Docstoc

Managing mill maintenance: Maintenance programmes

Document Sample
Managing mill maintenance: Maintenance programmes Powered By Docstoc
					                            Digital Re-print -
                           July | August 2013
  Managing mill maintenance: Maintenance
                programmes
Grain & Feed Milling Technology is published six times a year by Perendale Publishers Ltd of the United Kingdom.
All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies,
the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of
information published.
©Copyright 2013 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form
or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1466-3872




                        www.gfmt.co.uk
     FEATURE




                                                         Managing mill
                                                          maintenance
                                                                                           Maintenance programmes
                                                         by Alice Neal, associate editor, Grain and Feed Milling
                                                                                  Technology, United Kingdom



E
       very     miller   knows        the         the scheduled approach of preventive              how to make a smooth transition between
       importance of a comprehensive              maintenance and the precision of                  systems.
       maintenance programme. There               reliability centred maintenance.                  This case study looks at why a flour mill
are numerous strategies out from the                                                                in the United Kingdom, Whitworth Bros
‘if it ain’t broke don’t fix it’ attitude         Switching strategies is a big change and          Ltd, chose to change its maintenance pro-
of reactive maintenance to monitor-               therefore needs careful consideration, not        gramme and the technology it used in its
ing-centered predictive maintenance,              just in terms of which strategy to use but also   new strategy.




                                                  on its ability to supply (its customers with      company’s ability to meet customer delivery
 Maintenance case study
                                                  high-quality food safe products that fulfil       deadlines”.
                                                  customer expectations). Whitworth Bros            “By getting an early warning of possible bear-
 Whitworth Bros Limited
                                                  recognises the importance of monitoring           ing / gearbox failures of the key production
 Acoustic emission technology prevents hun-
                                                  key elements of plant and equipment to            plant, the company could organise remedial
 dreds of hours of downtime for century-old
                                                  ensure the company is always able to meet         action which would allow maintenance to
 flour specialists.
                                                  customer demands.                                 be undertaken in a planned manner and in
 Established in 1886, Whitworth Bros Ltd
                                                                                                    timescales that would not adversely effect
 supplies flour to some of the largest food
                                                  Maintenance strategy challenges                   the companies ability to deliver first class
 manufacturers in the UK. The company
                                                  In 2009, Whitworth Bros took the decision         service to its customers.”
 operates from production sites located
 in Wellingborough, Northamptonshire and          to move from a reactive to a predictive           The main driver for this initiative was to
 Peterborough, Cambridgeshire and supplies        maintenance strategy. A Whitworth Bros            ensure Whitworth Bros used the best tech-
 flour in bulk loads as well as bag deliveries.   technician explains the reasons behind the        nology available to minimise any potential
                                                  switch, “Whitworth Bros had witnessed             for unplanned production plant downtime.
 As one of the UK’s largest independent flour
                                                  several occasions where bearing failure           The necessity to minimise the risk of equip-
 millers, Whitworth Bros prides itself
                                                   within key plant drive systems had caused        ment failure and resulting impact on produc-
                                                      significant disruption to production,         tion, led the company to devise a proactive
                                                                  which in turn affected the        condition monitoring (CM) strategy.
                                                                                                    Part of the switch in maintenance strategies was
                                                                                                                                      to employ a




38 | July - august 2013                                                                                       Grain  &feed millinG technoloGy
                                                                                                                                        FEATURE


CM technician to implement the system across       eficial in help-
its sites. “Employing a dedicated technician to    ing justify the
roll out and monitor plant across the site using   expenditure
the technology, allowed a rapid roll out across    and resource
all facilities and plant issues to be addressed    costs allocated to
accordingly,” says the Whitworth CBM techni-       this particular CM
cian.                                              strategy, as well as
In terms of technology, the company                balancing the CM
considered various monitoring options -            approach against
such as vibration and temperature - and            that of machinery
attended numerous trade shows, eventually          failure.
discovering the MHC-Memo Pro Acoustic              Data collection
Monitoring system from Holroyd, part of            now takes place on
Parker Kittiwake.                                  a regular basis for
“Acoustic emission technology was chosen           all critical plant and
as it provided the most suitable solution to       machinery. This
effectively monitor the type and volume of         allows engineering
plant used in the Whitworth Bros facilities.”      resources to be direct-
                                                                                                         gathered and analysis to be undertaken
                                                   ed to the plant in need of maintenance
Whitworth Bros started collating data cap-                                                               and completed promptly,” says a
                                                   and this is organised as part of planned,
ture routes across all its sites and within a                                                            Whitworh Bros spokesperson
                                                   proactive activity, rather than as a result of
very short time, commenced data acquisi-                                                               • Multiuser application - it offers good
                                                   machinery breakdown.
tion and analysis.                                                                                       value as it can be used across different
                                                          Whitworth Bros uses a suite of sen-            sites due to the multiuser applications
                                                          sors that are compatible with the
                                                          MHC-Memo Pro system. The stand-             Results
                                                          ard magnetic mounted sensor is used         Whitworth Bros currently carry out rou-
                                                          to collect the vast majority of infor-      tine monthly data capture, supplemented
                                                          mation with the hand-held, extended         with weekly collections for any machines
                                                          probe, allowing data capture in hard        suspected of having an underlying bear-
                                                          to reach areas. Low profile sensors         ing issue. The Memo Pro is also used to
                                                          have also been installed to allow           take one-off readings to help correctly
                                                          critical plant data to be gathered. All     diagnose individual machine issues as they
                                                          three sensors are readily connected         arise, thus reducing incorrect diagnosis of
                                                          to the MHC-Memo Pro and data can            plant issues.
                                                          be captured almost instantaneously.
                                                                                                      Current coverage at the Wellingborough site
                                                          “The hardware and software associ-          sees the collection of data spanning a staggering
                                                          ated with the Memo Pro system               2,500 separate data points. This ensures that
                                                          has been very well designed and             a comprehensive dataset exists which allows
                                                          constructed. It is portable, robust and     machine condition trending to be completed.
                                                          straightforward to use. This function-
                                                                                                      Whitworth Bros has devised a cost metric
                                                          ality is mirrored with the analysis soft-
                                                                                                      calculation to assess the savings to the com-
                                                          ware, which allows new data to be
                                                                                                      pany off the back of the newly implemented
                                                          quickly downloaded and compared
                                                                                                      CM activity. The company recognises that
                                                          against historic data for all machines
                                                                                                      the CM approach has significantly reduced
                                                          detailed for each production area.”
                                                                                                      the potential for unplanned production
                                                           Since the equipment was installed,         stoppages.
                                                           Whitworth Bros has recognised that
                                                   the MHC-Memo Pro is a robust, user-
Solution                                           friendly and comprehensive tool. The data          Future
With data acquisition routes established,          reduction and analysis software is well-           Existing coverage sees the majority of the
condition monitoring of the production             written, allowing analysis to be completed         Wellingborough site plant captured using
critical plant commenced. This enabled             in an effective and timely manner.                 the range of standard sensor products, so
Whitworth Bros to take a proactive                                                                    Whitworth Bros are now looking at the
                                                   “The technology requires minimal training
approach to monitoring and mainte-                                                                    monitoring challenges they face with oscil-
                                                   to use and interpret data captured and can
nance of the equipment at the company’s                                                               latory equipment (flour sifters) and will be
                                                   also be used for spot checks as needed.”
Wellingborough and Peterborough sites.                                                                investigating technology that allows condi-
                                                   Whitworth Bros’ experience of the MHC-             tion monitoring of these machines.
The MHC-Memo Pro readily identified
                                                   Memo Pro shows the following key benefits:
machines which were in need of reme-                                                                  In collaboration with Holroyd, part of Parker
dial action and appropriate preventative                                                              Kittiwake, Whitworth Bros will continue to
maintenance was undertaken as required.             • Usability - its data collection method is       monitor further advances in condition moni-
Machines thought to be beyond routine                 straightforward and hardware easy to            toring technology with a view to minimising
servicing, were withdrawn from service as             operate has excellent ergonomics and            future plant breakdown and maximising
part of planned maintenance activity.                 is extremely robust                             production efficiency across all of its sites.
                                                    • Intuitive - it doesn’t require intensive
Whitworth Bros devised a cost metric
                                                      training, “[it] really is a turn-key
calculation to assess the savings to the com-
                                                      solution. Data routes can be compiled           More InforMatIon:
pany off the back of the newly implemented
                                                      readily, allowing important data to be           Website: www.kittiwake.com
CM activity. This approach was very ben-


Grain &feed millinG technoloGy                                                                                                   July - august 2013 | 39
 This	digital	Re-print	is	part	of	the	July	|	August	2013	edition	of	Grain	&	Feed	
 Milling	Technology	magazine.		
 Content	from	the	magazine	is	available	to	view	free-of-charge,	both	as	a	full	
                                                                                 LINKS
 online	magazine	on	our	website,	and	as	an	archive	of	individual	features	on	
 the	docstoc	website.	
 Please	click	here	to	view	our	other	publications	on	www.docstoc.com.
                                                                                                                 July - August 2013




                    first published in 1891
                                                                                                                                      •	 See	the	full	issue
                                      •       Aflatoxins in
                                              Europe:
                                              a new risk in maize
                                              production?
                                                                                                                                      •	   Visit	the	GFMT	website
                                                                                       In this issue:


                                                                                                                                      •	   Contact	the	GFMT	Team
                                      •       Improving                            •    Pig feed
                                              poultry health                            pelletizing
                                              and production                            technology
                                              efficiency with
                                              probiotics                           •    Feed focus
                                                                                        Cattle

                                                                                   •    Exploring
                                                                                        the challenge
                                      •       Sweeping                                  of single


                                                                                                                                      •	   Subscribe	to	GFMT
                                              changes                                   versus multi-
                                              to OSHA’s                                 enzyme dosing
                                              sweep auger                               comparisons
                                              enforcement




                 INCORPORATING PORTS, DISTRIBUTION AND FORMULATION
              A subscription magazine for the global flour & feed milling industries - first published in 1891




 To	purchase	a	paper	copy	of	the	magazine,	or	to	subscribe	to	the	paper	edi-
 tion	please	contact	our	Circulation	and	Subscriptions	Manager	on	the	link	
 adove.		



INFORMATION	FOR	ADVERTISERS	-	CLICK	HERE



 Article reprints
 All Grain & Feed Milling Tecchnology feature articles can be re-printed as a 4 or 8 page booklets (these
 have been used as point of sale materials, promotional materials for shows and exhibitions etc).
 If you are interested in getting this article re-printed please contact the GFMT team for more informa-
 tion on - Tel: +44 1242 267707 - Email: jamest@gfmt.co.uk or visit www.gfmt.co.uk/reprints




                                                      www.gfmt.co.uk

				
DOCUMENT INFO
Description: Every miller knows the importance of a comprehensive maintenance programme. There are numerous strategies out from the ‘if it ain’t broke don’t fix it’ attitude of reactive maintenance to monitoring-centered predictive maintenance, the scheduled approach of preventive maintenance and the precision of reliability centred maintenance.