Documente Academic
Documente Profesional
Documente Cultură
2016
MFC Netform
Shelby Township, Mich.
NEW!
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Cylinders
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All prices are U.S. published prices. Many other part numbers are available from all vendors. AutomationDirect prices as of 4/27/2016. Norgren prices are from
www.mscdirect.com 4/18/2016. McMaster-Carr prices are from www.mcmaster.com 4/18/2016. Prices subject to change without notice.
1-800-633-0405
input #1 at www.plantengineering.com/information
success story
Clean Sweep!
Air system study yields multiple benefits to bottom line
Problem:
An aerospace parts manufacturer was experiencing high maintenance
costs as well as excessive downtime with their compressed air system.
Their modulation control compressor caused unnecessary energy usage
on the weekends and off peak times, resulting in exceptionally high
energy costs. Additionally, problems with air quality led to product rejects
and costly scrap rates.
Solution:
A comprehensive Air Demand Analysis was conducted to understand
the plants fluctuating demand. It revealed that the 200 hp modulating
control compressor was grossly oversized. With proper controls and
additional storage, two 50 hp compressors could efficiently handle the
demand and save 871,500 kWh per year. A third 50 hp unit was added
to ensure uptime and accommodate growth.
kaeser.com
Result:
These sweeping changes created immediate and sustainable energy
savings. The combination of more storage, more efficient compressors
and master controls drove system specific power consumption down
77%and that doesnt include the savings from leak reduction. As a direct
result of the new air treatment equipment, the plant also saw improved
product quality and reduced maintenance on the expensive production
equipment that may surpass energy in terms of bottom line benefits.
Specific Power of Previous System:
$107,431/year
$ 87,151/year
$ 12,500/year
Utility Rebate:
$ 92,000
$191,651
Let us help you measure and manage your compressed air costs!
COMPRESSORS
input #2 at www.plantengineering.com/information
customer.us@kaeser.com
Join forces
wITH THE FUTURE OF
GLOBAL MANUFACTURING
We Deliver Results in Productivity.
input #3 at www.plantengineering.com/information
December 2016
Volume 70, No.10
2 0 16
Top Plant
2016
MFC Netform
Shelby Township, Mich.
PLANT ENGINEERING (ISSN 0032-082X, Vol. 70, No. 10, GST #123397457) is published 10x per year, monthly except in January and July, by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523.
Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. PLANT ENGINEERING copyright 2016 by CFE Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media, LLC used
under license. Periodicals postage paid at Oak Brook, IL 60523 and additional mailing offices. Circulation records are maintained at CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. E-mail: customerservice@
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addresses to: 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Email: customerservice@cfemedia.com. Rates for nonqualified subscriptions, including all issues: USA, $145/yr; Canada, $180/yr (includes 7% GST,
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to PLANT ENGINEERING, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523. Printed in the USA. CFE Media, LLC does not assume and hereby disclaims any liability to any person for any loss or damage
caused by errors or omissions in the material contained herein, regardless of whether such errors result from negligence, accident or any other cause whatsoever.
www.plantengineering.com
PLANT ENGINEERING
December 2016 3
Maximize
Manufacturing
Growth
Manufacturers are under constant pressure to meet demanding timelines with little
margin for error. Epicor solutions help you uncover potential production obstacles
as well as new growth opportunitiesso you always know how your business
stacks up.
input #4 at www.plantengineering.com/information
Copyright 2016 Epicor Software Corporation. All rights reserved. Epicor, the Epicor logo, and Grow Business, Not Software are trademarks
of Epicor Software Corporation in the United States and certain other countries.
21
40
36
2016 Best Practices
29 Building on manufacturings progress
Manufacturing is focused on continuous improvement. While we may not be able to
see what that improvement might look like in five years, we can look back at where we
began and where we are to see that progress is being made every day. This years collection of best practices builds on that progress.
30
Global manufacturing
32
VFD efficiency
35
Electrical testing
36
39
43
Air casters
45
Performance reviews
46
48
Digital plant
Whats Inside:
6
8
18
49
56
InSight
IN Focus
Research
Innovations
IN Conclusion
www.plantengineering.com
PLANT ENGINEERING
December 2016 5
INSIGHT
In search of excellence
6 December 2016
PLANT ENGINEERING
PlantEngineering.com
1111 W. 22nd St. Suite 250, Oak Brook, IL 60523
Ph. 630-571-4070, Fax 630-214-4504
CONTENT SPECIALISTS/EDITORIAL
BOB VAVRA, Content Manager
630-571-4070 x2212, BVavra@CFEMedia.com
EMILY GUENTHER, Associate Content Manager
630-571-4070 x2220, EGuenther@CFEMedia.com
AMANDA PELLICCIONE, Director of Research
631-320-0655, APelliccione@CFEMedia.com
CHRIS VAVRA, Production Editor
630-571-4070 x2219, CVavra@CFEMedia.com
Bob Vavra
Content Manager
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IN FOCUS
Larry Turner
input #6 at www.plantengineering.com/information
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Mark Watson: Suppliers are commenting that 2016 has been a difficult
year; sales have been down by between
6% and 10%. The 2017 outlook is for
flat sales. If there is any growth, it will
be limited.
The overall sentiment is that were
at the bottom (or very close to it); the
only way for the market to go is up, but
were unlikely to see much evidence
until 2018 at the earliest.
With the U.S. election, its a wait
and see attitude. Its a bit too soon
to know what the impact will be and
if the Trump Administration will go
through with rhetoric [that] Brexit will
have no real impact on the EU market next year; the U.K is not seen as
important enough to make a big difference to overall regional performance.
There are potentially some negative tax
implications for U.K. manufacturers.
If the U.S. and Brexit decisions are
impacting at all right now, its with
smaller companies. Larger players
look confident enough to continue
with planned investments; smaller companies seem more nervous
about the implications of
the changes in the U.K.,
and U.S. investments may
be postponed.
www.centuryspring.com
(800) 237-5225
input #8 at www.plantengineering.com/information
10 December 2016
plant engineering
IEEE 1683-2014, IEEE Guide for Motor Control Centers Rated up to and including 600 V ac or 1000 V
dc with Recommendations Intended to Help Reduce
Electrical Hazards
IEEE P1814 (under development), Recommended
Practice for Electrical System Design Techniques to
Improve Electrical Safety.
These and other standards are bringing awareness and
action to enable standards developers, manufacturers,
designers and end users to
adopt more robust and comprehensive application of risk
assessment methodologies to
further reduce risk of electrical
injuries and fatalities.
Reliability
Gerald Gerry Bauer
is everything
Sullair.com/GerrysStory
It is a world of
not
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It doesnt quit.
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In fact, it doesnt think of anything but the job at hand.
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2016 Sullair, LLC. All rights reserved.
plant engineering
December 2016 11
input #9 at www.plantengineering.com/information
IN fOCUS
Cyber threats need
a fresh approach
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input #11 at www.plantengineering.com/information
Converged resilience
12 December 2016
plant engineering
security. That is what he called con- does not have the stopping capability it tiple components took place.
verged resilience.
had 10 years ago. The same is true of fireIn that incident, Langill said, attackers
It is about physical security. If you are walls. Yes, there are some good ones out were able to login via remote connecnot physically secure, then you may not there, but they can be averted. The way tions and disconnect breakers along with
be cyber secure, he said.
of thinking is the same as it was in 1996. installing destructive malware to disable
Langill talked about the evolution of The way we fight threats in 2016 has to be selected assets.
a physical threat in todays world. He different than the way we did it in 1996.
While awareness of the assault was
said it all started with box cutters
high, even after this blatant attack
on planes which led to the 9-11
in the ICS sector, end users still
attacks and that created the Transdid nothing.
Everything has to be risk-based and
portation Security Administration
The mindset attacks will hit
(TSA) that now searches all air passomeone else and not me has got
you have to have a risk factor against to change along with the archaic
sengers. Add on top of that, the
capability to create a bomb from
your assets. Security is all about risk approach the industry continues
a sports drink and some hydrogen
to take toward security, Langill
management.
peroxide, which led to the 3-1-1
said.
rule on airplanes.
People are trying to do the
Joel Langill, AECOM
Those were physical attacks that
same thing they have been doing
had a cause and effect. But in the
in the past, Langill said, but with
cyber environment, we are seeing attacks,
On Dec. 23, 2015, power went out for a a new risk-based model could give end
but no real change in how the industry high number of customers (reports range users a fighting chance to ward off any
approaches the issue.
from 80,000 customers to 700,000 homes) type of attack. PE
Antivirus is dead. Malware is able to in the Western region of the Ukraine
Gregory Hale is the editor and founder
get through it to attack a system, Langill served by regional power distribution
said. That is not to say, a user does not companies. A picture has become clear of Industrial Safety and Security Source
need it, they just have to understand it that a coordinated attack involving mul- (ISSSource.com), a CFE Media partner.
IN fOCUS
Five ways to avoid electrical hazards
By David Manney
L&S Electric
ROLLER CHAINS ENGINEERING CLASS CHAINS BACKSTOPS SPROCKETS CABLE & HOSE CARRIERS POWER TRANSMISSION PRODUCTS
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input #13 at www.plantengineering.com/information
14 December 2016
plant engineering
Performance
Meets Peace
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Engineered for precision and power, the Model 850 picks up even
the finest powders, anywhere in your plant. With clean, HEPA-filtered
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system, and a performance guaranteeits more than a cleaning
system; its a business asset.
December 2016 15
WET/DRY AIR OPERATED AND ELECTRIC DRUM-TOP CONTINUOUS DUTY COMBUSTIBLE DUST
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INTERCEPT HOPPERS & PRE-SEPARATORS HSE / INDUSTRIAL HYGIENE SOLUTIONS
SUBMERGED RECOVERY METALWORKING PHARMACEUTICAL STEEL SHOT
IN fOCUS
as an opportunity or an area for
judgment on the individual?
16 December 2016
plant engineering
Conveyor Equipment
Manufacturers Association
WE ARE CEMA
Jerry Heathman,
CEMA Past President
www.cemanet.org
5672 Strand Ct., Suite 2 Naples, Florida 34110 239-514-3441
input #16 at www.plantengineering.com/information
2016
Access the 2016 Industrial Internet of Things & Industrie 4.0 report with
additional findings and insights. www.controleng.com/2016IIoTStudy
research
2016 SAFETY STUDY
top strategies or technologies that process facilities use to enforce safety are
personal protective equipment (86%),
lockout/tagout systems (82%), and job
safety analysis procedures (77%).
28%
of plant personnel
expect an increase in bonus
compensation for 2016; the
average increase of 3.1% is
expected. Source: Plant Engineering 2015 Salary Survey
37%
of facilities are challenged with a lack of understanding about new maintenance
options/technologies, coupled
with a lack of employee training.
Source: Plant Engineering 2016
Maintenance Study
18 December 2016
PLANT ENGINEERING
MORE RESEARCH
Plant Engineering surveys its audience on several topics each year,
including: salary survey, maintenance, energy management, safety,
and workforce development. All
reports are available at
www.plantengineering.com/research.
www.plantengineering.com
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Top Plant
2016
MFC NETFORM
e talk a lot about technology in manufactur- What we cannot reduce to data is the way workers feel about
ingabout the machines and software and the their jobs and about their organization. In developing a plant
strategies around them that make our plants strategy, MFC Netform started with its customers and built a
safer and more efficient. Those are impor- manufacturing process that met their needs. This allows for
tant advancements in developing a modern MFC Netform to customize and even redesign products to
manufacturing facility.
meet the needs of their end users.
One aspect we try not to overlook, but one that
To accomplish this, MFC Netforms focus on
is even more crucial to a plants success, is the
employee input and employee training makes
human element. Improving the way humans
every worker part of quality control and
work with the plant operations and with each
of process improvement. They also have
other go a long way to making your plant
embraced a Lean manufacturing philosophy,
more successful.
which brings workers and processes closer
People are at the cornerstone of the manutogether. They also have a fundamental comfacturing philosophy at MFC Netform, the
mitment to safety at all times.
2016 Plant Engineering Top Plant recipient.
All this reliance on people doesnt mean
As Tim Cripsey, the executive vice president
the company has overlooked technology of
of MFC Netform, notes in the story to folcourse. Quite the contrary; MFC Netform
low: The technology is a secondary tool.
has a sophisticated enterprise resource planWhat makes us successful is our people and
ning (ERP) system, and it uses robotics and
2 0 16
how we trust our customer focus and our
automation extensively to enhance the manuemployee focus.
facturing process.
When asked why his plant was recognized as this years Top
But it was the people-first commitment from MFC Netform
Plant award winner, Cripsey said, There are only two real of Shelby Township, Mich., that elevated the facility to this years
reasons in my opinion: The people and the culture.
Top Plant award. It stands as an example of just how important
As manufacturers aspire to be a Top Plant, the focus is on people are to building a successful manufacturing plant.
metrics and measurements. Plant managers offer key performance indicators (KPIs) and overall equipment effectiveBob Vavra,
nessdata we reduce to acronyms such as KPIs and OEE.
Content Manager, CFE Media
www.plantengineering.com
PLANT ENGINEERING
December 2016 21
2 0 16
A focus on
While much of the U.S. automotive industry was struggling to survive the aftermath of
the most recent recession, MFC Netform held its own.
Making powertrain parts in Michigan
By Jack Smith
Content Manager, CFE Media
22 December 2016
PLANT ENGINEERING
MFC Netform focuses on flowforming and machining. Flowforming is a cold metal forming process in which a preformed
metal blank is pressed against a hardened mandrel using CNC
equipment to ensure that part profiles and dimensions are
accurate. Secondary processes include milling, broaching,
turning, drilling, staking and deburring.
The Shelby Township facility is relatively new. It began operation in 2003, and added three major machining and forming lines in 2012. The parts start in the cell as either a cold
forging, hot forging or a stamping, Cripsey said. Using cold
formed preforms manufactured in the Maumee facility gives
us an advantage over our competitors, as it is a unique process
that has weight and strength advantages. That said, we are not
tied to that processwe will use whatever preform makes the
most technical and fiscal sense. The parts pass, without being
touchedapart from inspectionthrough the entire line. At
the end of the line, the parts have been washed and deburred.
Typical cells have from five to 10 CNC, flowforming, or
broaching, machines that produce several hundred thousand
parts per year working three shifts. And it takes no more than
two operators to run an entire cell. Operators do setups, continuous improvement, equipment checks, load and unload
parts and do visual inspections, said Cripsey. We use robots
extensively for part loading and unloading, or for holding parts
for deburring. We also make sure our cells are not dedicated
pieces of equipment. We have to remain flexible in terms of
what we can make here.
Being involved in customers product designs prior to the first
round of prototypes is a key strategy for MFC Netform. We can
sometimes redesign customers products from two pieces to one,
from three pieces to two and in doing so, we can save them money
and complexity in their product designs, Cripsey said. A good
supplier is involved early in the design process, because as soon
as they test that one prototype as a two-piece, its too late for us to
offer a one piece because they have already tested it. We will also
suggest alternate solutions for customer problemseven ones
that we do not offer. While customers find it unusual at first, it
goes a long way to gaining their trust.
Customers sometimes have difficulty controlling inventories,
which can create scheduling challenges. Schedule leveling is
www.plantengineering.com
Managing operations
December 2016 23
2 0 16
MFC Netform uses a pull system to order perishable tooling. A preset finished goods level is used to pull production
from the manufacturing cells. The manufacturing lines are
designed based on single-piece flow, said Januszek. There is
a formal continuous improvement program in place. Operators
are engaged in all activities within the company. Our customer
supply modelvarying at short notice with large fluctuations
means we need to keep 1 to 2 weeks safety stock. We use the
safety stock level to pull production from the manufacturing
cells at the required rate.
Cripsey said you are what you measure. The Shelby Township plant uses an OEE report from its ERP system for overall
reporting and the supporting reports of scrap, downtime, and
root-cause issues. It also uses the ERP systems labor reporting metrics to track labor efficiency. Best practices are shared
Focusing on Lean
24 December 2016
PLANT ENGINEERING
www.plantengineering.com
Embracing technology
MFC Netform relies heavily on its ERP system to run not only
its Lean-based manufacturing operations, but every aspect of
the business. It stands to reason that
technology is fully embraced at the
Maintaining uptime
December 2016 25
2 0 16
Conducting weekly layered process audits with representatives from maintenance, operations, plant engineering
and quality
Completely sealing and interlocking machines with controls. If machines are opened, machines automatically
shut down.
A culture of safety is an expectation at the Shelby Township
facility. The smallest of injuries are reported and tracked. By
continuously being prudent about small issues, big issues are
avoided.
Januszek said that equipment maintenance presents the biggest safety challenge. Because each repair is unique, safety
protocols dont always address stress- and strain-related risks.
He said that the plant approaches safety aggressively by sending the message that production never trumps safety. Safety
issues are dealt with immediately and have absolute priority
over anything else.
Looking ahead
26 December 2016
PLANT ENGINEERING
www.plantengineering.com
CFE Medias
DIGITAL REPORTS
Plant Engineering is excited to introduce our new Digital Reports.
2016 Digital Report
Compressed
Air Strategies
Its often called the fifth utility. Compressed air plays a vital role in most
manufacturing plants, and availability of compressed air is crucial to a
wide variety of operations.
Sponsored by:
Atlas Copco, FS Elliott
To view and download this digital report visit:
www.plantengineering.com/DigitalReport/AirCompressedStrategies
It's clear by now that the Industrial Internet of Things (IIoT) is a transformative manufacturing strategy that will improve operations, reduce cost and
increase quality and safety.
Sponsored by:
Cisco, Epicor, Festo, Iconics, Kepware Technologies, Red Lion
To view and download this digital report visit:
www.plantengineering.com/DigitalReport/lloT
MAINTENANCE STRATEGIES
There is no more fundamental right in the American workplace than the right
to work safely. Creating that safe work environment is both a mechanical and a
human process.
Sponsored by:
Gates Industrial Safety
BESTPRACTICES
Building on
manufacturings progress
n publishing, the last really great idea was moveable type. Today, almost 700 years later, print communications really is not much more just people
taking that basic idea and refining it and adapting
it to changes in customer needs and technology.
www.plantengineering.com
30
Global Manufacturing
43
Air casters
32
VFD efficiency
45
Performance reviews
35
Electrical testing
46
36
48
Digital plant
39
PLANT ENGINEERING
December 2016 29
odern automation initiatives are gaining traction across the globe. Following three previous revolutionsthe development of the
steam engine, mass production on the conveyor belt, and the dawn of computersthe
term Fourth Industrial Revolution might
have some believing the manufacturing world is changing
overnight. Although tempting to characterize an influx of
technology as revolutionary, the long history of manufacturing shows us that the nature of all change is evolutionary.
A logical next phase, digital automation technologies
ushered in an era of unprecedented machine intelligence.
Advancements in sensors, networking and the use of new
communication systems created a surge of Industrial Internet
of Things (IIoT) initiatives aimed at producing goods with
improved flexibility, speed and efficiency. The rate of adoption for automation technologies has been extraordinary,
with nearly every factory now automated, and projections
show the global robotics industry expanding to over $226
billion by 2021.
Many companies already use machine intelligence to
expand the efficiency and performance of operations. A
recent survey (Business Insider) found that over 80% of
executives agree that successful adoption of IoT technologies will be critical for future success. Another study (Quest
Technomarketing, Germany) reports that half of all mechanical engineers already rely on modular, intelligent machines.
The number of these machines will increase twice as quickly
as generic machine production over the next few yearswith
modular, intelligent machines slated to reach an 80% market
share within three years.
All of these trends are boosting demand for intelligent
motion controlalong with the need to manage complexity.
Lets look at some successful strategies for implementing
automation technologies.
30 December 2016
plant engineering
Focus on simplicity
Speed, flexibility, productivity and efficiency remain cornerstones of manufacturing production, packaging and logistics.
Yet the dynamics in global markets are changing, reflecting
new supply chain models with more variation and shorter
production cycles requiring greater agility to reduce machine
development time and turnkey system integration.
The design and engineering of machines has always been
characterized by a high degree of customer centricity, requiring
the translation of manufacturing needs into technical solutions. Thats where scalable and easily configurable modular
motion control and drive components and software designed
to address a wider range of application requirements can make
the greatest impact.
IIoT technologies have proliferated not only in large companies but also in small and mid-sized companies. There is
no lack of on-ramps, so the choice ultimately comes down to
leading or lagging behind competitors. Harnessing technology to simplify complexity is the direction the industry has
been headed for many years. The goal now is to continue
systematically down this path. The IoT framework supports
this trend and stands to act as a stimulus to all segments of
industry. PE
plant engineering
December 2016 31
BestPractices: V FD e FFiciency
VFD efficiency:
Three best practices
By Gary Jacott
Motion Industries
he use of variable frequency drives (VFDs) to control the speed of an ac induction motor has many
benefits including improved process control, energy
savings, higher reliability and reduced wear and tear.
Ac motors are very common in manufacturing and
processing plants.
When a motor is run at half its maximum speed, it consumes
significantly less energy than it does at full speed.
For centrifugal loads (fans and some pumps) the power at half
speed can be as little as 1/8th the base speed power. When using
a VFD, motor speed can be changed almost instantaneously to
address load and process changes (temperature, pressure, force,
etc.). An added benefit is its ability to increase the precision
of process control with the ability to control motor speeds to
within 0.1% tolerance.
Transient voltages on the ac power lines can cause inrush currents to a VFD drive, resulting in an overvoltage condition of
the dc bus. These transient voltage conditions are often caused
by utility capacitor switching and will cause VFDs to shut
down without warning. The addition of a line reactor will limit
the magnitude of inrush current. This current prevents trips
and component failures and reduces the amount of potential
downtime.
A line reactor will also reduce input line distortion, which
is caused by the nonlinear characteristics of drives. The line
reactor will limit the inrush current to the rectifier, rounding
the waveform, reducing the peak currents, and lowering the
harmonic current distortion. High-peak currents may cause
distortion of the voltage waveform. The reduction of those peak
currents also reduces total harmonic voltage distortion and
mitigates harmonics sent back on to the line.
32 December 2016
plant engineering
www.plantengineering.com
Speed-torque characteristics
plant engineering
December 2016 33
Installation
Shaft currents
34 December 2016
plant engineering
typically associated with high-voltage power distribution systems. It injects a test current into the
primary side of the system to see how it behaves with
that level of current. Secondary injection testing
may also be of value. However, it applies the test current to the trip relay directly on the secondary side.
2.
www.plantengineering.com
plant engineering
December 2016 35
plant engineering
plant engineering
December 2016 37
Figure 3: Fatigue
and overload are
two of the more
common failure
modes. Many bolt
failures occur at
the first engaged
thread of the bolt,
as that is the point
of the highest
stress.
During assembly
ensure that bolt preload
is sufficient as previously
discussed. This will minimize the cyclic load that
the bolt will see which will
increase the resistance to
bolt fatigue. As seen on
the joint diagram on Figure 4, once the external
force on the joint exceeds
a low-bolt preload, the
joint compression can
quickly be compromised
and then all the exter-
38 December 2016
PLANT ENGINEERING
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plant engineering
December 2016 39
Considerations
40 December 2016
PLANT ENGINEERING
www.plantengineering.com
12 issues to consider
2. Break the process down into steps. Painting is a very complex process. Are the raw materials of the right quality? Leaders
have to be open to change and recommendationswhen leaders
set aside preconceived notionseven longstanding assumptionsat the start of a project, new opportunities to achieve
the next level take center stage. When you coat a product, the
orientation of the part is important.
3. Throughput is more than a number, it is a mindset based
on passion and process. The old adage that cleanliness is next
to godliness must have come from a paint shop leader. Nothing affects quality like dirt and unfortunately most of the dirt
defects are from paint shop personnel (see defect graphic below).
December 2016 41
Because of the number of variables in the development of a complex process, data capture and
benchmarking are essential features in planning
throughput and maintaining quality standards.
Rapid changes in the market and in technology
require managers to continuously troubleshoot
the logic of process steps and to look for delays
that can result in costly downtime on the production line, as throughput is a mindset based on
passion and process. PE
Gary Winslow is group manager for Ghafari
Associates.
42 December 2016
plant engineering
www.plantengineering.com
BestPractices: A ir C Asters
December 2016 43
BestPractices: A ir C Asters
plant engineering
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December 2016 45
ver the years, electronics, software and technology in general have become less expensive for
power plants, but operators wages continue to
riseespecially as the labor pool diminishes.
As equipment is becoming engineered for more
reliability and controllability, power plants are
becoming more automated. This has become the justification
for fewer power plant operators on staff, with some facilities
attempting to become or successfully becoming completely
unmanned.
While this seems to make sense on a financial report, the
reality is that technology is not advanced enough for complete
automation of essential occupationsand for critical facilities,
it can never fully be automated.
Reliability
46 December 2016
plant engineering
Maintainability
Planned outages
Unplanned outages
Prepared outages
If minimizing scheduled downtime is the practice of maintainability, then the art of maintainability is achieved when
plant operators proactively prepare for unplanned outages.
By definition, you cannot plan an unplanned outage, but you
can prepare for common unplanned outages. This can be done
by first anticipating the most likely modes of an unplanned
outage.
There are certain techniques that can be done that have
proven effective in preparing for unplanned outages:
1. Hold a lessons-learned meeting after each outage to
get all operators views and opinions on what could have
been done to prevent the event and what could be done
to prevent future repeat events.
2. Ensure proper depth of inventory and supply chain
management. Operators should make sure you have
backup inventory should any equipment fail.
3. Practice emergency procedures. Owners should quiz
operators on What do you do if ? situations. It is a
great exercise to make sure everyone knows the proper
procedures, in order to avoid disagreements or confusion during a crisis.
4. Owners should make sure they have the right tools
on-hand to address common repairs to critical components. This can save time and ensure the repair is more
than just temporary.
As owners practice maintainability, it helps to envision how
multiple complications can hit you all at once and anticipate
these problems. These exercises provide valuable training and
build operator confidence. Plant operators are an owners biggest resourcethey are often very familiar with handling highrisk situations and can provide foresight and advice during
similar situations.
In an industry that is enamored by reliability, it is easy
to underestimate and underappreciate the value of skilled
plant operators and the value of maintainability. There is true
elegance in the ability of a seasoned power plant operator to
acknowledge, identify, assess, adapt and resolve a perfect storm
from being a multi-million dollar publicized excursion into
only a minor blip on the trending historian of the power plant
parameters. This is something that cannot be automated; it is
something that is not necessarily intuitive; it is an expertise
that power plant operators hone over years.
During a critical situation, a power plant operators skill is
judged by their speed of resolution. While the power plant is
in crisis, owners are not concerned about operators ability to
maximize uptime, but by their ability to minimize downtime.
With an infinite number of ways things can go wrong, calm,
level-headed, decision-making in time of crisis, along with
proper preparation, are skills only available from an experienced operatorwhich can never be fully automated. PE
Brian Wodka is a mechanical engineer and partner at RMF
Engineering. He leads the power plant assessment and reliability team at RMF Engineering and has performed power
plant assessments and boiler inspections for the past 15 years.
plant engineering
December 2016 47
The future of
the digital plant
By Corey Foster
Valin Corp.
Internet of Things
Machine-to-machine communication
48 December 2016
plant engineering
For the last 20 years, automation manufacturers have had the ability to connect controllers to each other which effectively means
machines are talking to each other. This concept of machines
sharing information and working together is commonly referred
to as machine-to-machine (M2M) communication.
With M2M communication, sensors can be added to machines
so that they are then able to send alerts when machines are not
running optimally. The IIoT allows machines to communicate
on a more precise and productive manner.
The IIoT has provided the production business benefits that have
not been previously available. One of the most prominent benefits that the IoT provides is the ability to improve the efficiency
of the plant production.
Plants that had previously taken a less stringent maintenance
schedule are now able to prevent large maintenance problems
because the machines within the IIoT are connected and providing
constant, real-time feedback on production. The more connectivity between machines that a plant implements, the more it will
save thanks to scheduled and predictive maintenance.
The IIoT has also changed the way that we look at information.
The technology within plant manufacturing has not significantly
changed, but the fact that the machines are able to connect with
one another and provide larger amounts of data is where the IIoT
and M2M allows the manufacturing world to make advancements. Companies are now able to take the large amounts of
data that M2M communication provides and analyze it. After
analyzing the data, engineers can make the necessary changes
to the production line and machinery in order to optimize the
efficiency and output of the system as a whole.
Looking ahead
The IIoT has helped to pave the way for Industrie 4.0, which
refers to the next wave of the industrial revolution. Industrie 4.0
has allowed companies to conceptualize and even implement
systems that are then used in a factory that is completely run
through connectivity and considered to be lights out.
By adding sensors to specific areas of already highly connected
factories, the information is available in real-time and also, in
some instances, self-correcting. There are a handful of companies
that have implemented these strategies and seen the benefits of a
lights-out factory, but the concept is far from perfected.
The IoT will allow for further research to be done and advancements to be made towards creating factories that will optimize
the connectivity options that are available. PE
Corey Foster is application engineering manager for Valin
Corp., www.valin.com.
www.plantengineering.com
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December 2016 49
IN NOVATIONS
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Allied Electronics is a small order, high service level distributor of electronic components and electromechanical
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Modular work platforms and aluminum stairs pre-engineered for unlimited configurations. Platforms and metal
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Flexicon designs and manufactures bulk handling equipment and custom-engineered and integrated plant-wide
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cemanet.org
Century Spring has been supplying quality stock and custom springs, metal stampings, and wire forms for MRO
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CEMA is a trade association serving the manufacturers
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donaldson.com
dynatect.com
est-static.com
EST specializes in mitigating static charges, induced voltages and random discharges on rotating shafts, moving
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54 December 2016
plant engineering
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December 2016 55
INCONCLUSION
Keep focus on manufacturing
improvement, not bonuses
By Bob Argyle
Leading2Lean
For example, if a
56 December 2016
PLANT ENGINEERING
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