by Ed Sullivan

To some industrial managers, maintenance is a necessary evil, a secondary activity that detracts from production and depletes capital. Paradoxically, that viewpoint has caused many companies to paint themselves into a corner, causing emergency downtime that is both exorbitant and avoidable.

"In many business sectors, maintenance is synonymous with pain," says Dan Schreiner of the North Central Group (Prince George, BC). His company performs both maintenance contracting and consulting services. "And they're right, equipment outages and forced downtime is painful, mostly because it is expensive and impacts production."

Schreiner knows that the pain can turn into downright resentment when companies end up paying maintenance contractors hefty overtime charges compounded by the cost of production losses for emergency services and equipment replacement that may very well have been avoidable.

"To a great extent, maintenance is not a 'core' value of a company's business philosophy," Schreiner adds. "Many maintenance-related decisions are long-term. And the reason that so many industrial operations are struggling with maintenance issues and forced downtime is not because of decisions they made last week or last quarter. It's because of decisions they made three-to-five years ago."

In both Schreiner's and his partner, Peter Dawley's experience, performing maintenance in the "fire fighting" mode is a primary reason for emergency shutdowns and the exorbitant repair of untimely replacement of equipment.

"Those who consider maintenance as an ancillary business function are headed for those problems," Dawley explains. "a well-planned, ongoing maintenance program should be a core business activity, just like production or sales."

On the IDCON website, Maintenance and Reliability guru Christer Idhammar asks, "Why would maintenance not be a core business, while operations and manufacturing are considered core businesses?" Idhammar adds that a maintenance contract should be long term - no less than five years and preferably longer than that.

According to North Central, those who consider maintenance a core business activity can only minimize emergencies and accidents, but also use planned shutdowns and maintenance providers to improve operations. They may even increase capacity by optimizing processes and integrating more efficient systems.

"In some respects this is going against the grain," he says. "Most maintenance contractors prefer emergency work because it is highly profitable and they can specialize in a certain set skill set. But, from the customers point of view, this is all pain and no gain."

One such example is Vancouver, BC-based Canfor Corporation the integrated forest products company with interests in over 33 facilities in the U.S.A. and Canada. In recent years Canfor undertook a maintenance cost reduction initiative whereby maintenance work was reviewed by facility engineers as well as contractors who met newly instituted Best Practices guidelines for repairing or replacing equipment.

Rod Duncan, Shutdown Manager at Canfor's Intercontinental Pulp and Prince George Pulp & Paper facilities, says that although his plants use contractors for maintenance, the company's policy stresses ownership of the work entailed. "That is helping us to reduce the amount of maintenance work we do on shutdowns, which has proven to be the key to saving over 20% on maintenance costs per year," he says.

Duncan uses his relationship with North Central Group as an example. "They have a lot of capabilities under one roof. Plus, a lot of North Central's managers come from our industry, and their experience makes them even more valuable to our (internal) maintenance group."

Schreiner says that pro-active maintenance programs such as Canfor's are strategic and can be made a core business activity in many industries. In fact, Schreiner and Dawley purchased and redesigned North Central Machine Works for that purpose. Now known as North Central Group, the company provides fully integrated emergency and scheduled maintenance services along with consulting services to pulp and paper plants, mining and other industrial operations throughout British Columbia and Alberta. Having direct experience inside various industrial operations, the vision of North Central was to provide more pro-active and comprehensive maintenance services to customers. This experience includes industrial facilities where processes are especially diverse and complex.

"We consider these relationships to be 'strategic' because they are integral to business operations and involve a long-term plan," Schreiner explains. "Because Peter and I have considerable experience with processes as well as maintenance service, and we often see equipment failures that could have been avoided or processes that could be improved through timely maintenance or improved system integration."

Schreiner believes the ability to offer strategic maintenance relationships is fraught with challenges, but the firms offering integrated services such as his can add much value to maintenance programs.

Christer Idhammar advises that when outsourcing maintenance, you need to set up a contract that includes an incentive for the contractor to continuously perform better. "If your contract is based on buying service alone, there is no real incentive for the contractor to perform better," he says. "The more hours they sell, the more money they make, and they can sell more hours if your maintenance needs are reactive. Only the fear of losing the contract will motivate the contractor to perform better."

Idhammar adds, "If your contract is based on delivering results, you can create a win-win situation for yourself and the contractor. In most mills, results should be in the following order of priority and safety and environmental issues:

1. Reliability of equipment.

2. Cost of delivering reliability

If there is an incentive for a contractor to deliver reliability, it naturally follows an incentive to prevent maintenance and to perform preventive maintenance, plan maintenance, schedule maintenance, and so forth. In summary, they need a disciplined process in place and a good system to support it."

If strategic maintenance programs are such a good idea, why is it that so many companies are not doing it? "For one thing, many companies are reluctant to take on 'relationships' with outside companies," says Patrick Francis, a longtime manager and consultant in the building infrastructure industry. "They may not really trust the contractors they now use for emergencies. But if they do their homework and establish the strategic maintenance program as a mission, they can get it done right."

North Central Group, Ltd.

Easy Laser D90BTA shows the parallel and angular misalignment between the sheaves. The tool is attached in seconds and you can easily see the laser line projected on the targets. When the beam disappears in the slots of the targets, the machine is in the right position. The result is a fast precise alignment. The tool is suitable for both horizontal and vertical mounted machines. Alignments can be made by one operator. This instrument is expandable. To move up to digital just add a detector unit. Also available for intrinsically safe applications.

Alaron Instruments

EVR Clean Air Solvent is a high strength solvent for removing grease, oil and dirt from metal parts and equipment. It has a low Volatile Organic Compound (VOC) content. It has no ozone depleting compounds and is not a hazardous air pollutant.

LPS Laboratories

The EZTherm 880 series of infrared cameras features outstanding image quality, accurate temperature measurement (+/­2°C or 2% accuracy), quality construction and a wide range of accessories. The EZTherm 880 is very easy to use and features motorized focus for real one hand operation. The camera also features a five hour battery, removable image storage card, optional lenses and an optional protective lens shield for dirty environments.

Electrophysics

The North-Gen disposable overalls feature ventilated gussets. There are three models: North-Gen Air made from a white, soft polyethylene, bonded to a non-woven polypropylene that offers resistance to dust and minor chemical splashes. North-Gen Pro is made from a blue, non-woven breathable, multi-layer polypropylene, also for dust and chemicals. North-Gen FR is made from a green, non-woven, breathable multi-layer polypropylene with a flame retardant treatment for arc flash risks and fire fighting.

North Safety Products

For bearings and metal parts exposed directly to humid or corrosive environments, the SQ171 coating solution provides simple and effective protection against corrosion. The coating can be used for all parts exposed to corrosive environments and provides reliable protection against water condensation, weak alkaline and weak acidic cleaning agents. The new coating technology is Cr(V1) free and is compliant with RoHS Directive. Typical applications include mate rials handling, food processing and agricultural machinery.

Global Bear Inc.

The Nilfisk GD 10 Back vacuum is designed with comfort and ease-of-use in mind. It features a lightweight, ergonomic design to reduce fatigue and low noise level for operator comfort and cleaning in noise-sensitive areas. An upstream HEPA-filter allows for safe collection of hazardous materials, trapping 99.99% of particles, down to and including 0.3 microns. It is equipped with a sack-style main filter that will prolong the life of both the HEPA-filter and motor. Exhaust air is directed upward so that it does not interfere with the operator.

Nilfisk CFM

Double barrel syringes consist of a manual plunger, a dual cylinder syringe and a static mixer. The separated cylinders of the double syringe prevent diffusion of the two components. The system provides precise mixing and dispensing for those applications that require nominal amounts of adhesive. Syringes are also available in black, which is optimal for light sensitive materials. Syringes are available in 2.5, 5 and 10mL capacities and offered in 1:1, 4:1 and 10:1 ratios.

Sulzer Mixpac

Flexco has introduced a Chevron Belt Cleaner featuring a new approach and design for cleaning chevron, cleated and raised rib belts. The Eliminator® Chevron Belt Cleaner is ideally suited for wet sand belts, wood chip belts and other raised top or grooved belts. Key to the unit's long operating life and abrasion resistance is a 63mm ring featuring hundreds of 50mm fingers that dislodge carryback from the belt, allowing it to fall with no danger of abrasive wear or damage to the belt. The self-cleaning fingers are molded from SBR rubber and securely nested to the ring, which is stretched to fit snugly onto the drum. The design provides rotary cleaning action for trouble-free cleaner operation with minimal maintenance. The belt cleaner cleans mechanically spliced or vulcanized belts. It is compatible with belts operating at speeds up to 500fpm and works in temperatures ranging from ­35°C to 82°C.

Flexco

Oil Eater's eco-friendly line of absorbent pads is made of natural plant by-products and features woven construction. The line includes Oily Only Pads and Rolls which soak up oil yet repel water; Universal Pads and Rolls which soak up oil, water and other products and Absorbent Socks which control larger spills and protect drains. All are available in a variety of weights and finishes. Applications include production lines, industrial floors, loading docks and paint shop floors.

Kafko International Ltd.

Piston Kleen cleans carbon build-up off engine parts. Biodegradable, it is safe to use on aluminum, steel, iron and most other metals. The new formula penetrates deeper to pull carbon out of the pores of the metal. You can simply soak the parts or for quicker results, Piston Kleen can be heated up to 130° and agitated in an ultrasonic parts washer.

Orison Marketing

Garlock's leak-free, no-dilution sealing system for slurry pumps reduces water consumption. A rotary shaft sealing system, HYDRA-JUST™ forms a bearing relationship with the surface of the shaft in the seal chamber, preventing process media from migrating into the stuffing box. HYDRA-JUST™ can withstand temperatures up to 260°C, pH range of 0-14, stuffing box pressures up to 500 psi and shaft speeds of 4,000-plus fpm.

Garlock Sealing Technologies

The InterTech Multi-Channel M1075-94X Pressure Change Leak Detector features up to four independent test circuits each with separate pressure transducers. Six models are offered for either two or four-channel testing at high, low or standard pressure. All models feature a transducer repeatability of 0.05% F.S.D., 0.01 second timer increments and a low internal volume. Up to 1000 test records can be stored and analyzed for mean standard deviation or +/­3 standard deviation. An easy-to-use touch panel displays all phases of test status, indicating reasons for rejects. The unit can either be used as a stand-alone instrument or integrated with a PLC or PC.

InterTech Development Company

The Series SLD Single Channel Leak Detection Relay is used to monitor the shaft seal of a submersible pump to detect a leak before pump failure. A leak is detected by sensing the status of a float or conductivity switch installed in the seal cavity. When this resistance drops below the set sensitivity, the output relay energizes and the LED indicator illuminates. The SLD offers normally open and normally closed relay contacts to energize an alarm and de-energize the pump in the event of a leak. When the seal failure condition clears, the relay automatically resets. Installation is made simple with the standard 11-pin socket mount.

Dwyer Instruments, Inc.

The KleenGuard A30 Breathable Splash and Particle Protection Stretch Coverall combines comfort and dry particulate protection with a stylish new design that features stretch panels under arms and across the back. It offers increased range of motion, quality protection and fit. The iFlex stretch technology builds in freedom of movement and enables the coveralls to move and stretch with the wearer. Key features include: a new elastic front to complement the existing elastic-back design and a greater range of sizing options -- from medium to XXXXL -- to fit men and women, as well as a wide range of body types.

Kimberly-Clark Professional

The Master Coalescer Jr.™ removes tramp oils and provides clean, reusable coolant. Removing the tramp oil from the coolant removes a food source for bacteria, reduces undesirable residues on machine tools and work pieces, and reduces smoke and oil mist in shop. The unit is designed for use with water-miscible coolants and parts washing fluids that "reject" tramp oils (chemical emulsion or chemical solution types). The Master Coalescer Jr.'s compact design works with CNC machines with small, hard-to-access coolant sumps and requires minimum maintenance.

Master Chemical Corporation

The NCG8450A-3 rotating water jet lance has a UHP seal that lasts an average of 40 hours. The field-repairable lance delivers UHP water (up to 40,000 psi) with a rotating action, widening the spray pattern and making product removal more productive. Its rotation speed is variable up to 3,000 rpm and is provided by a reliable, air-driven swivel. The ergonomic lance enhances operator protection in several ways, including dual-trigger operation and instant pressure dump. It comes with a 36" barrel; another model, the NCG 8450 LA-3, has a 48" barrel. Operation of an NLB rotating lance requires an NLB 8488 Bi-Mode™ valve and a hose assembly.

NLB Corp.

IDEAL-Wipes multi-purpose towels are packaged in a re-closable moisture-retaining dispenser. These extra-large disposable wipes do not require water to activate their powerful cleaning solution. The towels clean tools of deeply embedded dirt, grease, grime or lube, yet are safe to use on hands. Infused with Vitamin E and natural moisturizers, the wipes prevent skin from chapping, cracking or drying. The orange-scented wipes will not leave an unpleasant solvent odour on the skin. IDEAL-Wipes have two unique sides: a non-scratching, textured side for scrubbing tools and hands, and a smooth wiping side for delicate surfaces. Heavy-duty fabric assures no tearing or shredding.

Ideal Industries, Inc.

The GPA-200 Graffiti Proofer® Anti-Stick coating is a highly durable, fluoro coating with chemical resistance and slip coefficient. It can be sprayed, brushed or rolled on and dries in a few short hours.

SEI Chemical

The ThermoVision A325 infrared camera for machine vision applications is designed to be compatible with GigE Vision and supporting the GenlCam protocol for easy integration with digital cameras and third-party software as part of Machine Vision monitoring. The A325 allows for easy integration of an infrared camera with the machine vision system architecture to detect thermal irregularities, assess problems and potential equipment failure in real-time. The A325 features image flow control that allows an external signal to control the image streaming, digital I/O for triggering and synchronization with external equipment, infrared monitor software to run up to 9 cameras simultaneously, a built-in 25 degree lens with both motorized and auto focus, and high sensitivity for sharp images and excellent image quality.

FLIR Systems, Inc.

The Splindle Alignment Tool for lathes, turning equipment, spindles and related machinery is easy to use and versatile. Applications include aligning lathes and turning centres, adjusting boring mills, aligning drive shafts, adjusting bar feeders, and many other industrial applications. The new Microgage system provides information on runout, centerline offset, parallelism, concentricity and other useful parameters that can guide machinery back to optimal align ment. This lathe & spindle alignment system is simple and quick to use with a round laser that is secured into a chuck or attached to the end of a shaft or spindle.

Pinpoint Laser Systems

New feature options are available for the Sidewinder™ Tube Skimmer. They include: mounting brackets -- magnetic tank mount or discharge pail mount types; integrated timer; on/off switch and motor configurations with fuse protection.

Zebra Skimmers Corporation

Canadian Industrial Equipment News September 2008

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