In my years meeting with and advising countless reliability professionals, everyone has a story. Sadly, many of these stories are better described as nightmares.
One case study, that I typically share with reliability folks of all kinds is about an incident that happened right in our back yard near Houston, TX. In this example, there was a pump that had catastrophic failure due to misalignment. This failure rendered the motor totaled and left the inboard bearing of this pump needing to be replaced. Due to an oversight of parts on hand, they were unable to replace this bearing and instead began a mad scramble to find a part supplier to overnight this particular bearing to this company, so they could get this critical piece of equipment back up and running.
Many reliability and maintenance professionals dread this nightmare and want to do everything in their power to avoid these types of incidents that lead to countless hours of downtime. The solution after this company had about 36 hours of downtime and hundreds of thousands of dollars lost, was to get spare parts on hand. This way, when they inevitably suffered from catastrophic incidents—they could get the machinery up and running quicker. They also implemented a program which replaced bearings after so many months of use.
This seemed to work for a few years, four to be exact, before the maintenance manger that put this program into place was moved to a new position in a different facility. The company replaced this manger with an up and coming manager that was much younger and focused on more cost saving measures from an accounting standpoint. One of these measures in the next few years included getting rid of the spare parts and pieces that were kept on the company’s books and cost money to account for each year. This was deemed acceptable, because they hadn’t had a pump go down in years. As a matter of fact, many of the bearings they kept in storage had become fatigued from lack of care and upkeep and even had become infested with cobwebs.
Inevitably, a few years after they had rid themselves of the excess inventory, they had an almost identical failure to the first example that cost them about the same in downtime and repair costs. It was also a huge learning experience for the new maintenance manager for why an entity keeps spare parts on hand.
From the case study, this run to failure measure mixed with the doing away of the preventative maintenance program, ended up costing this company roughly $360,000 dollars in down time and another $30,000 in repairs and labor when you account for both of these incidents together in the 8-year gap they had between the failures. Unfortunately, this is all too common with many of those nightmares that our customers describe.
The quick numbers from those two failures indicates that this run-to-failure maintenance program on this one critical pump ended up costing this company about $48,000 dollars A YEAR when you evaluate the whole process of what they lost with both of these incidents in less that 80 hours of downtime. This could have paid for a new pump in each of those 8 years. So the question we reliability focused professionals must ask ourselves is:
“How do we prevent these massive and frivolous costs?”
That’s where Machine Saver comes in. We are a reliability focused vibration and temperature monitoring company that provides the tools to help you eliminate downtime. With the total Machine Saver solution for this pump and years of data and monitoring, our ROI in this instance would have been just under 2 months.
So how do we do it? We start with the most cost effective 3 axis vibration and temperature sensor in our industry. This sensor is connected and powered through our web portal that provides remote monitoring capabilities, so you and our team of reliability experts have access to trends, time waveforms, and spectral information from anywhere at any time. This dynamic data is also stored in a historian in our Web Portal. Our solution is also automated to send a text message and email to all desired parties every time an alarm limit is breached on the temperature, acceleration or velocity trend. Gone are the days of confused operators resetting a vibration alarm at a control panel. Instead with our system, our experts and yours know exactly where a problem is when vibration increases past an initial alarm limit threshold.
What sets us apart at this juncture, is that we are typically automated to alert local vibration analysts and service companies (for free) to indicate that one of our customers may have a problem on the horizon. The call and expertise are totally free, and our customers do not pay for any services until one of our local reliability partners is on site helping you solve the problem months before it is catastrophic damage. It is like having your own OnStar system for your machines. Like OnStar in GMC/Chevy vehicles, you do not pay for this “road side assistance” until we or our hundreds of local partners do a service for you.
The bottom line is that we make common sense proactive and predictive vibration monitoring a no-brainer from a cost perspective.
Machine Saver is the solution….before the problem.
What makes Machine Saver, Inc. the preferred all-encompassing solution for reliability and maintenance? | Machine Saver – Houston, TX