pictures i to id identify if routes and d equipment i iin order by name and number. • Every point on a route is labeled to ensure consistency in measurement location.
©Frito-Lay, Inc. All Rights Reserved
DBS Best Practices • Priority listing on what to check and not check on route development • Items that are considered critical: – Motors – Gearboxes – Drive bearings / tail bearings / pinch and tension bearings – Pumps • Items that are less critical: – Plastic housing g bearings g ((hard to hear)) – Idle bearings (can prolong the route) – Bearings that do not make a full rotation
©Frito-Lay, Inc. All Rights Reserved
DBS Next Steps • Optimize scheduling PMs based on ultrasound readings to determine required lubrication and inspection • Condition C diti b based d vs. ti time/usage /
• IIncrease utilization tili ti and d kknowledge l d off sound d signatures i t to recognize impending failures • Continue modifying machine guards to facilitate safe ultrasonic measurements without guard removal removal. • Increase Level 1 certifications ©Frito-Lay, Inc. All Rights Reserved
Observations / Recommendations • Precision-based equipment (i.e. modules, gun) • Training on the UE 10,000 is critical to properly using the equipment. If routes are developed, it should take no more than 2 full days to bring a mechanic up to speed. • Marking inspection points on parts has proved to be difficult as bearings and motors are replaced. • Some equipment may already be near failure and will affect the initial baseline. • Air/gas leak finds will be large at first. • The DBS team recommends moving to 3 beta sites with this technology. ©Frito-Lay, Inc. All Rights Reserved
Beta Site Deliverables • Diligent selection of ultrasound point person • Set up and coordinate 2.5-day implementation • Attendees to include: point person and MX BUL or resource • Headquarters is picking up the cost of the equipment and implementation. Site picks up the labor costs costs. • Insure equipment is secured and well maintained • Development of site-wide game plan for PdM routes • Documentation • Document findings and “saves” • Record changes g in PM set-up p conversion to condition-based PMs • Document before and after reading on equipment rebuilds ©Frito-Lay, Inc. All Rights Reserved
Beta Site Roll-Out Roll Out Success
©Frito-Lay, Inc. All Rights Reserved
Condition-Based Preventive Inspections Muncho Department – Muncho M h P Pellet ll t B Belt lt Drive – Ultrasonic measurement indicated the motor/gearbox was starting to fail – Prevented 1 hour of unscheduled d downtime ti
Condition-Based Preventive Inspections Fritos Main Oil Circulation Pump – Ultrasonic identified bearing failure – Planned motor change for change over – Prevented 4 hours total downtime
©Frito-Lay, Inc. All Rights Reserved
Condition-Based Preventive Inspections UTC Corn C Cook C k Kettle K ttl – Kettle Agitator Gearbox – During periodic route checks, a significant g sound change was noted. – Changed bevel gears during shutdown and saved 6 hours of unscheduled downtime
©Frito-Lay, Inc. All Rights Reserved
Resource Conservation Copyright 2008 by UE Systems Inc. Patent Pending.
©Frito-Lay, Inc. All Rights Reserved
Air
Year to Date
$14,834.14
Month
Identified leaks Cost Avoidance
Repaired Leaks Cost Avoidance
% Comple te
CFM
Cost
Dec-09
$2,684.75
$2,684.75
100%
25.9
$2,684.75
Nov-09
$5,839.94
$5,278.83
90%
50.9
$5,278.83
Oct-09
$6,309.45
$3,444.39
55%
33.2
$3,444.39
$11,407.97
81.5% L k Repaired Leaks R i d
Condition-Based Preventive Inspections PC #2 – R Replaced l d coupling li on submerger motor – $30 pa part, t, p prevented e e ted 8 hours of downtime, a hot rinse and bent paddles.
©Frito-Lay, Inc. All Rights Reserved
–Early detection saved a total of $2,020 in parts and prevented 8 hours of unscheduled downtime.
Condition-Based Preventive Inspections PC #1 – Combustion Blower – Found fan had dirt buildup, causing an imbalance – Cleaned fan and replaced motor
©Frito-Lay, Inc. All Rights Reserved
–Repaired motor for $650, saving $850, and prevented 3 hours of unscheduled d downtime. ti
Potential Reduction of PM / Labor Hours Preventative to Predictive Shift Hrs/pd reduced PM 6.8 5.75 4 7 23.55
4 4 4 4 5 8 8 6 2 0 45
68.55
Change
Running Corn Conveyor PMs Running PC Conveyor PMs FCC Th Thermographic hi PM Warehouse Pickbelt Running PM's Mechanic hours already reduced per period
changed to quarterly from every 6 weeks. 19 entities at 1 hr each changed to quarterly from every 6 weeks. 16 entities at 1 hr each C Cancelled. ll d It was sett up bi biweekly kl ffor 2 hhrs Cancelled. 2 hrs every 8 weeks
PC PC back Allens Running Checklist PC PC middle Allens Running Checklist PC PC front Allens Running Checklist PC 2 Running Checklist PC 1 Running Checklist TC 2 Running Checklist TC 1 Running Checklist FCC running Checklist PC Thermographic PM Kroma Sort routine idle end bearing replacement Possible Mechanic hours reduced per period
Currently Monthly. 4 hrs Currently Monthly. 4 hrs Currently Monthly. 4 hrs Currently Monthly. 4 hrs Currently Monthly. 5 hrs Currently biweekly. 4 hrs Currently biweekly. 4 hrs Currently biweekly. 3 hrs Currently Monthly Monthly. 2 hrs Currently set to trigger every 6 months.
Total Potential Reduction of hours identified
©Frito-Lay, Inc. All Rights Reserved
Questions? Th k You! Thank Y !
©Frito-Lay, Inc. All Rights Reserved
