Virtual Planning Results in Efficient Design

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In a huge expansion project, Uponor North America benefits from digital-twin technology and other tools to plan for current and future growth. 

By Michelle Segrest, Navigate Content, Inc. - Reporting for Efficient Plant Magazine

Jon Sillerud has spent half of his 30-yr. career managing new-growth projects for large manufacturing facilities. This experience has taught him valuable lessons about strategic planning. “Spending time in detailed planning is always time well spent,” said Sillerud, the vice president of operations for Uponor North America and executive leader for the biggest expansion project the company has ever undertaken. Follow this link to read the full article. 

PM Helps Eliminate DM

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Michael Flint drives a preventive-maintenance strategy at Brown University to help direct wasted man-hours toward reducing a large and growing deferred-maintenance backlog.

By Michelle Segrest, Navigate Content, Inc. - Reporting for Efficient Plant Magazine

Growing up on a dairy farm in western New York state, Michael Flint learned early the value of proper maintenance and the safe operation of equipment. He also learned the importance of properly caring for the livestock. Though he didn’t know it at the time, this experience prepared him for his current challenge—driving a seven-year program at Brown Univ., designed to redirect 57,000 work-process man-hours used to maintain 226 buildings covering 6.34-million sq. ft. at the Providence, RI, campus. Read the full article. 

Solution Seeking vs. Problem Solving

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For four decades, Stephen Matthews has been helping facility personnel improve reliability with a “boots on the ground” approach.

By Michelle Segrest - Reporting for Efficient Plant Magazine

You won’t find Stephen Matthews sitting in an office, and you won’t see him wearing a coat and tie. “I am totally embedded on the shop floor—100% of the time,” the veteran reliability consultant said. “Whether it’s in operations or in maintenance, I firmly believe that the shop floor is where everything happens. I also work on all shifts, and that is where you really see what is going on. I look like one of the guys, and I ask questions.” Matthews uses his 39 years of engineering, maintenance, operations, and reliability experience to work with companies on various projects in many types of asset-intensive industries. He is based in Montréal, but works with companies all over Canada, the United States, and even travels as far as Siberia, Russia, to help companies with various reliability-improvement programs. He evaluates work management, supply-chain management, and reliability engineering practices, in addition to identifying performance gaps and recommending short-, medium-, and long-term solutions. To read the full story, please follow this link. 

Avoid Common Pump Spec Mistakes

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When it comes to keeping food and beverage pumps running efficiently, a pump expert identifies errors you should avoid.

By Michelle Segrest, Navigate Content - Reporting for Efficient Plant Magazine

For the past 30 years, Jim McCormick has been solving problems for his sanitary- and process-equipment customers. Most of the time, he says, these problems could have been avoided. “There are a lot of things I’ve learned over the years as far as things that can go wrong and why pumps fail,” said McCormick, director of sales and corporate development applications and technical sales engineer for SANI-PUMP Inc., Sanitary Pumps and Equipment (sani-pump.com, Chattanooga, TN).  “I’ve made a list of some of the reasons this happens. I work closely with my customers to hopefully avoid these common mistakes.” To read the full story, please follow this link. 

Filling the Skills Gap

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This maintenance and reliability leader builds successful programs while leveraging key skills and making sure all bases are covered.

By Michelle Segrest, Navigate Content - Reporting for Efficient Plant Magazine

George Parada has a knack for filling the gap.  While building expertise in development and change management, he began to also develop a sixth sense about what was missing. “When you think about implementing reliability, change management is so important,” said Parada, CMRP and the maintenance and reliability leader for Cargill Salt Inc., Newark, CA. “You have to know how you are going to manage your stakeholders and understand what is the communication plan for each individual."  Please follow this link to read the full story. 

Bionics Drive Future Factories

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Festo’s Bionic Learning Network studies the movement and behavior of animals in nature to inspire interactive, intelligent technology and machines that stretch the boundaries of factory automation.

By Michelle Segrest, Navigate Content - Reporting for Maintenance Technology Magazine

Walk through Festo’s headquarters in Esslingen, Germany, and you’ll witness what appears to be science fiction. Artificial intelligence and energy efficiency are deeply imbedded into its bionic robots. The engineers at Festo believe that by turning to nature to study the behavior, movement, and communication techniques of mammals, insects, and reptiles, you can build a smart factory with advanced automation. In fact, you can build the factory of the future. Please follow this link to read the full story. 

Water & Wastewater Pumping Solutions

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Advancements in water treatment and plant modernization drive growth in the water and wastewater pumping industry.

By Michelle Segrest, Navigate Content - Reporting for Maintenance Technology Magazine

While new construction in the municipal water-treatment market has remained relatively flat, growth in the industrial water-treatment market has increased—driven largely by modernization efforts that seem to be pervasive across the power-generation segment, according to Charles P. Crowley Company (CPC, Baldwin Park, CA, cpcrowley.com) managing director Jon Crowley. One trend that Crowley sees throughout the industry is modernization through “repowering.”

Read the full article by following this link. 

Powering Auto Production

A highly sophisticated electrical protection-and-control system helps Mercedes-Benz keep the power running and its people and equipment safe.

By Michelle Segrest, Navigate Content - Reporting for Maintenance Technology Magazine

When electric current flows through an air gap between conductors, it creates an arc flash. Sparks fly, equipment can explode, and anyone who happens to be nearby can be injured—or even killed. 

To read the full story and to view informative videos, please follow this link. 

Redefining Reliability

Biopharmaceutical manufacturing company AstraZeneca leverages an advanced reliability program to streamline more-effective maintenance processes.

By Michelle Segrest, Navigate Content, Inc. - Reporting for Maintenance Technology Magazine

Even though the AstraZeneca manufacturing facility in Mt. Vernon, IN, looks like a hospital surgical unit—with key equipment separated into concentrated clean rooms—for years it operated like an emergency room. When an equipment breakdown occurred, personnel jumped into action, triaging the issue and not always looking into the true symptoms to prevent future occurrences. Follow this link to read the full story. 

 

Hydraulic Transient Simulation Analysis Predicts and Solves Problems

As a Senior Hydraulics Engineer for Freese and Nichols, Inc., Tom Hill solves problems for his clients by building hydraulic transient simulation models of pump stations and pipelines. 

By Michelle Segrest, Navigate Content - Reporting for Valve World Americas and Pump Engineer

Whether onsite with his hands on the equipment, or in front of his computer utilizing simulation software, Tom Hill has spent nearly four decades solving problems for his clients. Through the simulation process, he constructs models that can be utilized to demonstrate upset conditions such as tripped pumps, broken pipe, closing valves, or emergency shutdown operations. 

For the full story, follow this link. 

Training, Automation, Innovation Drive Reliability

German-based Aquatherm provides reliable, sustainable pipe production as a result of advanced technology, automation, and in-house design and innovation.

By Michelle Segrest, Navigate Content, Reporting for Maintenance Technology Magazine

As one of the first three companies in the European market to manufacture under-floor heating systems, Attendorn, Germany-based Aquatherm has come a long way since the company was founded 44 years ago. It now leverages state-of-the-art automation and innovative energy-saving systems to drive its reliability and sustainability programs. For the full article and more, please follow this link.

Lubrication Best Practices from a Hoarder of Information

When it comes to lubrication, Scott Arrington relies on 34 years of information gathering to ensure he always has the correct answer for his customers.

By Michelle Segrest, Navigate Content, Reporting for Maintenance Technology Magazine

Scott Arrington is a hoarder—a self-described hoarder of information, that is. The World Wide Web is not big enough to hold all the information upon which he relies. In fact, he has so many manuals, binders, and oil samples, he needs two offices—one to work in, and another to contain all the valuable records, documentation, and research he will never throw away. 

To read the full story, please follow this link. 

Reliability Changes Lives

Using skilled technicians and advanced technology, Eli Lilly and Company creates life-saving medicines and devices worldwide. 

By Michelle Segrest, Navigate Content, Inc., Reporting for Maintenance Technology Magazine

At Eli Lillythe motivation to improve production reliability is not just something that is tracked on graphs and charts for upper management to review. In fact, for maintenance and reliability engineer Carrie Krodel, it’s personal. Krodel, who is responsible for maintenance strategies at the Eli Lilly Indianapolis facility’s division that handles Parenteral Device Assembly and Packaging (PDAP), has a family member who uses the company’s insulin. “I come to work every day to save his life,” she said. To read the full story, please follow this link.

Obsessed with Change

A transformation in management and culture, combined with an investment for future growth, revitalizes a 97-year-old tool-manufacturing company.

By Michelle Segrest, Reporting for Maintenance Technology Magazine

For Empire Level, giving new life to a company that was family-owned for five generations is more than an investment. It is an obsession. “There is a big difference between passion and obsession, and we are truly obsessed,” said Richard Gray, the senior vice president and general manager of Empire Level, Mukwonago, WI, a division of Milwaukee Tool Corp., Brookfield, WI. “Anyone can be passionate, but we go beyond that. We are obsessed about our brand being the best, obsessed about the quality of our manufacturing, obsessed about how clean our plant is, how happy our people are, and how well they are trained. We are obsessed about how much fun we have watching the company grow every day. This obsession really drives us.” To read the full story, please click here. 

Art Meets Reliability Science

Lawrence Gardner uses his artistic background to craft well-designed reliability and maintenance programs for the Univ. of South Alabama Medical Center.

By Michelle Segrest, Reporting for Maintenance Technology Magazine

Each day, Lawrence Gardner looks at a blank canvas and finds new ways to paint a masterpiece. Whether it’s sketching a plan that creates more space for beds in a trauma center or designing effective preparedness plans for intense weather events that can attack the Southeastern Gulf Coast, Gardner finds a way to make the brush strokes blend together.

Click here to read the full story.

Old-School Approach to New-World Technology

Colorado window and door manufacturer creates sophisticated, energy-efficient products with tried-and-true maintenance and operations best practices.

By Michelle Segrest, Reporting for Maintenance Technology Magazine

Even in an ultra-modern world where technology is king, a small window and door manufacturer nestled in a valley of the majestic Colorado mountains still relies on proven old-school techniques to keep its machines running. To read the full story full of best maintenance practices and insightful tips, and to view exclusive videos, please click here

Inject Reliability in Water and Wastewater Pumps

Address the most common problems and follow best maintenance practices to keep critical water movers running around the clock.

By Michelle Segrest, Reporting for Maintenance Technology Magazine

One faulty $5,000 pump in a wastewater-treatment facility can shut down an entire operation and end up costing the company or municipality $500,000/day, according to Jim Elsey, vice president and general manager of Summit Pump Inc., Green Bay, WI. Why do pumps fail? The 44-year veteran of the pump repair and maintenance business has five very specific reasons and they all trace back to the people who are charged with making those pumps perform and those who provide (or don’t) the resources needed to purchase, install, and service the devices that form the backbone of every water-handling system. To read the full story, click here. 

Voice from the Field - Women Excel in Engineering

Jayne Beck uses her own life experience to encourage girls to pursue careers in engineering.

By Michelle Segrest, Reporting for Maintenance Technology Magazine

At the 12th annual Siemens “Introduce a Girl to Engineering” event in West Chicago in March, Jayne Beck showed a group of 100 girls what stuffed animals, cheesecake, music, perfume, airplanes, medical equipment, motors, and cell phones all had in common. It’s easy, she explained. The designs all depend on the creativity and skills of engineers. To read more about Jayne Beck's inspiring story and for more information about the Introduce a Girl to Engineering program, please read the full story by clicking here.