Properly executed precision maintenance results in improved equipment reliability and considerable cost savings
Precision maintenance is where rubber meets the road in any effort to improve the mechanical reliability of your equipment. The best laid reliability centered maintenance (RCM) plans, from equipment strategies to detailed job packs, will disappoint if you do not execute with precision. You have to do the right work, right. When it comes to rotating equipment, this means managing the sources of vibration (fasteners, alignment, and balance) and ensuring that the machine’s surfaces are properly lubricated. Put it all together and you are cutting the FLAB: fasteners, lubrication, alignment, and balance. Cutting the FLAB is more than a clever phrase, however. Following this mnemonic results in increased equipment reliability and efficiency that yields quantifiable cost savings to your organization.By: Drew Troyer & Peter Munson
- 5 to 15% reduction in repair costs. This is the most direct and immediate benefit to be realized by a focus on precision maintenance. This reduction can be realized fairly quickly and is attributable to reduced wear, more proactive corrective actions, and fewer catastrophic failures. In short, machines that run smoother, cooler, cleaner, and quieter do not chew through components nearly as quickly.
- Roughly 15% savings in asset replacement costs. Most rotating equipment requires replacement well before its designed end of life due to wear. Precision maintenance restores equipment to its designed reliability, recapturing a significant portion of that lost life expectancy. This cuts your operating and capital expenditures for asset replacement – a fixed cost savings.
- 2 to 5% savings in energy costs. Less parasitic friction and cooler operation results in more efficient operations and reduced energy costs. These improvements are directly measurable, as well as being reflected in your monthly energy fixed cost expenditures.
- The improvement in efficiency also yields a 2 to 5% reduction in emissions. Less energy required means less emissions. While not a fixed cost, reduced emissions are an increasingly important goal for many companies.
- Improved equipment reliability can result in up to 5% improvement in production throughput. More efficient equipment and increased operating envelopes can enable additional production throughput – process dependent.
- 20 to 30% defect reduction. Precision maintenance results in less induced defects through invasive work.