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SKF Reliability Systems
Training Calendar 2011
January July
SUN 30 2 9 16 23 SUN 31 3 10 17 24
ICR
MON 31 3 10 17 24 MON 4 IR1 LF1 11 18 25 IR1

ICR VA1
TUE 4 11 18 25 TUE 5 IR1 LF1 12 BTM 19 BTM IRW LF1 ESA 26 IR1
BTM
RCM
LF1

ICR VA1 LF1

WED 5 12 19 26 Australia Day WED 6 IR1 BTM PSA 13 BTM 20 BTM IRW LF1 27 IR1
BTM
RCM EMM

ICR VA1
THU 6 13 20 27 THU 7 IR1 BTM 14 BTM 21 BTM 28 IR1
BTM
RCM
EMM

ICR
FRI 7 14 21 28 FRI 1 8 IR1 BTM 15 22 29 IR1

SAT 1 New Years Day 8 15 22 29 SAT 2 9 16 23 30

February August
SUN 6 Waitangi Day (NZ) 13 20 27 SUN 7 14 21 28

MON 7 14 21 IR1 BTM 28 MON 1 Bank Holiday (NSW) 8 15 22 PMS

LF1 29
VA2

TUE 1 8 BTM 15 BTM 22 IR1 BTM RCB

TUE 2 SMP 9 BTM ML1 RCB 16 BTM
ESA Queen’s Birthday
23 PMS ICR LF1
RCB 30 OA
VA1 (East Pilbara) VA2 BTM SST

WED 2 9 BTM 16 BTM EMM IRW 23 IR1 BTM RCB ESA

WED 3 SMP EMM 10 BTM ML1 RCB 17 BTM VA1 24
PMS ICR LF1
RCB 31 OA
VA2 BTM SST

THU 3 10 BTM 17 BTM EMM IRW 24 IR1 BTM ICR

THU 4 EMM 11 BTM ML1 18 BTM VA1 25
PMS ICR
LF1
VA2 BTM

FRI 4 11 18 BTM 25 IR1 ICR

FRI 5 12 19 26
PMS
ICR
VA2

SAT 5 12 19 26 SAT 6 13 20 27

March September
SUN 6 13 20 27 SUN 4 11 18 25
Canberra Day (ACT)
MON 7 Labour Day (QLD) 14 Labour Day (VIC) 21 IR2 28 MON 5 12 OAM 19 26

TUE 1 BTM 8 BTM RCB 15 VA1 LF1 22 IR2 OAM BTM RCB 29 MP1 ESA TUE 6 BTM ML1 EMM 13 OAM BTM IRW ESA 20 RCB SST PSA 27 ESA

WED 2 BTM IRW 9 BTM RCB LF1 16 VA1 LF1 EMM 23 IR2 OAM BTM RCB 30 MP1 WED 7 BTM ML1 EMM MP1 14 OAM BTM IRW 21 RCB SST 28

THU 3 BTM IRW 10 BTM LF1 17 VA1 EMM 24 IR2 OAM BTM 31 THU 1 OA 8 BTM ML1 MP1 15 OAM BTM IRW 22 29

FRI 4 11 18 25 IR2 OAM FRI 2 9 16 23 30

SAT 5 12 19 26 SAT 3 10 17 24

April October
SUN 3 10 17 24 SUN 30 2 9 16 23
Easter Monday Queen’s Birthday (WA)
MON 4 11 18 25 Anzac Day MON 31 3 Labour Day (NSW, ACT, SA) 10 17 24 IR1 Labour Day (NZ)

LF1
TUE 5 BTM LF1 RCB 12 BTM VA1 19 SMP 26 Bank Holiday (TAS) TUE 4 OA 11 ICR BTM VA1 18 BTM SRC EMM
ESA 25 IR1 BTM VA1

WED 6 BTM LF1 RCB EMM 13 BTM VA1 20 SMP 27 WED 5 OA RCB 12 ICR BTM VA1 19 BTM SRC EMM LF1 26 IR1 BTM VA1

THU 7 BTM EMM 14 BTM VA1 21 28 THU 6 OA RCB 13 ICR BTM VA1 20 BTM SRC 27 IR1 BTM VA1

FRI 1 8 15 BTM 22 Good Friday 29 FRI 7 14 ICR 21 28 IR1

SAT 2 9 16 23 Easter Saturday 30 SAT 1 8 15 22 29

May November
SUN 1 8 15 22 29 SUN 6 13 20 27

MON 2 IR1 Labour Day (QLD) 9 16 23 MSR 30 MON 7 UT1 VA2 14 21 IR1 28 IR2 VA3

ML1 VA1 Melbourne

TUE 3 IR1 ESA 10 BTM RCB 17 BTM ML1 IRW 24 MSR BTM
LF1 SST 31 RCB TUE 1 BTM RCB 8 UT1 VA2 ML1 ESA 15 BTM 22 IR1 BTM EMM SST 29 IR2 VA3
Cup Day
ML1 VA1
WED 4 IR1 EMM ICR 11 BTM RCB LF1 18 BTM ML1 IRW 25 MSR BTM
LF1 SST WED 2 BTM RCB EMM LF1 9 UT1 VA2 ML1 LF1 16 BTM 23 IR1 BTM EMM SST 30 IR2 VA3

THU 5 IR1 EMM ICR 12 BTM LF1 19 BTM ML1 26 SPI BTM ML1 VA1 THU 3 BTM EMM LF1 10 UT1 VA2 ML1 LF1 17 BTM 24 IR1 BTM

FRI 6 IR1 13 20 27 SPI FRI 4 11 UT1 VA2 18 25 IR1

SAT 7 14 21 28 SAT 5 12 19 26

June December
SUN 5 12 19 26 SUN 4 11 18 25 Christmas Day

MON 6 Foundation Day (WA) 13 Queen’s Birthday (AUS) 20 27 MON 5 12 19 26 Boxing Day
Queen’s Birthday (NZ)

LF1 RCB
TUE 7 BTM EMM
SMP
ESA 14 BTM 21 BTM
VA1
LF1 SST 28 ML1 TUE 6 BTM RCB 13 20 27

LF1 RCB LF1

WED 1 RCB 8 BTM EMM
SMP 15 BTM IRW 22 BTM
VA1 EMM
SST 29 ML1 WED 7 BTM RCB 14 21 28

THU 2 9 BTM 16 BTM IRW DB 23 BTM VA1 EMM 30 ML1 THU 1 IR2 VA3 8 BTM 15 22 29

FRI 3 10 17 24 FRI 2 IR2 VA3 9 16 23 30

SAT 4 11 18 25 SAT 3 10 17 24 31
SKF Public Course Locations

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For further information on

Public, On site or future courses:
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Do our people
get smarter when
they travel?

This can’t be true, however in

the past twelve months more
than 70% of our work has
come from overseas clients.
We want to reverse this number.

WHY OUR CLIENTS CHOOSE OUR PMO PROCESS

AND WHY YOU SHOULD TOO...

T
he PMO2000 ® (our unique approach) • Creates a closed loop system that makes
Process has always been a simple and investigations into losses very efficient and
effective means for you and your team highly effective
to understand the principles of reliability
International clients:
and how to deploy them. Our systems are built The Benefits
• Indonesia around simplicity, not complexity, but they work in
any capital intensive organisation. Our clients Put simply, successful implementation of our
• Malaysia
range from the current holder of the North program results in a reduction in maintenance
• Philippines American Maintenance Excellence awards to related downtime by one half. This can be
• Taiwan companies that are yet to install a computerised achieved site wide in 12 months.
maintenance management system.
• New Zealand • Reduced reactive or emergency
We help you create a culture of “Zero tolerance maintenance activities
• North America to unexpected failure”. We are not a company • Increased workforce productivity while
• Chile that just helps you write a maintenance strategy providing greater job satisfaction
- we assist you to deploy a reliability assurance
• South Africa • Reduced costs of spares and overall
program which is a living program.
maintenance activity
• Holland We will also assist you with a change of culture
• Saudi Arabia not only in your maintenance departments, but Our Strategy
within the production areas as well. This is
because we view reliability and maintenance as Our current strategy is to attract more local
processes not as departments. business than overseas business.
We are also highly experienced in assisting you If you suffer more reactive maintenance
develop corporate reliability assurance initiatives. than you should - contact us
Our reliability improvement software, PMO2000,®
For more information please contact our
is now SAP ® certified and can seamlessly pass
Melbourne office and arrange for us to provide
information to and from SAP. All the other modules
®
you with a presentation.
of our full suite of Reliability Assurance software
packages can also be directly integrated with SAP. ®
Contact us
How the process helps you Steve Turner
Director and Principal Consultant
• Defines what maintenance is value adding and
OMCS International
what is not and keeps this up to date
Email: steve@omcsinternational.com
• Trains and motivates your staff to build reliability Mobile 0419 397 035
concepts into their daily activities
• Groups all your results into practical schedules Or contact any of our local or global
and works to quickly implement what has licensees through our website at
SAP® Certified
Powered by SAP NetWeaver ® been learned www.reliabilityassurance.com
2011 RELIABILITY AND APOLLO
ROOT CAUSE ANALYSIS BOO
O K
TRAINING SCHEDULE NLIN
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ARMS Reliability offer a range of reliability training courses for glo @ balre
engineers, maintenance professionals and asset managers liabil
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looking to learn more about RCM, Availability, Asset Management, m
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RCA201: Apollo Root Cause Analysis
Facilitators
The course examines the basic concept of
problem solving, and how to facilitate an
effective investigation. Learn the simple
4-step methodology that is currently used by
hundreds of companies throughout Australia.
II201: Incident Investigation
Investigating incidents is important to learn
what went wrong so repeat occurrences can
be prevented. Participants will learn why and
how to conduct incident investigations that
get to the root cause and help prevent further
incidents.

RELIABILITY TRAINING

MRI201: Managing Reliability RCM201: Managing Reliability Centred

Improvement
A practical course addressing the integration
of a range of reliability initiatives into an asset
management strategy. This course covers
RCM, Life Cycle Costing, Root Cause Analysis,
Data Analysis and Plant Availability Simulation.
Maintenance
Provides an understanding of the RCM method
of maintenance task optimisation. Participants
will gain an understanding of the use of failure
data analysis and failure forecasting and how
to choose optimum maintenance tasks that
reduce the costs to the business.

RBD201: Managing Plant Availability AWB201: Availability Workbench

Provides an understanding of the applicable
methods for evaluating and improving system
performance and to understand the important
considerations in performing system analysis
using failure rate data and failure behaviour
parameters.
This course is designed to fast-track you
through the process of using Isograph’s
Availability Workbench software to make
maintenance and reliability decisions.
Students the three main modules in Availability
Workbench, RCMCost, AvSim & LCC.

RELIABILITY WEEK: PERTH SEPTEMBER 12TH – 16TH

Training courses delivered at major cities throughout Australia &

New Zealand as well as onsite for your team. View dates and book
online for public courses at globalreliability.com/2011training or
phone 03 5255 5357 for more information.
 AMMJ
Complimentary Half Copy
8 Laser Cladding - A Versatile Proactive and
Reactive Technology
Laser Cladding is increasingly
being used for repair of worn
components.
14 Mine Loader Failure Prediction
Accurately predict whether any of the equipment was
in danger of immediate failure
16 Strategic Maintenance Reporting To Enable
Sustained Improvement
Strategic maintenance reporting facilitate sustained
improvement, leading to smarter maintenance.
22 What’s The FRACAS - Failure Elimination
Made Simple
Failure Reporting Analysis and Corrective Action
System is an excellent process that can be used to
control or eliminate failures.
28 2011 Listing of Maintenance Internet
Addresses
AMMJ’s annual listing of Internet Addresses for
maintenance, condition monitoring, maintenance
analysis and asset management web sites.
34 Mill Downtime Tracking Database Analysis
Identifying short term strategies to improve Mill
Availability and then put into place long term
strategies to sustain this uptime.
42 Maintenance News
The latest maintenance news, products and services.
46 Maintenance Books
Asset Management and Maintenance Journal
ISSN 1835-789X (Print) ISSN 1835-7903 (Online)
Published by:
Engineering Information Transfer Pty Ltd
Publisher and Managing Editor:
Len Bradshaw
Publishing Dates:
Published in January, April, July and October.
Material Submitted:
Engineering Information Transfer Pty Ltd accept no
responsibility for statements made or opinions expressed
in articles, features, submitted advertising, advertising
inserts and any other editorial contributions.
See website for details of how to submit articles or news.
To Subscribe to the AMMJ go to www.maintenancejournal.com
Contents
January 2011 Issue Vol 24 No 1
Asset Management and Maintenance Journal
The Following Articles Are Not Included In
This Complimentary Half Copy of the AMMJ
Only paid Subscribers receive the full AMMJ.
Forecasting Underground Electric
Cable Faults
Managing the replacement of 7000 miles of
direct-buried primary electrical cable that is at or
approaching the end of its useful life.
Role of Vibration Monitoring
In Predictive Maintenance
Vibration based CM can be used to detect and
diagnose machine faults and form the basis of a PM
strategy.
Six Tips to Improve Your MRO
Spare Parts Management
Follow these six MRO spares management tips and
you will go a long way to achieving the reliability
results that you deserve.
V-Belt Maintenance
V-Belt Maintenance is essential if you want to insure
optimum belt drive performance. With a scheduled
maintenance program, belt drives will run relatively
trouble-free for a long time.
CM Is An Insurance Policy
Condition Monitoring and automatic lubrication
systems can reduce the risk and costs associated
with unforeseen breakdowns.
Green CMMS The Engine of Sustainability
The move to be green is more than just a fad or
buzzword, but rather a key component of an effective
maintenance operation.
Copyright:
This publication is copyright. No part of it may
be reproduced, stored in a retrieval system or
transmitted in any form by any means, including
electronic, mechanical, photocopying, recording or COVER
otherwise, without the prior written permission of the
publisher.
SHOT
For all Enquiries Contact: This Issue’s cover
Engineering Information Transfer Pty Ltd shot is from the
PO Box 703, Mornington, Victoria 3931, Australia article “Laser Clading
Phone: (03) 5975 0083 Fax: (03) 5975 5735 A Versatile Proactive
E-mail: mail@maintenancejournal.com
and Reactive
Web Site: www.maintenancejournal.com
Technology” page 8.
to download the SUBSCRIPTION FORM. Annual Subscription is from $80.
Laser Cladding
A Versatile Proactive and Reactive Technology

M. Rombouts 1, J. Meneve 1, D. Robberecht 2, E. Geerinckx 1, J. Gedopt 1

1 Flemish Institute for Technological Research (VITO), Laser Centre, Mol, Belgium 2 Maintenance Partners Heavy Duty nv, Belgium
Paper presented at COMADEM 2009 (The full Proceedings of COMADEM 2009 are available for sale – please contact aarnaiz@tekniker.es)

Laser cladding is an additive process wherein a laser source is used to melt metal-based powder or
wire on to a metal substrate. The result is a thick metal or metal matrix composite coating (order of 1
mm thickness) of a high quality: it has an excellent bonding to the substrate and is completely dense.
The laser cladding process enables the treatment of heat sensitive materials and deformation sensitive
components, which cannot be processed by conventional techniques like surface welding.
The technique is increasingly being used in industry as a pro-active technology for corrosion and wear
protection and as a reactive technology for repair of worn components. In both aspects, laser cladding
is a technology contributing to cost-effective maintenance.
Various research efforts are devoted to customised coating development with the aim to reduce
maintenance. This paper will discuss the advantages and limitations of laser cladding as a repair
and coating technique. The capabilities of the process will be illustrated by industrial case studies
performed by VITO.

INTRODUCTION
The functionality of components can often be ameliorated by
combining materials with optimised properties. The bulk material
can be chosen as a function of formability, strength, stiffness and
cost. The surface of this component can then be adapted to satisfy
demands in the field of friction, wear, and corrosion.
A possible process to optimise the surface of metal components
is laser cladding [1,2]. The process can also be used as a repair
technique. During laser cladding, additive material is supplied in the
form of wire or powder to the substrate to be treated. A laser beam
melts the additive material together with a thin surface layer of the
substrate resulting in a coating with a typical thickness of 0.5-1 mm
(Figure 1). Figure 1 Principle of laser cladding
In most cases powder is used as feedstock and transported in an argon gas flow. It is possible to use an
additional protective gas flow to minimise oxidation during laser cladding. Due to the superficial melting of the
substrate, a strong metallurgical bond is formed between substrate and coating. This is an important benefit
compared to thermal spraying where only a mechanical bond is formed between the coating and substrate.
Another advantage compared to thermal spraying is the higher powder yield, which is typical 75%.
Thanks to the low and local heat input, laser cladding is very well suited for the treatment of heat sensitive
materials and components, deformation is limited and the heat affected zone is small. Moreover, the high
cooling rate during laser treatment results in coatings with a fine microstructure. After deposition, machining of
the component to its final dimensions is mostly required.
As laser source, different types of lasers can be used: CO2, Nd:YAG, diode, disk or fiber laser. The former
two lasers are the most commonly used lasers in materials processing by laser welding and cutting. However,
there is currently a strong development in new, more compact and more efficient lasers including the diode,
disk and fiber lasers. The results presented in this paper are obtained using a diode laser as processing tool.
Laser cladding is a relatively new process, which is being used in industrial sectors like petrochemical,
aerospace, machine and die building, automotive, energy production, to: repair damaged high-value machine
components like turbine blades, shafts, motors, etc. improve the corrosion and/or wear resistance of metallic
components like tooling, pumps, valves, off-shore pipes, etc
The possibilities of laser cladding as a repair and surface treatment technology in energy production industry
is illustrated with two case studies carried out for the company Maintenance Partners. Maintenance Partners
is leader in the Benelux for the repair and revision of mechanical and electrical rotating machines. The case
studies presented in this paper are the repair of a compressor shaft, and the repair of turbine wheels.
EXPERIMENTAL SETUP
Figure 2 shows the experimental setup used for laser cladding in this study. It uses a 3 kW fiber-coupled
diode laser (Laserline), using specific optics to obtain a circular spot with a diameter of about 3,7 mm at the
substrate. A powder supply unit of Medicoat, which is commonly used for thermal spraying, is used. The
powder is supplied in an argon gas flow to the coaxial cladding head. A CCD camera, which looks through a
semi-transparent mirror coaxial with the laser beam, enables aligning of the cladding head to the area to be
treated.
Vol 24 No 1
info@infratherm.com.au

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AMMJ Laser Cladding 10

Figure 2 Laser cladding setup used in the study.

REPAIR OF COMPRESSOR SHAFT

The compressor shaft is made of martensitic stainless
steel AISI 410 (DIN 1.4006 / X12Cr13). Near the end of
the shaft an area with an axial length of 70 mm was worn
off. The total length of the shaft was about 3,7 m and
the weight was about 1 ton. For laser cladding, stainless
steel powder AISI 316L is used as feedstock. A coating
with a total thickness of 2 mm is required. Since it is not
possible to obtain a coating with a thickness of 2 mm
after a single pass, multiple layers are applied on top
of each other. The typical maximal layer thickness for a
single pass is 1-1,2 mm. After laser cladding about 0,2
mm of the thickness needs to be removed to obtain a
smooth surface.
PRELIMINARY TESTS
Before treating the shaft, experiments are performed on a small bar to
evaluate the quality of the coating in terms of absence of cracking, the
degree of deformation of and the bonding to the substrate. To evaluate the
deformation behaviour, a bar with a diameter of 30 mm and length of 700
mm was cladded at both ends over a length of 20 mm. The results of a
run-out were satisfactory and showed a deformation of only 0,02-0,04 mm.
The cross section of the coating near the beginning is shown in Figure 3.
No cracks in the coating or in the martensitic stainless steel substrate are
present.
Due to the presence of key-seatings, which did not need to be treated,
copper inserts were placed at these positions to prevent these areas being
damaged by the laser beam. The stainless steel 316L material does not
adhere to the copper and the copper insert can be easily removed after Figure 3 Cross section of AISI 316L
laser cladding. on a AISI 410 stainless steel substrate

LASER CLADDING OF SHAFT

The same laser cladding parameters as used in the preliminary tests were applied during laser cladding of the
shafts. The experimental setup is shown in Figure 4. The presence of the copper insert at the key-seatings is
visible at the left image of Figure 4. Two layers of stainless steel are applied on top of each other. The shafts
are machined afterwards and the repair was positively evaluated: adequate thickness and good bonding of
coating to substrate, minimal deformation induced by laser cladding, and no porosity in coating.
Figure 4 Setup used for laser cladding of compressor shafts

Vol 24 No 1
 Tough Times Demand
Smart Solutions
Deliver real improvements in reliability and cost reductions with
EXP Enterprise; the world’s first asset health management system

This world-leading technology based solution has been developed

by the Aladon Network to enable real benefits to be delivered quickly
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whole reliability improvement process or take activities from existing
programmes that have failed to deliver the expected results.

Benefits:
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MAKE IT HAPPEN!
Contact: Stuart Hylton
The Asset Partnership
Suite 1, Culdees Road
Burwood NSW 2136, Australia
AUS: T +61 (0)2 9715 1405 F +61 (0)2 9715 1043
NZ: T +64 (0) 9625 7167 M +64 (0) 21 466 283
E stuart.hylton@assetpartnership.com
AMMJ Laser Cladding 12

REPAIR OF COMPRESSOR WHEELS

Various compressor wheels were worn near the outer diameter. The wheels are made of 30CrNiMo8 steel. The
wheels are manufactured from 2 separate parts that are connected to each other by mechanical fasteners.
In between the upper and lower plates 17 blades are present. This construction makes it impossible to use
conventional welding to repair the wheels since the excessive heat input will result in distortion, which finally
results in loosening of the upper plate from the lower plate. Another phenomenon observed when trying to
repair the wheels by conventional TIG welding is the presence of cracks
Figure 5 Cross section of stellite 21
near the mechanical fasteners, which are located very close to the area
coating applied on a 30CrNiMo8 substrate.
being welded.
PRELIMINARY TESTS
Prior to treatment of the wheels, laser cladding experiments with stellite
21 powder on a 30CrNiMo8 substrate are performed to evaluate the
absence of cracks in the coating and in the heat affected zone of the
substrate. No cracks or large pores were observed after metallographic
analyses (Figure 5). The Vickers hardness of the stellite 21 coating after
laser cladding is 450-460 HV (0.5 kg load).

REPAIR OF COMPRESSOR WHEELS

The setup used during laser cladding of the wheels is shown in Figure 6. The wheel is mounted on a rotational
axis. To prevent damage of the blades the laser is not placed perpendicularly but at an off-axis position.
Figure 7 shows a close-up of a wheel after Figure 6 Setup used for laser cladding of compressor wheels
laser cladding. At the outer diameter of the
wheel about 13 laser cladding passes are
applied to ensure an increase in diameter
from 624 mm to 632 mm. The applied scan
speed was 1000 mm/min. No cracking in the
substrate or the coating is observed visually.
After laser cladding and machining, the
wheels are evaluated by a spin test, which
consists in rotating the wheels in vacuum at a
rotation speed of 20.000 rpm. All the treated
wheels survived that test successfully.

CONCLUSIONS
- The local repair of a compressor shaft of
martenstic stainless steel by laser cladding
proved to be successful thanks to the low
heat input of the laser process and high
quality of the resulting laser cladded coating
in terms of metallurgical bonding to the
substrate and high coating density.
- Damaged compressor wheels have been
repaired by laser cladding. The repair
process proved to be successful after spin
testing the wheels at 20.000 rpm in vacuum. Figure 7 Close-ups of compressor wheels after laser cladding

REFERENCES
[1] de Damborenea J., Surface modification of metals by
high power lasers, Surf. Coat. Technol. 100–101;1998.
p.377–382.
[2] Sexton C.L., Byrne G., Watkins K.G., Alloy
development by laser cladding: an overview, J. Laser
Appl. 13 (1); 2001 2–11.

Vol 24 No 1
 Mobile/Cell: +61 (0) 402 731 563
Fax: +61 (8) 9457 8642
Email: info@lifetime-reliability.com
Website: www.lifetime-reliability.com
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 Mine Loader Failure Prediction
“Intervene Immediately” after 10,000 trouble free hours

OMDEC and FIRM Solutions Australia

In a joint project with its Australian partner, FIRM Solutions Pty Ltd in 2010, OMDEC’s EXAKT failure prediction
analysis tool accurately identified a critical impending failure in a large front end loader for a mining giant.
Starting with an incomplete data set, the joint team successfully refined the data to the point where the failure
modeling produced a startling prediction: a 90% probability of failure in the main engine bearing within the next
500 operating hours in a unit that had no history of similar problems for 12,500 operating hours.
By analyzing multiple equipment conditions, EXAKT developed an easily measurable formula to accurately
predict whether any of the equipment was in danger of immediate failure. The answer was “Yes”.

BACKGROUND AND OBJECTIVES:

The mining company operates a fleet of loaders as a key part of its continuous production operation. Downtime is both
critical and expensive: a ratio of 4:1 is used to compare run to failure costs with preventive replacement.
The key objective was to determine whether smart data analysis could produce meaningful results relating to the
probability of failure and remaining useful life of the fleet.
A second objective – which turned out to be even more significant Figure 1: Replacement Recommendation
in the short run – was to apply the fleet model to individual units to
predict and prevent expensive impending failures. Where failure was
predicted, management needed to be confident of the probability within
a given time frame so that spurious results did not cause unnecessary
maintenance.
METHODOLOGY:
Multi-year condition data was available for the fleet and was used as
the basis for the analysis. 31 failures were analysed covering 10 failure
modes for the fleet of 64 engines. Main engine bearing failure was
the dominant failure mode accounting for about one third of critical
failures. This became the focus of the detailed analysis, using a variety
of condition measurements to determine which combinations had the
best predictive capability.
Among the possible conditions such as vibration, engine operating
temperature, fuel burn etc, two specific measurements met the standard
95% test for confidence levels. These were derivatives of the Lead and
the Antimony measurements obtained gained from oil sample analysis. Figure 2: Probability of Failure
This was integrated with event data such as oil changes, operating
starts, out-of-service intervals and actual failure dates extracted from
the EAM work history database.
From this data, an EXAKT statistical model was developed to correlate
the condition monitoring data with actually experienced failure or
potential failure events. The model was then applied to the individual
units in the fleet. Two very timely output reports were produced for one
loader:
Figure 2 shows that for the engine main bearing failure mode being
analysed, the unit has operated without significant risk of failure for its
working life of 12,500 operating hours. However:
- The probability of failure within the next 250 hours is 75%
- Probability of failure within the next 500 hours is slightly over 90%.
These results are confirmed in Figure 1 with the recommendation to
intervene immediately to prevent costly damage to the equipment.
CONCLUSIONS:
Three important conclusions were reached:
1. EXAKT failure prediction and decisions models were successfully developed and tested for the fleet’s key failure
modes at the 95% confidence level
2. A readily applicable formula was developed to enable tracking of multiple equipments
3. By applying the modeling to individual equipment, a critical impending failure was predicted with a probability of over
90% within the next 500 operating hours on a unit that had no history of this failure mode.
info@omdec.com mail@firmsolution.com.au
Vol 24 No 1
 Locate electrical
problems

Detect plumbing issues

Check mechanical
devices
 Strategic Maintenance Reporting To
Enable Sustained Improvement
Jim Harper APMMS P/L Australia

This is the third in a series of articles based around a successful national Computerised Maintenance Management
System (CMMS) implementation. The first two articles dealt with application selection, change management and
lessons learnt on the journey.
• The Rise and Rise of Tier One ERP Maintenance Systems (AMMJ October 2007)
• Lessons from a Successful National CMMS Implementation (AMMJ July 2010)
This article discusses how strategic maintenance reporting can facilitate sustained improvement, leading to smarter
and more focussed maintenance and ultimately cost reduction.

Background
The challenge of any systems implementation firmly rests with the business after the implementation has finished.
The real challenge will be after the implementation team has left and the “novelty” factor of having a well structured
and usable tool has worn off. How is interest and focus maintained for the long haul?
Whilst the second article covered many areas that help system and process sustainability (such as maintenance
ownership, process reinforcement tools etc) this article will deal with strategic reporting and how it can positively
influence maintenance behaviour and lead to sustained improvement. It must be assumed that senior business
managers are committed to sustained improvement for, as stressed at length in previous articles, nothing will happen
without this leadership.
So how can strategic reporting drive these ongoing benefits?
What reports are needed and who should receive them?

Reporting Strategy Figure 1a

Maintenance Actuals and Budget Report - YTD Costs By Location
Any reporting strategy will ultimately
determine the data presented. This data
will need to be presented in a format that
will enhance and focus on the desired
outcomes of the business. So naturally
an agreement on the most relevant key
performance indicators (KPI’s) is needed
as a starting point.
The standard report set developed during
this national CMMS implementation was
built around 5 key areas and put together
in a “report pack”. The key areas were:
• Cost control
• Work management
• Maintenance effectiveness
• Asset husbandry
• System administration
This paper will briefly summarise 5 key
reports (out of a total of 12 standard reports
in the “report pack”). Each is explained,
with examples of the report outputs. In
all examples it should be noted that the
report content is always presented the
same way, with “total” values presented
first as a summary and then drill down
details (in this case by site).
• Cost Control
Whatever your involvement in
maintenance (whether actively managing
or keenly monitoring) a key driver will be
cost control. The key message of course
is to be able to maintain your assets to
Vol 24 No 1
AMMJ Strategic Maintenance Reporting 17

agreed standards at the lowest achievable cost. Thus costs vs. budget and cost details will always be required.
The report set detailed costs in 3 ways:
• Rolling graphical trend report showing monthly expenditure vs. budget
• Monthly costs to cost centres & departments
• Monthly focus on high cost assets (Top 20 by spend)
Figures 1a and 1b show the monthly cost performance of a regional quarry business. The graphical rolling monthly
expenditure vs. budget is extremely easy to interpret and the same data is then presented at each site level.

Figure 1b
Maintenance Actuals and Budget Report - YTD Costs By Location

Vol 24 No 1
AMMJ Strategic Maintenance Reporting 18

• Work Management
In simple terms managers need to know if they are keeping up with their maintenance workload. So we present
graphical trend charts clearly showing the work order count and the amount of outstanding work orders (i.e. still in
an active status and not completed) monthly. This trend is presented for preventative maintenance (PM) work orders
as well, but as a rolling count of scheduled work not completed within 14 days. Adverse trends in workload and
completion rates are then easy to manage.
Figures 2a and 2b presents the PM workload of the same quarry business. The monthly PM outstanding work order
count is clear to see, with sub graphs presenting the data as a percentage of the total. Managers can easily see their
trends and direct attention where needed, with site specific data also presented.

Figure 2a Overdue PM Work Orders Management Report - Overdue PM’s (14 Days) by Location

Figure 2b Overdue PM Work Orders Management Report - Site Specific

Vol 24 No 1
AMMJ Strategic Maintenance Reporting 19

• How smart is my maintenance effort?

The division of work between PM and planned work vs. reactive work is a key measure of the effectiveness of your
maintenance effort. Minimising reactive work and focussing on planned preventative work should be a key driver in
your business. A graphical trend (bar) chart clearly shows the division of PM work, follow up work and planned work
vs. reactive work in red. The clarity of this information was exceptionally well accepted by business managers. The
decision of which metric to use (i.e. work order count, work order value or resource effort) will need to be discussed
and locked down, and will ultimately depend on the type of business involved.
Figure 3 clearly highlights the trend in planned vs. reactive work by using the colours blue (PM work), orange (Follow
up work), green (planned) and red (reactive). The visual clarity of this report was very well accepted.

Figure 3 Maintenance Analysis Management Report (Bar) by Location

• Equipment Husbandry
Whatever maintenance regime is implemented a key driver in maintenance costs can be the “care factor” of the
equipment users. Using the old adage “nothing can be improved without first measuring” we presented a very clear
graphical trend report of monthly maintenance costs attributed to operator damage or neglect. Some businesses were
able to effectively target this area and achieve real savings by incorporating this metric into business unit KPI’s.
Figure 4 presents the monthly trend in maintenance costs attributed to operator damage. Again the results are shown
in drill down detail to each individual site.

• System Administration
Any CMMS needs to be well serviced (in terms of master data management, new assets etc) and the standard of data
entered monitored both for quality and timeliness. The report set presented system administration data in 3 areas, all
with rolling monthly trend graphs:
• Missing or late meter readings
• Costs attributed to cost centres instead of individual assets
• Amount of unreceipted purchasing monthly
Figure 5 shows the business trend in keeping up with the input of asset meter readings. Whilst the algorithm to
calculate the raw data presented some opportunity for debate, the intent here is more around trend patterns.
Vol 24 No 1
AMMJ Strategic Maintenance Reporting 20

Strategy Reinforcement
Whilst the strategy above serves an excellent base for measured improvement, the key to achieving real success
lies with all parties working towards the same goals. Much effort needs to be placed in ensuring that CMMS users
understand what data they are entering and managers at all levels need to fully aware of what they are managing!
This can be achieved in a number of ways:
• Process Training and Feedback
It is critical that standard processes are defined, taught and reinforced. Basic user training must cover these together
with strong reinforcement around data integrity. All users should understand the importance, for example, of defining
a work order as reactive and appreciate the importance of timely close out of work orders. On the same vein users
and workshops should receive feedback on their performance. The workshop communication board can be invaluable
here.
• Report Pack Explanation
A standard document should be developed that clearly outlines the reporting strategy. Each reporting area should
be explained, and an overview of the intent and data format of each report should be provided. With this simple
“handbook” all levels of management can be fully cognisant of their business reporting requirements.
• Senior Manager Training
Training sessions must be held to engage senior managers. They must understand the strategic significance of the
report pack and more importantly be able to understand trend variances and take necessary actions where needed.
As part of business sign off during this national project was the prerequisite that senior mangers attend a formal
session on the maintenance system/processes and reporting. Senior managers must be engaged.

Report Delivery
The report packs should be scheduled monthly (in this case on Day 6) to be automatically emailed to the recipients.
Most report systems have this facility and it is important to remove the need for manual running.
Figure 4 Work Order Classification Trend Management Report (Costs of damage i.e. by operators)

Vol 24 No 1
AMMJ Strategic Maintenance Reporting 21

Whilst the core content was not varied the reporting content was set up to be dependent on the recipient’s management
level. This ensured that all reporting communication was targeting the same content, the same KPI’s and ultimately the
same goal. It should be not uncommon for a “red circled” report to be emailed down the line to seek explanation!
Examples of these reporting levels are explained below:
• Regional Manager – to receive a report pack reporting regional KPI trends, then drilling down to businesses
• Business Manager - to receive a report pack reporting business KPI trends, then drilling down to sites
• Site Manager - to receive a report pack reporting site KPI trends, then drilling down to departments
Examples of this data “levelling” can be seen in the report examples presented.

Benefits
• The amount of effort put into the reporting focus can reap large and sustained benefits. With a common
set of reports targeted to all levels of business (from regional managers to workshop supervisors) the
advantage in having “one language” to trend and debate maintenance is realised.
• Strengths vs. weaknesses are easily identified, with managers easily able to drill down within their
responsibility scope. This enables true national (even international) benchmarking.
• Tangible results are presented which can be discussed at management meetings.
• Outcomes from initiatives can easily be trended.
• Report outcomes can be linked to job performance management.
• A successful reporting strategy can lead to sustained improvement.

If you would like a full “report pack” together with detailed comments and example reports (in pdf format) please email
Jim at the address below. APMMS (Asset & Process Maintenance Management Solutions) has offices in Sydney and
Newcastle, and provides services in process, maintenance and inventory management. See www.apmms.com.au or
contact Jim Harper (Director/Principal) at jimapmms@primusonline.com.au.

Figure 5 Missing and Late Meter Reading Score Management Report (Bar) by Location

Vol 24 No 1
 What’s The FRACAS
Failure Elimination Made Simple
Ricky Smith and Bill Keeter Allied Reliability (USA)

“Your system is perfectly designed to give you the results that you get.”
W. Edwards Deming PhD

How good is your organization at identifying failures? Of course you see failures when they occur, but
can you identify when recurring failures are creating serious equipment reliability issues? Most companies
begin applying RCA or RCFA to “high value failures”. While this is not wrong, I prefer to either not see the
failure in the first place, or at the least, to reduce the failures to a controllable level.

Failure Reporting Analysis and Corrective Action System (FRACAS) is an excellent process that can be used to
control or eliminate failures. This is a process in which you identify any reports from your CMMS/EAM or a specialized
Reliability Software that can help you to eliminate, mitigate or control failures. These reports could include cost
variance, Mean Time Between Failure, Mean Time Between Repair, dominant failure patterns in your operation,
common threads between failures such as “lack of lubrication” (perhaps due to lubricator not using known industry
standards). One poll was conducted recently covering 80 large companies. Shockingly, none of these companies
were capturing the data required to understand and control equipment failures.
Answer the following questions honestly before you go any further to see if you have any problems with identifying
failures and effectively eliminating or mitigating their effects on total process and asset reliability.
1. Can you identify the top 10 assets which had the most losses due to a partial or total functional
failure by running a report on your maintenance software?
2. Can you identify the total losses in your organization and separate them into process and asset
losses for the past 365 days?
3. Can you identify components with a common thread due to a specific
failure pattern, such as theone shown oposite?
Many times, the cost of unreliability remains unknown because the causes of unreliability are so many. Whether you
want to point the finger at maintenance, production (operations) or engineering, each functional area plays a role in
unreliability. Here are a few examples of those losses:
1. Equipment Breakdown (total functional failure)
Causes of Equipment Breakdown
• No Repeatable Effective Repair, Preventive Maintenance, Lubrication, or Predictive MaintenanceProcedures
• No one following effective procedures
2. Equipment not running to rate (partial functional failure)
Causes of Equipment not Running to Rate
• Operator not having an effective procedure to follow
• Operator not trained to operate or roubleshoot equipment
• Management thinking this is the best rate at which the equipment can operate because of age or condition
3. Off-Quality Product that is identified as “first pass quality” (could be a partial or total functional failure)
Causes of Quality Issues
• Acceptance by management that “first pass quality” is not a loss because the product can be recycled
4. Premature Equipment Breakdown
• Ineffective or no commissioning procedures. We are talking about maintenance replacement of parts or
equipment that fails prematurely because no one has identified if a defect is present after the
equipment has been installed, repaired, serviced, etc. If you have ever seen equipment break down or not
running to rate immediately after a shutdown, you know what we are talking about.

The Proactive Workflow Model - Eliminating unreliability is a continuous improvement process much like the
Proactive Work Flow Model in Figure 1. The Proactive Workflow Model illustrates the steps required in order to move
from a reactive to a proactive maintenance program.
What the Proactive Work Flow Model really means to your organization - Implementing the Proactive Work Flow
Model is the key to eliminating failures. The built-in continuous improvement processes of Job Plan Improvement
and the Failure Reporting, Analysis, and Corrective Action System (FRACAS) help ensure that maintainability and
reliability are always improving. All of the steps and processes have to be implemented in a well managed and
controlled fashion to get full value out of the model.
The foundational elements of Asset Health Assurance are keys because they ensure that all of the organization’s
assets are covered by a complete and correct Equipment Maintenance Plan (EM). These are requirements (not
options) to ensure that you have a sustainable proactive workflow model.
Vol 24 No 1
 What’s The FRACAS 23

Figure 1 Proactive Workflow Model Figure 2 FRACAS Loop

You cannot have continuous improvement until you have a repeatable, disciplined process.
The objective of the Proactive Work Flow Model is to provide discipline and repeatability to your maintenance
process. The inclusion of the FRACAS provides continuous improvement for your maintenance strategies. There are
fundamental items you must have in place to insure that you receive the results you expect.
Think of FRACAS this way. As you have failures, you use your CMMS/EAMS failure codes to record the part-defect-
cause of each failure. Analyzing part-defect-cause on critical assets helps you begin to make serious improvement
in your operation’s reliability. Looking at the FRACAS Model in Figure 2, we begin with Work Order History Analysis,
and from this analysis we decide whether we need to apply Root Cause Analysis (RCA), Reliability Centered
Maintenance, or Failure Modes and Effect Analysis to eliminate or reduce the failures we discover. From the RCA, we
determine maintenance strategy adjustments needed to predict or prevent failures. Even the most thorough analysis
doesn’t uncover every failure mode. Performance monitoring after we make the strategy adjustments may find that

Planning 4 Reliability National Forum

Planning for a Reliable Future
The Planning for Reliability National Forum provides
a showcase for practitioners in Planning, Scheduling
and Reliability Improvement to share how they have
overcome pitfalls and achieved success.
The National Forum will introduce user groups of leading
solutions providers for participants to learn new concepts
Learn about
and to contribute valuable information to develop products
‡ Shutdown and Outage Management
and services that work for your business.
‡ Planning & Scheduling Best Practice
‡ Establishing Effective Reliability of your Assets
‡ Co ordinating the Maintenance Schedule

Key features of the event

‡ Leading practitioners presenting case studies
‡ Speed networking - meet other like minded individuals
‡ Pre - conference User Groups
‡ Industry exhibitors

Registration/Information
Anna Civiti
Tel:+ 61 (0) 3 9697 1103 / anna.civiti@sirfrt.com.au
www.sirfrt.com.au
5th and 6th April 2011 Practitioner Companies

The Langham Hotel Melbourne

 AMMJ What’s The FRACAS 24

new failure modes not covered by your strategy occur. You can now make a new failure code to track the new failure
mode so additional failures can be tracked and managed when you review work order history. You can see this is a
continuous improvement loop which never ends.

Steps to Implementing an Effective FRACAS

Let’s back up a little. The foundational elements of an effective FRACAS are an effective validated equipment
hierarchy, criticality analysis, failure modes analysis, and equipment maintenance plans.
FRACAS Checklist:
• Equipment Hierarchy should be built and validated so that similar failures on like equipment can be identified
across an organization.
• Criticality Analysis is developed and validated so that equipment criticality is ranked based on Production
Throughput, Asset Utilization, Cost, Environment, and Safety.
• Failure Modes Analysis is completed on all critical equipment using FMA, FMEA, or RCM.
• Equipment Maintenance Plans are developed on all critical equipment to prevent or predict a failure.
Effective Equipment Hierarchy
Asset Catalog or Equipment Hierarchy must be Figure 3 Reason for Equipment Hierarchy is Valiidated
developed to provide the data required to manage
a proactive maintenance program which includes
failure reporting or FRACAS (Failure Reporting,
Analysis and Corrective Action System). In order
to eliminate failures, one needs to ensure this is a
successful first step. Figure 3 displays the findings
from a plant with 32 total “Part – Bearing” failures
from different size electric motors (“Part” is identified
from a CMMS/EAM Codes drop down screen). One
type “Defect – Wear” occurred in 85% of the failures
(“Defect” is identified from a CMMS Codes drop
down screen).
In 98% of the cases, “Cause” was found to be
”Inadequate Lubrication”. Now it is time to perform a Root Cause Failure Analysis on this common thread of failures.
(“Cause” as identified on CMMS/EAM Codes drop down screen).
Once the hierarchy is
established you can find
similar failures in one area
of an operation or across the
total operation. Validation
of the equipment hierarchy
is required against the
organization’s established
equipment hierarchy
standard. We are looking for
“Part” – “Defect” – “Cause”.
Maintenance personnel
may not have the training
or ability to determine
the “Defect” (Predictive
Maintenance Technician
could identify Defect) and
“Cause” can be typically
identified by a maintenance
technician, maintenance
engineer, reliability engineer,
or predictive maintenance
technician.
After a thorough analysis
you will find that most
failures come from a small
amount of equipment.
Figure 4 Intersept Model
The question is, “Which
equipment?”.

Vol 24 No 1
 AMMJ 25
Figure 5 “4 Way Prioritisation Model”

Asset Criticality Analysis

Everyone says they have identified their critical equipment. But, in many cases, equipment criticality could
change based on how upset people are about an equipment problem or because people are confused about what
consequences associate to failure and the probability it will occur if we manage equipment reliability effectively. The
purpose of the Asset Criticality Analysis is to identify which equipment has the most serious potential consequences
on business performance, if it fails. Consequences on the business can include:
• Production Throughput or Equipment / Facility Utilization • Cost due to lost or reduced output
• Environmental Issues • Safety Issues • Other
The resulting Equipment Criticality Number is used to prioritize resources performing maintenance work.
The Intercept Ranking Model illustrates this process (Figure 4). On the “Y” axis you see the asset criticality is listed
from none to high. I like using a scale of 0-1000 because all assets are not necessarily equal.

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AMMJ What’s The FRACAS 26

Using the Intercept line which is struck down the middle, a planner or scheduler can define which job should be
planned or scheduled first, or at least get close to the best answer, because management has already been involved
in determining the most critical asset and the equipment has told you (on the “X” axis) which one has the highest
defect severity (in the worst condition).
The only other two factors I would add in determining which job to plan or schedule would be based on work order
type (PM, CM, CBM, Rebuild, etc) plus time on back. Figure 5 shows the 4-Way Prioritization Model for planning and
scheduling.
Identify what equipment is most likely to negatively impact business performance because it both matters a lot when
it fails and it fails too often. The resulting Relative Risk Number is used to identify assets that are candidates for
reliability improvement. A consistent definition for equipment criticality needs to be adopted and validated in order to
ensure the right work is completed at the right time. This is the key to the elimination of failures.
Identification of Failure Modes
The goal of most maintenance strategies is to prevent or predict equipment failures. Equipment failures are typically
caused by the catastrophic failure of an individual part. These parts develop defects, and when left alone, those
defects lead to the ultimate catastrophic failure of the part. The defects are, in turn, caused by “something”. Eliminating
that “something” (the cause) will eliminate the failure.
The primary goal of an effective Preventive (PM) program is to eliminate the cause and prevent the failure from
occurring. The primary goal of a Predictive Maintenance (PdM) or Condition Based Monitoring (CBM) Program is to
detect the defects and manage the potential failures before they become catastrophic failures.
In addition, many program tasks are designed to maintain regulatory compliance. Many companies have PM
programs. However, many of the tasks in them do not address specific failure modes. For example: An electric motor
with roller bearings has specific failure modes which can be prevented with lubrication. The failure mode is “wear”
caused by “Inadequate Lubrication”. The next question may be why you had Inadequate Lubrication. The Inadequate
Lubrication could be identified as a result of no lubrication standard being established for bearings. In other words
someone gives the bearing “x” shots of grease even though no one knows the exact amount to prevent the bearing
from failure.
The best way to identify failure modes is to use a facilitated process. Put together a small team consisting of people
knowledgeable about the equipment, train them thoroughly on the concept of part-defect-cause, and go through the
basic equipment types in your facility such as centrifugal pumps, piston pumps, gearboxes, motors, etc.. You will
find that a relatively small number of failure codes will cover a lot of failure modes in your facility. The failure modes
developed during this exercise can later become the basis for the failure modes, effects, and criticality analysis
that takes place during Reliability-Centered Maintenance (RCM) projects. In our book, we focus on failure mode
identification as an output of FRACAS (Failure Reporting, Analysis and Corrective Action System), which, again, is a
strong continuous improvement process.
If, over a period of one year, the dominant failure mode is “wear” for bearings caused by Inadequate Lubrication then
one can change or develop a standard, provide training and thus eliminate a large amount of failures.
The problem is that most companies do not have the data to identify a major problem on multiple assets (No data in
equals no effective failure reports out). For example, it isn’t the motor that fails; the motor fails because of a specific
part’s failure mode, which then results in catastrophic damage to the motor. Unless, of course, the defect is identified
early enough in the failure mode.
Maintenance Strategy
The maintenance strategy should be a result from either a Failure Modes and Effect Analysis, Reliability Centered
Maintenance or from failure data collected from your CMMS/EAM.
Elimination Strategy: The best way to eradicate this deadly waste is get a better understanding of the true
nature of the equipment’s failure patterns and adjust the Maintenance Strategy to matc - Andy Page
So what is a maintenance strategy? Let’s break down the two words: Maintenance is to keep in an existing condition,
or to keep, preserve, protect, while Strategy is development of a prescriptive plan toward a specific goal.
So, a Maintenance Strategy is a prescriptive plan to keep, preserve, or protect an asset or assets. Keep in mind that
one specific type of maintenance strategy is “run to failure” (RTF). However, RTF is used only if, based on thorough
analysis, it is identified as the best solution for specific equipment to optimize reliability at optimal cost. Less invasive
maintenance is preferred to more invasive maintenance.
This is one of the fundamental concepts of any well-defined maintenance strategy. Specific maintenance strategies
are designed to mitigate the consequences of each failure mode. As a result, maintenance is viewed as a reliability
function instead of a repair function. Saying this means Predictive Maintenance or Condition Monitoring is the best
solution because it is mainly noninvasive.
Knowing that both systemic problems and operating envelope problems produce the same type of defects, a
maintenance strategy that merely attempts to discover the defects and correct them will never be able to reach a
proactive state. Technicians will be too busy fixing the symptoms of problems instead of addressing the root cause.
To reach a truly proactive state, the root cause of the defects will need to be identified and eliminated. Maintenance
Vol 24 No 1
 AMMJ What’s The FRACAS 27

Figure 6 Percentage of Assets With

No Identifiable Defects

strategies that accomplish this are able to achieve a step change in performance and achieve incredible cost savings.
Maintenance strategies that do not attempt to address the root cause of defects will continue to see lackluster
results and struggle with financial performance.
A Maintenance Strategy involves all elements that aim the prescriptive plan toward a common goal. Key parts of a
maintenance strategy include Preventive and Predictive Maintenance based on a solid Failure Mode Elimination
Strategy, Maintenance Planning consisting of repeatable procedures, work scheduled based on equipment criticality,
work executed using precision techniques, proper commissioning of equipment when a new part or equipment is
installed, and quality control using Predictive Maintenance Technologies to ensure no defects are present after
this event occurs. The very last part of your maintenance strategy is FRACAS, because it drives the continuous
improvement portion of this strategy.

Failure Reporting
Failure reporting can come in many forms. The key is to have a disciplined plan to review failure reports over a
specific time period, and then to develop actions to eliminate failure. Following are a few Failure Report examples,
which should be included as part of your FRACAS Continuous Improvement and Defect Elimination Process.
Asset Health or Percent of Assets with No Identifiable Defect
Reported by maintenance management to plant and production management on a monthly basis at least (see Figure
6). An asset that has an identifiable defect is said to be in a condition RED. An asset that does not have an identifiable
defect is said to be in condition GREEN. That is it. It is that simple.
There are no other “but ifs”, “what ifs” or “if then”. If there is an identifiable defect the asset is in condition RED. If there
is no identifiable defect, it is GREEN. The percentage of machines that are in condition GREEN is the Asset Health
(as a percentage) for that plant or area. The definition for defect is: an abnormality in a part which leads to equipment
or asset failure if not corrected in time.
Example: the plant has 1,000 pieces of equipment. Of that number, 750 of them have no identifiable defects. The
plant is said to have 75% Asset Health. There is an interesting aspect about Asset Health. Once this change is
underway, Asset Health, as a metric, becomes what most maintenance managers and plant managers have wanted
for a long time — a leading indicator of maintenance costs and business risk.
Mean Time Between Failures and Mean Time Between Repairs
Reported by maintenance or reliability engineers on a monthly basis on the top 5-20% of critical equipment. The report
to management should include recommendations to improve both metrics and should be measured and posted on a
line graph for all to see.
Cost Variance by area of the plant
Reported by maintenance and production supervisor area of responsibility. Cost variance must be reported to
maintenance and production management on a monthly basis. The report should not be acceptable without a known
cause of the variance and a plan to bring it in compliance.
Most Frequent Part-Defect-Cause Report
Reported monthly by maintenance or reliability engineers. If you do not have maintenance or reliability engineers, you
may need to appoint a couple of your best maintenance technicians as “Reliability Engineering” Technicians, even if
unofficially, and train them to be a key player in this failure elimination process. This one report can identify common
failure threads within your operation which, when resolved, can make a quick impact to failure elimination.
There are many more reports that can be used effectively, but will not fit in the space of this article. You will be able
to find more reports in the book on “FRACAS” written by Ricky and Bill.
Bill Keeter (email at bkeeter@gpallied.com) and Ricky Smith (email at rsmith@gpallied.com) are currently Senior
Technical Advisors with Allied Reliability.
This article was first published in the June/July issue of Uptime Magazine. www.uptimemagazine.com
Vol 24 No 1
 MAINTENANCE and RELIABILITY WEB LINKS
Compiled by Len Bradshaw (2011)

ALS Industrial Division www.alsglobal.com

ALS Industrial Division operates within the ALS group. ALS provides diversified testing services globally. In Australia, ALS Industrial provides Non
Destructive Testing (NDT) & Inspection, Integrated Condition Monitoring and Reliability Services, Materials Engineering Consulting, Mechanical
Testing, Asset Management and Shutdown Planning / Execution Services from some 25 offices across Australia.

APMMS (Asset & Process Maintenance Management Solutions) www.apmms.com.au

In its 7th year of business APMMS offers specialised consulting services around asset lifecycle management. APMMS’s’ skill base includes CMMS
implementations (specialising in Oracle eAM with over 41/2 years of experience), process analysis, workplace training and inventory excellence.
APMMS has offices in Sydney and Newcastle.

Applied Infrared Sensing www.applied-infrared.com.au http://twitter.com/AISdefence

Applied Infrared Sensing specialises in active infrared and thermal imaging technologies since 2004. The company works in industrial and
scientific markets offering a wide range of thermal imaging cameras for asset management as well as sophisticated equipment for research and
development.

Apt Group www.aptgroup.com.au

The apt Group of companies (apt Technology & apt Risk Management) provides a holistic approach to physical asset management & reliability,
covering mechanical & electrical (LV/HV) disciplines in Plant Condition Monitoring & Engineering Improvements. Representative for All-test Pro
motor diagnostics, Pruftechnik vibration/alignment/balancing, Guide Thermography, API Pro MMS and Aptools asset optimisation.

Aquip Systems www.aquip.com.au

Aquip Systems is an exclusive distributor for Prüftechnik Alignment and Prüftechnik Condition Monitoring in Australia, providing sales, technical
support and training. For information on Rotalign ULTRA, Rotalign PRO, Optalign smart, ShaftALIGN, VibSCANNER, VibXPERT, VibroWEB and
VibNODE please see our website.

ARMS Reliability www.globalreliability.com

Linkedin - http://www.linkedin.com/companies/arms-reliability-engineers Twitter - http://twitter.com/armsreliability
The ARMS Reliability website is an informative portal for information on Reliability Engineering Principles,Products and Services. With a knowledge
base of current Reliability and Root Cause issues and trends it provides an immediate link with ARMS Reliability.

Asset Capability Management www.assetcapability.com.au

acm designs and delivers management systems and tools to help asset owners more effectively manage their people and plant to improve
productivity and be globally competitive.

Asset Reliability Services www.assetreliability.com.au

Reliability Education and Condition Monitoring Specialists, we are your single point of contact for all your CM and Machine Problem Solving.
Experienced on-site CM Specialists and world renowned seminar speakers is what makes us the leaders in Plant Asset Reliability Education and
Services

Assetivity www.assetivity.com.au
A hybrid management and engineering consulting organisation, focused on improving Asset Management and Maintenance performance for
organisations in the Mining and Mineral Processing, Oil & Gas, Utilities, Power Generation, Defense and Heavy Manufacturing sectors.

ATTAR www.attar.com.au
ATTAR provides leading practice Engineering Training & Consulting services! Established in 1985 ATTAR offers a variety of consulting services
including Metallurgical services, Acoustic Emission Testing, Slip Resistance Testing, Failure Analysis, Expert Witness and other tailored services.

AyaNova Service Management & Workorder Software www.ayanova.com

Manage all aspects of service management and maintenance including automated work orders, dispatching, scheduling, preventive maintenance,
notifications, customer equipment tracking, history, management reports, full inventory, custom fields and labels, notification of events, QuickBooks
and Peachtree integration, remote access and web browser interface and much much more.

Balmac Inc www.balmacinc.com

Since 1976, Balmac Inc. has manufactured high quality vibration meters, monitors, monitoring systems, switches and analyzers for oil and gas,
energy, industrial process and commercial building applications around the world.

BEIMS www.beims.com
BEIMS Facilities Management software can assist with facilities management in organisations of all sizes. BEIMS is a powerful solution for:
Planned/Ad Hoc Maintenance; Asset Management; Contractor Management; PDA Solutions; Web Requests; Condition Assessment; Visitor
Registration; Materials Management; Reporting; Essential Services.

BMS Technology www.bmstech.com/mantra

Free maintenance management software for planned maintenance scheduling, job history, including planned, unplanned and breakdown, job
issuing, stock control.

CMMS Software www.cmmssoftware.co.uk

Maintenance Coordinator and PM Coordinator are two low-cost CMMS Software applications that are easy to install and implement. You can
download a demo and purchase either of these online through this website. You can have a CMMS system up and running in your plant in a jiffy.

COGZ Systems, LLC www.cogz.com/

COGZ CMMS - Preventive Maintenance Software - Work Order Software Simple installation, quick setup, ease of use and speed of operation sets
the COGZ preventative maintenance software apart from other maintenance management systems. Take command of your maintenance with
COGZ CMMS Software! With its intuitive interface and user-friendly design, COGZ integrates preventive maintenance and work orders
.
CRC for Integrated Engineering Asset Management (CIEAM) www.cieam.com
As a Cooperative Research Centre, CIEAM’s research is driven by industry requirements in collaboration with scholarly researchers. CIEAM
works closely with industry partners to develop solutions to address their needs and as a result, contribute to improving the engineering asset
management industry sector.

Vol 24 No 1
 AMMJ Maintenance and Reliability Web Links 29

CyberMetrics Corporation www.cybermetrics.com

CyberMetrics Corporation is a leading developer and worldwide supplier of quality, supply chain, and facilities maintenance and asset management
software solutions. CyberMetrics is dedicated to providing our customers with high-quality, open-standards software solutions that are affordable,
scalable, easy to implement, manage, and use.

Davison Systems, LLC www.DavisonSoftware.com

Davison CMMS manages work by personnel on equipment and other facility assets. PredictMate (tm) for predictive maintenance (PdM) receives data
from printouts, handheld device, or SCADA. It creates work orders in the CMMS from predicted alarms or for condition-directed maintenance.

Dbase Developments www.mainplan.com

MainPlan CMMS for asset and spares control in manufacturing, mining, food processing. Save money, lower downtime, increase production with
better asset control.

Deep Cove Consulting Services Pty Ltd www.deepcove.com.au

Deep Cove Consulting Services (DCC) is the exclusive Australian agent for GUARDIAN CMMS software. We can provide a turnkey solution
tailored to your needs that includes: Needs Assessment, Implementation, Training and ongoing Support. From a single-user to a large multi-user
system, GUARDIAN will help you manage all of your Asset Maintenance requirements.

Design Maintenance Systems Inc. (DMSI) www.desmaint.com

Learn about the profound effect of rugged handhelds with DMSI’s MAINTelligence InspectCE, for operator / reliability basic care; preventive
maintenance; safety and environmental routes; work orders; and upload to process historians or maintenance software. Customers see significant
reductions in inspection times (up to 60%), maintenance costs (upward of 30%) and key performance indicators (60%).

Eagle Technology, Inc. www.eaglecmms.com

http://twitter.com/ProTeusCMMS http://www.linkedin.com/company/452453?trk=null
ProTeus is a full-featured Enterprise Asset Management system designed for a global environment for intelligent buildings and facilities. ProTeus is
widely acclaimed as one of the most versatile easy to use software solutions for intelligent buildings maintenance, plants & equipment, hospitals/
healthcare facilities, school & college campuses, airports, resorts and more.

eMaint Enterprises www.emaint.com

http://www.facebook.com/CMMSSoftware http://twitter.com/emaintx3
eMaint’s web-based CMMS system manages work orders and work requests, preventive maintenance, purchasing and inventory control, planning
and scheduling, asset history, cost tracking, condition monitoring and robust reporting in one user-friendly and affordable solution that can be
accessed across multiple locations in multiple languages from any browser-based device (including smartphones).

EPAC Software Technologies, Inc www.epacst.com

Manage Maintenance As a Business” with ePAC. The ePAC user interface, written by maintenance people for maintenance people, along with
superior functionality, makes ePAC a great value. As an EAM/CMMS solution, users find no other product as intuitive. Onsite Options: Web-based,
Network, Work Station, Mobile. ONLINE OPTIONS: Monthly subscription. Access via internet. Database Options: Access, SQLServer, Oracle.

Signing the order was easy...

Greg wondered why he had taken so long to get outside assistance. Perhaps it was the fact that
Maintenance consultants seemed to have a bad reputation – “Borrow your watch to tell you the time – then
sell you your watch”. Perhaps it was because they had a reputation for charging exorbitant fees. Perhaps
there was a little bit of pride involved – “It is my job to make this plant safe, efficient and reliable, and I am
going to do it – myself!”
But finally he had to admit that the challenges he faced were too great for any one person to deal with on
their own, and he had contacted Assetivity. It’s amazing how a series of equipment failures (including a
catastrophic conveyor pulley shaft failure that had caused a major safety incident and significant downtime)
can focus the mind, he thought, wryly.
At the initial meeting with the senior Assetivity consultant, Greg had been impressed by the way in which
his problems and issues had been listened to, considered, and absorbed. He had liked the way that, in the
course of their discussion, they had together been able to give focus to the complex network of issues and
opportunities that he faced, and put these in perspective. He been attracted to the down-to-earth and
practical discussion regarding implementation issues. And he was impressed by the focus on developing
and implementing solutions, rather than on selling specific products, tools or methodologies.
It had become clear, in the course of their discussion, that there was an urgent need to “get back to the
basics” – to ensure that the current Preventive Maintenance program was appropriate, and was being properly executed at shop floor level, and that failures
were being prevented, and the causes of those failures eliminated. They had agreed that the first step was to conduct a quick diagnostic review, focusing on
these areas, in order to develop a plan of action. Getting authorisation from the Plant Manager had been surprisingly easy, and Greg was signing the Purchase
Order for this review now. So far, it had been smooth sailing, but Greg knew that the real challenges lay ahead. But, with the involvement of Assetivity, he had
confidence that they were on the right track.

More than availability and reliability...

Perth, Brisbane, Melbourne
Ph +61 8 9474 4044 Asset Management Consultants
www.assetivity.com.au
 AMMJ Maintenance and Reliability Web Links 30

FLIR Systems Australia Pty Ltd www.flir.com/thg

FLIR Systems is the global leader in the design, production and marketing of thermal imaging camera systems for a wide variety of thermography
and imaging applications, including condition monitoring, maintenance and process control. FLIR provides service, training and application support
for infrared camera users.

FSI (FM Solutions) APAC Pty Ltd - Concept™ systems www.fsifm.com.au

Microsoft Gold Partner awarded FSI, has headquarters in the UK, offices in Australia and Dubai, and an international partner network. Concept
Evolution™ from FSI is a fully web-enabled, complete Facilities and Maintenance Management solution. Solutions are scalable and can range
from single user to large national or multi-national solutions.

GrandRavine Software Limited www.maintscape.com

MaintScape is powerful and easy-to-use software for maintenance management, calibration, facilities management, and asset management.
MaintScape’s robust functionality is very reasonably priced. Our customers enjoy top-notch support, and find their appreciation of MaintScape
grows over time.

IDCON www.idcon.com
IDCON’s mission is “To help our clients improve overall reliability and lower manufacturing and maintenance costs”. Our strengths are for example;
maintenance assessments, leadership and organization, planning and scheduling, preventive maintenance, condition monitoring, Root Cause
Analysis, and maintenance store room management.

Idhammar Systems Ltd www.idhammarsystems.com

Idhammar Systems keeps industry moving and improving with acclaimed manufacturing efficiency solutions. Our products include leading
European Maintenance Management Systems (CMMS), and leading edge OEE Management Systems delivering real-time, accurate performance
data to maximise assets and drive continuous improvement.

IFCS inc. www.mysenergy.com

Senergy EAM / CMMS automate and control all the operations of the maintenance process. It satisfies all the needs concerning Preventive,
Conditional and Corrective Maintenance, in order to increase the productivity of the maintenance’s team. It intervenes at all levels of management
of the maintenance activities, and satisfies the requirements of standards (ISO,HACCP,PEP,etc.)

Infor Global Solutions www.infor.com/solutions/eam/

Infor EAM enables manufacturers, distributors, and services organizations to save time and money by optimizing maintenance resources,
improving equipment and staff productivity, increasing inventory efficiency. Infor EAM software includes reporting tools that enable better decision-
making to help improve future asset performance management and profitability

Infrared Thermal Imaging, Inc www.itimaging.com

ITI offers infrared inspection services for industrial and commercial applications. Our services can be tailored to meet your facilities specific needs
for electrical distribution systems, fixed fired equipment, steam air decoking, or infrared detection on VOC gases.

Infratherm Pty Ltd www.infratherm.com.au

Infratherm is a premium supplier of thermal imaging radiometers, analytical and report writing software and applications support for the Preventative
Maintenance and Condition Monitoring tasks. With over 20 years experience in all aspects of thermal imaging, Infratherm can supply a complete
solution for your radiometric needs. Infratherm provide local service, calibration and formal training across all markets and applications.

Initiate Action www.phillipslater.com

Phillip Slater will help you to achieve your engineering materials and spare parts goals and get the right parts, in the right place, at the right time,
for the right reason. Visit the website for more information and access to our knowledge base

International Source Index, Inc. www.sourceindex.com

The Bearing Expert Toolkit provides immediate access to 1 million bearings in interchange and 350,000 base bearing frequencies for 100+
manufacturers. Users can immediately locate dimensional data, part numbers, bearing types, manufacturers, prefix and suffix descriptions, contact
angles, AFBMA part numbers etc. Internet subscriptions and CD-ROM. Available to end users, integrators and resellers

InterPlan Systems Inc www.interplansystems.com

Offers software, training and consulting solutions for estimating, planning, scheduling and managing refinery and petrochemical processing plant
shutdowns, turnarounds and outages.

Industrial Precision Instruments www.ipi-infrared.com & www.ipi-inst.com

The Infared Specialists: Visit our website for details on a wide range of infrared cameras, training and accessories. We offer equipment to suit all
budgets, expert advice and unparalleled service.

iSolutions International Pty Ltd www.isipl.com

iSolutions is a leading provider of Life Cycle Costing software, services and training. Used by leading Mining Companies, Equipment Dealers
and Earthmoving Contractors on over 200 sites our dynamic Life Cycle Costing methodology enables Equipment Managers to understand their
decisions affect the long term productivity and cost of their operations.

Lawson Software www.lawson.com

Lawson M3 Enterprise Asset Management (EAM) application is specifically designed for organisations where asset reliability & availability is
crucial to the success of your business. M3 EAM is a pre-configured, best-of-breed maintenance solution that provides asset data management,
preventive maintenance, work order control, diagnostics management & statistical analysis which can enhance the management of your assets.

Lifetime Reliability Solutions www.lifetime-reliability.com

Lifetime Reliability Solutions Consultants combine asset maintenance management, precision work quality and LEAN process waste elimination
into simple answers for production plant maintenance problems and equipment reliability improvement. Visit our website for articles on getting
long lifetime reliability and how to introduce precision maintenance practices.

Local Government Asset Management Wiki http://lgam.wikidot.com

The Local Government Asset Management (LGAM) wiki is a free site created for the use of and to promote collaboration between Local
Government Asset Management practitioners. It is a place to post asset related information of interest to Councils, and to search for information
already posted.

MACE Consulting (Aust) www.macecg.com.au

MACE is a specialist asset management and maintenance engineering professional services company. MACE assists its clients to solve or
manage complex business problems in an innovative, practical and efficient manner. The aim of MACE is to promote the good practice and
management of physical assets. MACE is focused on outcomes and achievement of all goals and recommendations.
Vol 24 No 1
 AMMJ Maintenance and Reliability Web Links 31

Mainpac Pty Ltd www.mainpac.com.au

Mainpac’s AM and Enterprise solutions offer you all the functionality of an Asset Management solution coupled with the capabilities of .NET
technology. Use Work Orders, Forecasting, Labour Resource Scheduling, Asset Registers (both operational assets and financial assets),
integration tools, BI reports plus more for all your asset maintenance needs.

Maintenance Experts Pty Ltd (MEX) www.mex.com.au

Maintenance Experts are the leading CMMS software provider in Australia with over 4000 users around the globe. The CMMS software MEX offers
you superior functionality and flexibility with modules such as; Work Orders, Asset Register, History, PM, Invoicing, Reports, Stores, Downtime,
Security and more. MEX allows you to efficiently and effectively track your assets/equipment.

MaintSmart Software – CMMS with Reliability Analysis www.maintsmart.com

MaintSmart maintenance management software (CMMS) provides work orders, PMs, equipment failure analysis, inventory/purchasing, asset
management, reliability analysis and skill analysis. MaintSmart manages, analyzes and reports on your entire maintenance operation. Automatically
print PMs, work orders and more based on schedules and events.

Mobius Institute www.mobiusinstitute.com

Mobius Institute develops the “iLearn” series of computer-based and Web-based vibration analysis and shaft alignment training, and offers vibration
analysis training courses (Category I, II, III) that follow ISO and ASNT standards. Our new Web site offers lots of articles, tips, presentations,
tutorials and more.

Monash University www.gippsland.monash.edu/science/mre

Find out about our postgraduate programs: two Graduate Certificates, Graduate Diploma and Master’s degree in maintenance and reliability
engineering. Hundreds around the world have graduated from these programs, available only by off-campus learning ( distance education) to
learners in any country. Study one or two units per semester. Also open to non-graduates (conditions apply).

Net Facilities www.netfacilities.com

Net facilities is a complete computerized maintenance management system. Our asset tracking software will tell you when preventive maintenance
is overdue so that you can take action before something goes wrong. It manages work orders, work flow distribution, vendor collaboration,
inventory management, budget tracking, and preventative maintenance for facility, property and school management.

OMCS International www.omcsinternational.com

OMCS specialises in reliability improvement programs based on simplicity. We supply cultural change programs supported by rapid analysis
techniques and customised software applications developed in-house. Customers range in standards from the winners of the North American
Maintenance Excellence Awards to those at the very beginning of their reliability journey.

OMDEC, optimal maitenance decisions Inc. www.omdec.com

OMDEC is the exclusive provider of EXAKT, Failure Prediction Software Tool. EXAKT optimizes Condition Based Maintenance activities. It provides
the maintenance manager with clear alarm levels tuned to the condition of assets, the risk of failure, and cost of the consequences of failure.

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 AMMJ Maintenance and Reliability Web Links 32

Oniqua www.oniqua.com
The Oniqua Analytics Suite software solution provides a platform for continuous improvement of reliability, maintenance, inventory and procurement
activities across the Enterprise helping them to save millions of dollars in improved asset performance. Our services arm, Oniqua Content
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Use Orbisoft’s latest award-winning Task Manager 2007/8(tm) task management software to get organized and manage all asset management
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PCWI International Pty Ltd www.pcwi.com.au
Manufacture, Sales, Service and Calibration of hand held industrial test and measuring instruments. In house laboratory and service facility, ISO
9000 Licenced and ISO 17025 Accredited.
Pennant Australasia Pty Ltd www.pennantaust.com.au
Pennant specialises in Integrated Logistics Support software and consultancy services to optimise the design, operation, and maintenance
of equipment to match each application. Utilising defence proven Logistics Support Analysis methodologies Pennant can assist in optimising
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Perspective CMMS www.pemms.co.uk
Perspective CMMS is an independent consultancy that provides assistance to maintenance and IT people tasked with selecting and implementing
a Computerised Maintenance Management system.
Plant Maintenance Resource Center www.plant-maintenance.com
The Plant Maintenance Resource Center is the premier web resource for industrial Maintenance professionals. It includes links to maintenance
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Projetech, Inc. www.projetech.com
Projetech provides full service eMaintenance(r), Maximo Hosting, Maximo System Administration and is an IBM Business Partner that provides
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Pronto Software is a leading provider of fully integrated ERP solutions designed to meet the evolving needs of the FM industry. PRONTO-Xi
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PT Maintama Servisindo Mandiri www.maintama.com/index.htm
PT MAINTAMA Servisindo Mandiri is Maintenance Management Service Company based in Indonesia. We specialise in CMMS software
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Pulse Mining Systems specialise in providing fully integrated ERP solutions to the Mining Industry. The software has been developed by mining
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Revere Inc. www.revereinc.com/
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Rushton International www.rushtonintl.com
Rushton International provides maintenance management consulting and maintenance management software for mines, fleets and facilities
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Shire Systems www.shiresystems.com
Practical software, priced to raise a smile – not make your eyes water! With 10 000+ customers, Shire is price leader and UK No 1 provider of
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SIRF Roundtables www.sirfrt.com.au
SIRF Roundtables provides opportunities for representatives from member organisations to come together to meet and learn from each other.
SIRF Rt does this through a number of forums and events conducted throughout the year across Australia and New Zealand. These forums and
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Maintenance Excellence Awards, and Workshops conducted by visiting experts.
SIRF Roundtables Root Cause www.rca2go.com & www.rcart.com.au
www.rca2go.com
Worlds best practice Root Cause Analysis documentation tool. Totally flexible tool with the functionality to document a spectrum of processes
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www.rcart.com.au
Keep up with Root Cause Analysis initiatives and training, case studies and excellence awards. The best way to reduce maintenance cost is to
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SKF Reliability Systems www.skf.com.au/reliability
No single company in the world offers the breadth of services available today from SKF, or the depth of real-world application expertise we bring
to the table. SKF’s Integrated Maintenance Solutions program applies the right mix of technology and service to help optimise capital operations
and reduce Total Cost of ownership of assets. For more information on SKF Reliability Systems integrated approach, contact your local SKF
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SKILLED Group www.skilled.com.au/clients/maintenance-trades.aspx#AssetGuardian
Asset Guardian is a leading–edge maintenance management system, allowing clients to easily manage all tasks associated with their maintenance
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Smartpath is a specialist asset and maintenance management software provider. Our flagship software suite, Loc8, provides comprehensive
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application designed for enterprise organisations and service providers. Available in Software-as-a-Service and perpetual editions.

Vol 24 No 1
AMMJ Maintenance and Reliability Web Links 33

SMGlobal Inc www.smglobal.com

SMGlobal’s FastMaint CMMS is preventive maintenance management software for small to mid-size maintenance teams. It is used worldwide for
plant maintenance, facility & building maintenance, resort & restaurant maintenance, fleet maintenance and more. Download a 30-day trial from
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SoftSols (Asia/Pacific) www.getagility.com/au
Agility is a simple browser based CMMS solution that provides all the features required tor easily manage breakdown and preventive maintenance
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TechnologyOne www.technologyone.com.au
TechnologyOne Works and Assets is a project management and asset maintenance solution for infrastructure intensive organisations requiring
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Techs4biz Australia www.pervidi.com.au
Pervidi is a suit of products that automate paper based activities including inspections, maintenance, repair, service, tracking assets, and managing
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The Asset Partnership www.assetpartnership.com
The Asset Partnership is amongst Australia’s leading consulting organisations. We specialise in helping a diverse range of clients make efficient
and effective use of their investments in physical assets.
The Online Workshop Pty Ltd www.theonlineworkshop.com.au
SmartAsset ODC overlays your current EAM, ERP (such as SAP) or CMMS to overcome user acceptance and training issues and deploys asset
maintenance functions from those products in the familiar Microsoft Outlook interface.
Third City Solutions Pty Ltd (AMPRO) www.thirdcitysolutions.com.au
Third City Solutions is one of Australia’s fastest growing CMMS providers. With our increasing presence in Australia and around the world, AMPRO
will meet your maintenance management needs in Scheduling and Recording of all your maintenance functions. With all modules you’ll need,
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UE Systems www.uesystems.com
UE Systems manufactures and supports portable and fixed ultrasound instruments for condition monitoring and energy conservation (mechanical,
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Vibration Institute of Australia www.viaustralia.com.au
Vibration Institute offers basic, intermediate and advanced vibration training courses around Australia and New Zealand. The courses and exams
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Warp Systems is an Australian owned “Value Added Distributor” providing hardware, software and services around best of breed mobile computing
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 Mill Downtime Tracking
Database Analysis
Gilbert Hamambi Ok Tedi Mining Limited
Gilbert.Hamambi@oktedi.com Papua New Guinea

Maintenance efforts need to be directed where it will matter most and the results should be measurable for
determination of success or failure. A systematic approach following Deming’s Plan-Do-Check-Act cycle to
identify short term immediate strategies to improve the Mill Availability at Ok Tedi Mine and put into place long
term strategies to sustain this uptime has been customized from the Mill Downtime Tracking Database.
A facility for drilling down to the dominant equipment failure causes is established. This now means that
rather than focusing on all the equipment the ‘significant few’ affecting Mill Availability can now be quickly
identified and their effects quantified using three key performance indicators: cost, frequency and downtime
duration. Viable solutions and improvement ideas can now be identified and focused at the dominant cause
of plant equipment failure. The drill down facilitation also enables quick justifications and easy tracking of
implemented solutions.

INTRODUCTION

The Mill comprises of two SAG Mills each having two Balls Mills in its circuit. The Mill Downtime Tracking Database
(MDTDB) is used for logging the downtime events of these two SAG Mills and their respective Ball Mills. In total
six mills’ downtime events are logged and tracked. The focus, however, will be on the two SAG Mills and the plant
equipment that have cost their uptime.
The MDTDB Analysis aim was to identify short term immediate strategies to improve the Mill Uptime and put into
place long term strategies to sustain it. The aim was also to provide a facility to drill down into the ‘significant few’
plant equipment rather than focusing on all the equipment. Viable solutions or corrective actions will be identified
for the dominant causes of each plant equipment breakdown which has cost Ok Tedi Mining Limited (OTML) in Mill
Availability. The data extracted for analysis was that logged over 18 months from July 2006 to December 2007.

Figure 1 The MDTDB record fields showing the type of data logged.

Vol 24 No 1
 AMMJ Mill Downtime Tracking 35

THE MILL DOWNTIME TRACKING DATABASE OVERVIEW

The MDTDB is an MS Access database which was set up in 1999 for the recording and reporting of mill downtime
incidents to facilitate the control of outages in the mill. The author has taken custody of it and has kept it up dated
since 2003.
The type of information entered in the MDTDB include the shift, the crew working the shift, productive unit which would
be either one of the six mills, equipment causing the productive unit to go down, the time and date of the downtime
event. The time and date are straight from the PI-Process Monitoring System and the duration is automatically
calculated when outage start and end times are entered into the MDTDB.
There is a field to describe the problem and the problem is stated using the 5 Whys Methodology [1]. The answer to
the 5th Why is usually stated in the ‘Suspect Cause’ field. Actions done to return the equipment back to service are
also stated in the ‘Action(s) Taken’ field.
Figure 1 is the screen shot showing the features of the form for recording of the mills downtime incidents.
To ensure accuracy of problem description a downtime record is sourced from and verified from three sources: Mill
Electrical Shift Reports, Mill Operations Logs and Personnel Interviews.
Year Achieved Availability Target Availability
COMBINED MILL AVAILABILITY
2003 88.08 % 94.60 %
The Combined Mill Availability is determined from the data extracted 2004 88.02 % 94.60 %
from the MDTDB. This is the reliability requirement of this project.
2005 94.67 % 93.70 %
Table 1 summarizes this combined availability since 2003.
The challenge of this project is about identifying solutions and 2006 95.01 % 95.00 %
implementing the solutions to improve and sustain this combined 2007 94.64 % 95.00 %
Mill Availability.
TABLE 1 COMBINED MILL AVAILABILITY SINCE 2003
UNDERSTANDING AVAILABILITY
So what is Availability? Since availability is determined by reliability and maintainability and to grasp the concept of
availability an upfront definition of reliability and maintainability is deemed most appropriate.
There are four elements to the definition of reliability. Reliability is (1) a probability that a system/component will
perform a (2) specific function over a (3) specific time interval under (4) specific set conditions. It is usually expressed
in terms of the mean life (MTBF).
Maintainability is the ease with which maintenance is done to prevent failure, or during breakdown, return a system/
component to service. Maintainability is often determined at the design stage and is also dictated by the availability
of spares. Maintainability is expressed in terms of the mean time to repair (MTTR).
Reliability and Maintainability interact to form Availability. Availability is the probability that a system/component will
be in operating condition at any point in a given time interval under specific operating conditions and with specific
support condition. This interrelationship between reliability, maintainability and availability can be simply expressed
as in (1).
MTBF
Availability = --------------------- (1)
MTBF + MTTR
Therefore Availability can be simply stated as the measure of the Mill’s Uptime. High reliability combined with short
maintenance duration gives high availability and vice versa.

SAG1 MILL DOWNTIME ANALYSIS

Equipment Cumulative Hours Equivalent Revenue
The data from the MDTDB was exported out in MS Excel Loss (USD)
spreadsheet format and analyzed using MS Excel. In 0231ML01 135.22 $ 10,135,145.00
particular the Pivot Tables from MS Excel were used to a 0231CV01 51.95 $ 3,893,808.00
great extent in carrying out these analyses.
IPC/TARA 44.97 $ 3,370,636.00

A. Top 10 by Cumulative Breakdown Hours and 0231SC10 24.35 $ 1,825,106.00

the Equivalent in Cost of Production Loss Unknown 18.48 $ 1,385,131.00
Flotations 8.70 $ 652,091.00
The graph in Figure 2 is a comparison between the cumulative
hours and the equivalent in cost of loss production in the 18 0231FE02 6.27 $ 469,955.00
months from July 2006 to December 2007. 0342UPS02 6.08 $ 455,714.00
The equipment contributing to SAG1 Mill’s downtimes 0231ML01B 5.67 $ 424,984.00
are ranked from the highest to the lowest by number of
cumulative hours. 0231CV03 5.62 $ 421,236.00
The Top 10 equipment contributing to SAG1 Mill’s downtimes
are listed in Table 2.
TABLE 2 SAG1 MILL TOP 10 EQUIPMENT BY
DOWNTIME DURATION
Vol 24 No 1
 AMMJ Mill Downtime Tracking 36

B. Top 10 by Frequency of
Figure 2 Equipment Contributing To SAG1 Mill Downtime Revenue Loss.
Occurrences
Equipment Contributing To SAG1 Mill Downtime Revenue Loss: Last 18 Months_Jul06-Dec07
The graph in Figure 3 is a
comparison between the number 160 $12,000,000

of incidents by equipment and the

140
average downtime in hours per $10,135,145 $10,000,000

incident. The Top 10 equipment 120

by frequency of occurrence is

Revenue Loos Estimate (USD)

No. Of Hours (Cumulative)
$8,000,000

listed in Table 3. 100

80 $6,000,000
Besides also ranking the
equipment from having the 60
$4,000,000
highest frequency of occurrence $3,893,808
$3,370,636
40
to the lowest this comparison
highlights another important 20
$1,825,106
$1,385,131
$2,000,000

perspective. By comparing the

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TABLE 3 SAG1 MILL TOP 10 EQUIPMENT

BY FREQUENCY OF OCCURENCE Figure 3 Equipment Causing SAG1 Mill Downtime.

Equipment No. of Incident No. of Hours Equipment Causing SAG1 Mill Downtime: Last 18 Months_Jul06-Dec07
(Avg.)
0231ML01 38 3.56 40 8.00

0231SC10 24 1.01
35 7.00
0231CV01 15 3.46
Unknown 11 1.68 30 6.00

0231CV03 10 0.56

No. Of Hours (Average)

25 5.00
No. Of Incidents

0231CV04 9 0.39
20 4.00
TPS/Ok Menga 7 0.59
IPC/TARA 6 7.50 15 3.00

0231FE02 5 1.25
10 2.00
0231ML01B 5 1.13
5 1.00

Using the average hours exposes 0 0.00

problem areas which would have slipped
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used. Apart from the low frequency and Equipment

high downtime the chronic recurring Incidents Avg Hours
problems can be detected.

Willmoth and McCathy [2] reiterated in the six losses of Total Productive Maintenance.
1. Equipment failure (short-term, immediate effect),
2. Set up and adjustment losses (from product change over),
3. Idling or short stops from abnormal operations (long-term cumulative effect),
4. Operation below design capacity (long-term cumulative effect),
5. Process defects (rejects, quality defects, reject scraps) and
6. Reduce yield.
Apart from the obvious ones in the graph in Figure 3 and Table 3, production losses brought about by chronic
recurring failures, which often tend to have long term cumulative effects, is a definite cause for concern.
Traditionally Root Cause Failure Analysis is carried out for ‘show stoppers’. That is, major one-of events causing a
lot of downtime hours. This focus has now also shift to addressing recurring chronic failures. Can you identify these
from the graph in Figure 3?
Chronic equipment breakdowns are frequently occurring, low impact events that demand attention but take little time
to restore the equipment to service. They almost never had a financial figure calculated for the total loss. However,
over the life of a system/equipment the total losses from chronic failures will far exceed the total losses from sporadic
failures.
Vol 24 No 1
 AMMJ Mill Downtime Tracking 37

The undetected recurring problems exhibit the pattern similar to that on the left side of the graph in Figure 3. These
are characterized by high occurrences and shorter downtime.
One-off critical breakdowns normally exhibit the pattern similar to that on the right of the graph in Figure 3 which is
characterized by low occurrence and longer downtime.

C. By Pareto’s 80/20 Rule: Equipment Causing 80% of the Breakdown Incidents.

Figure 4 is the same information as
presented in the graph in Figure 3 Figure 4 Equipment Breakdown Incidents Causing SAG1 Mill Downtime
but now Pareto analysis is used to
identify the equipments costing OTML
in SAG1 Mill’s Availability by frequency Equipment B/Down Incidents Causing SAG1 Mill Downtimes: Last 18 Months_Jul06-Dec07
of breakdown incidents.
40
22%

TABLE 4 EQUIPMENT CAUSING 80% OF 35

BREAKDOWN INCIDENTS IN SAG1 MILL

30
Equipment No. of Incidents
by %
25 14%
0231ML01 22%
No. Of Incidents

0231SC10 14%
20
0231CV01 9%
9%
Unkown 6% 15
0231CV03 6% 6%
6%
5%
0231CV04 5% 10
4%
4%
TPS/Ok Menga 4% 3% 3%
5 2% 2% 2%
2% 2% 2% 2%
IPC/TARA 4% 1% 1% 1% 1%
1% 1% 1% 1% 1% 1% 1% 1%
0231FE02 3% 0
0231ML01B 3% L0
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2 3 034 23 31 SG
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0231CV01A 2% Equipment

80%

Pareto’s analysis is centered on the 80/20 rule. That is, 80% of the problem (whatever it may be) is caused by 20% of
the cause (whatever they may be). Table 4 gives the 20% of equipment causing 80% of the breakdown incidents.

D. By Pareto’s 80/20 Rule: Equipment Causing 80% of the Breakdown Hours

and the Equivalent in Cost of Production Loss.

This is the same information as

provide by the graph in Figure 2 but Figure 5 Equipment Breakdown Hours Causing SAG1 Mill Downtime.
now we are using Pareto analysis
to identify the equipments costing
Equipment B/Down Hours Causing SAG1 Mill Downtime: Last 18 Months_Jul06-Dec07
OTML in SAG1 Mill’s Availability by
breakdown hours. Table 5 gives the 160
20% of equipment causing 80% of
the breakdown hours. 140 41%

120
TABLE 5 EQUIPMENT CAUSING 80% OF
No. Of Hours (Cumulative)

BREAKDOWN HOURS AND EQUIVALENT IN 100

COST OF PRODUCTION LOSS IN SAG1 MILL
80

Equipment No. of Cumulative 60 16%

Hours by % 13%
0231ML01 41% 40

0231CV01 16% 7%
6%
20
IPC/TARA 13% 3% 2% 2%
2% 2% 1% 1%
1% 1% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%
0% 0%
0
0231SC10 7%
Fl own
31 A

31 s
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31 1

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31 02

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31 7

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03 FE

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83%
Equipment

Vol 24 No 1
 AMMJ Mill Downtime Tracking 38

SAG2 MILL DOWNTIME ANALYSIS

A similar analysis as carried out for SAG1 Mill was repeated for SAG2 Mill. The graphs and tables are presented in
this section.

A. Top 10 by Cumulative Breakdown Hours and the Equivalent in Cost of Production Loss

The graph in Figure 6 is a Figure 6 Equipment Contributing To SAG2 Mill Downtime Revenue Loss.
comparison between the cumulative
hours and the equivalent in cost of
Equipment Contributing To SAG2 Mill Downtime Revenue Loss: Last 18 Months_Jul06-Dec07
loss production in the 18 months
from July 2006 to December 2007. 250 $18,000,000

$16,000,000
TABLE 6 SAG2 MILL TOP 10 EQUIPMENT $15,565,490
200
BY DOWNTIME DURATION $14,000,000

Revenue Loss Estimate ( USD)

No. Of Hours (Cumulative)

Equipment Cumulative Hours Equivalent Revenue $12,194,853 $12,000,000

Loss (USD) 150
0341CV01 207.67 $ 15,565,490.00 $10,000,000

0341ML01 162.70 $ 12,194,853.00

$8,000,000
0341FE01 43.68 $ 3,273,947.00
100
0341SC01 32.62 $ 2,444,967.00 $6,000,000
IPC/TARA 22.65 $ 1,697,685.00
Unknown 13.28 $ 995,376.00 50
$4,000,000
$3,273,947
0341PP01 12.88 $ 965,395.00 $2,444,967
$2,000,000
$1,697,685
0341CV02 12.33 $ 924,170.00
0341CV03 10.83 $ 811,741.00 0 $-

0342UPS02 8.70 $ 652,091.00

03 3 41 4 -2

L4 1

L 2
03 L0 8

L 1

CV 2
41 n

03 L0 4

03 PP 3
C 01

41 0 1

03 UP 3

TP 41 1 5D
41 01
41 01

03 1P 1
1

A
03 41 A

02 Ok 01 A

03 41 01 B

03 L0 3 A
02 41 1 1A
41 01

M 2

03 GH 2A

A
Un RA

03 H0 a

FS 4 -
M 1

FS -1
03 no w

M 0

FS L0

41 L0
03 CV0

42 V0

FS D-

41 P0
41 S0

4 2
03 09
SG n g

01
03 L01

41 1
41 1 -
IP SC
03 ML

41 CV
03 PP
03 CV

03 41
03 FE

M 0
S 0

0
0 42

41 L42
41 01
A

41 1 5
41 M

03 1M
03 1C

S/ SC
12 Me

03 ML
41 ML
12 PP
/T

k
41

4
03

03
The equipment contributing to Equipment

SAG2 Mill’s downtimes are ranked Hours

from the highest to the lowest by

number of cumulative hours. The Top 10 equipment contributing to SAG2 Mill’s downtimes are given in Table 6.

B. Top 10 by Frequency of Occurrences

The graph in Figure 7 is a Figure 7 Equipment Causing SAG2 Mill Downtime.

comparison between the number
Equipment Causing SAG2 Mill Downtime: Last 18 Months_Jul06-Dec07
of incidents by equipment and
the average downtime in hours 80 8.00

per incident. Can you identify the

recurring failures in the graph in 70 7.00

Figure 7?
60 6.00

TABLE 7 SAG2 MILL TOP 10 EQUIPMENT

No. Of Hours (Average)

BY FREQUENCY OF OCCURENCE 50 5.00

No. Of Incidents

Equipment No. of Incident No. of Hours 40 4.00

(Avg.)
0341ML01 71 2.29 30 3.00
0341CV01 34 6.11
0341FE01 21 2.08 20 2.00

0341PP01 19 0.68
10 1.00
0341CV02 17 0.73
Unknown 13 1.02 0 0.00
L0 -1
-2

U 2

41 1
M 18
41 n

P 3
L4 4

CV 2
41 1

41 1

41 1
Un V02

03 41C 1
TP M 03

M D

02 FS 9 1

03 H0 1
03 SL A

41 1 B

A
03 FS 1 A

02 41 1A
03 1S 2
41 1

H0 A

41 1A
03 1M A
03 3 41 ga

0341SC01 11 2.97
03 1 -1
03 o w

03 L0

41 L0
03 L0

03 V0

03 C0

FS 0

42 D-

41 0
03 FE0

03 P0

SG 12
O 15

SG 0 2

03 L03

01
IP 24

M 24

41 1 -
41 V

41 CV

03 1PP
41 40
03 PS
0 en

41 L0

41 C0

03 ML0
03 L01

03 P0
03 /TA

03 1 5

03 1M
M

12 L4
C

C
P

S
kn

S/ L0

12 PP
41 L4

M
41

4
C

F
k
03

0341CV03 9 1.20
0341ML015D 9 0.47 Equipment

TPS/Ok Menga 6 0.69 Incidents Avg Hours

The undetected recurring problems exhibit the pattern similar to that on the left side of the graph in Figure 7. These
are characterized by high occurrences and shorter downtime.
One-off critical breakdowns normally exhibit the pattern similar to that on the right of the graph in Figure 7 which is
characterized by low occurrence and longer downtime.
The Top 10 equipment by frequency of occurrence is given in Table 7.
Vol 24 No 1
AMMJ Mill Downtime Tracking 39

C. By Pareto’s 80/20 Rule: Equipment Causing 80% of the Breakdown Incidents.

Figure 8 is the same information as

presented in the graph in Figure 7
but now Pareto analysis is used to Figure 8 Equipment Breakdown Incidents Causing SAG2 Mill Downtime.
identify the equipments costing OTML
in SAG2 Mill’s Availability by frequency Equipment B/Down Incidents Causing SAG2 Mill Downtimes: Last 18 Months_Jul06-Dec07
of breakdown incidents. Table 8 gives
80
the 20% of equipment causing 80% of
28%
the breakdown incidents. 70

TABLE 8 EQUIPMENT CAUSING

60
80% OF BREAKDOWN
INCIDENTS IN SAG2 MILL
50
No. Of Incidents
Equipment No. of Incidents
by % 40
0341ML01 28% 14%

0341CV01 14% 30

0341FE01 8% 8%
8%
20 7%
0341PP01 8% 5%
4%
0341CV02 7% 10
4% 4%
2% 2%
2% 1% 1% 1% 1%
Unknown 5% 1% 1% 1% 1% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%
0
0341SC01 4%

1
2

42 D- 2

41 1
41 n

D
41 1

41 1

41 1
Un 02

FS 04

41 2
41 03

41 0 2
02 FS 9 1

1
03 FSL A

FS 1 A

41 1 B

41 A

A
02 41P A
02
41 1

RA

SG 2A

41 1A
03 41 a

M 24 -
IP 24 -

41 1 -1

03 1 -1
03 o w

03 L0
03 L0

03 V0

03 C0

41 V0
03 E0

03 P0

SG 12
g

11
O 15

03 03

01
03 ML
CV

41 CV

03 PP
41 40
03 PS
en

41 L0

03 L0
12 P0

03 P0
03 TA

03 1 5

M
M

12 L4
C

03 1C
P

03 1SC
kn

L
0
0
F

CV
L4

03 H0

H0
0341CV03 4%

L
L

03 1M

M
41

P
L0
/

M
TP M
4

C
k
03

03

4
41

03
41
S/

03
0341ML015D 4%
Equipment
82%

D. By Pareto’s 80/20 Rule: Equipment Causing 80% of the

Breakdown Hours and the Equivalent in Cost of Production Loss

This is the same information as Figure 9 Equipment Breakdown Hours Causing SAG2 Mill Downtime.
provide by the graph in Figure 6 but
now we are using Pareto analysis Equipment B/Down Hours Causing SAG2 Mill Downtime: Last 18 Months_Jul06-Dec07

to identify the equipments costing 250

OTML in SAG2 Mill’s Availability by
breakdown hours. Table 9 gives the 37%

20% of equipment causing 80% of the 200

breakdown hours.
29%
No. Of Hours (Cumulative)

TABLE 9 EQUIPMENT CAUSING 80% OF 150

BREAKDOWN HOURS AND EQUIVALENT

IN COST OF PRODUCTION LOSS IN SAG2
MILL 100

Equipment No. of Cumulative

Hours by % 50 8%
0341CV01 37% 6%
4%
0341ML01 29% 2% 2% 2% 2% 2% 1%
1% 1% 1% 1% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%
0341FE01 8% 0
03 41 -2

FS 4 -1

FS - 2
8

FS -11
41 n

TP 41S D

03 SL4 2

41 03

41 0 2
41 1

41 1

41 1

41 2
42 03

41 1
03 41M B
M 03 A

A
A

02 k M A

02 41P A
41 02
41 1

41 1A
Un RA

03 GH A
a
41 1 -1
w

03 V0

41 V0

0
03 V0

03 L0

IP C0
03 E0

03 P0

03 09

03 412
SG n g
5

01
03 01

S 02

03 24

41 5D

0341SC01 6%
41 ML

03 1ML

03 PP
03 CV

03 PS
o

03 L0
C0
03 01

03 L01

03 P0
2
41 01
A
M

L4
C

03 1C
S

P
kn

L
F

CV
L4
0
/T

03 01

L
L

M
M
41

H
U

P
M

4
4
C

L
03

03

F
O

41

41
12

12

80%
S/

03

Equipment

FACILITATION FOR ZOOMING IN ON THE DOMINANT BREAKDOWN CAUSE

This analysis provided some visibility to what has been costing OTML in Mill Availability in the last 18 months and
provided a facility for easy drill down to the ‘significant few’ plant equipment and their dominant breakdown causes.
Figure 10 is an example of this drill down facilitation.
Pivot tables from MS Excel were used to a large extent to achieve this easy drill downs. Also the pivot tables in MS
Excel were used for registering and tracking our action plans.
These drill down and tracking facilities were presented in [3] for SAG1 Mill and SAG2 Mill respectively.

Vol 24 No 1
AMMJ Mill Downtime Tracking 40

Figure 10 This is an example of the drill down facilitation created from MS Excel
Pivot Tables and shows further drill down for information provided in Figure 2.

PRIORITIZING AND ADDRESSING OUR PROBLEM AREAS

The following is the guideline of how to
Figure 11 Top 5 of SAG1 Mill equipment 0231ML01 sorted by Cost.
go about addressing further the identified
dominant issues. At the equipment level
drill down to identify the dominant failure
cause of each equipment. Rank Top
5 by cost and Top 5 by frequency. If a
dominant cause appears in the Top 5 of
both lists then it will be given priority for
addressing immediately.
As an example of the different ranking
criteria described above, refer to Figure
11 and Figure 12 respectively.
Optimum solutions will be selected for
addressing the problem areas. The
solutions must prevent recurrence,
improve/sustain Mill Availability and most
important of all be within our control.
Having done that it does not mean that
other failure causes which have made Figure 12 Top 5 of SAG1 Mill equipment 0231ML01 sorted by Frequency.
the Top 5 of either list are ignored. They
will only be given a lesser priority.
There are some clear-cut one-of events
that could be overlooked. Also there are
the chronic recurring failures that should
not be overlooked either.

COMMUNICATE FINDINGS TO
MANAGEMENT
As a summary of the findings of this
analysis the Top 10 equipment of both
SAG Mills are listed in Table 10. These
equipment have appeared in both the
20% of equipment in the downtime
incidents lists and downtime hours lists
(That is, Table 2 and Table 5 for SAG1
and for SAG2 that is Table 6 and Table 9
respectively).
These results from the MDTDB analysis were communicated to maintenance management by way of a presentation
similar to [3]. This also included some of our strategies to address some of the equipment breakdown root causes.

Vol 24 No 1
 AMMJ Mill Downtime Tracking 41

Basically what we are doing is seeking management approval by selling our

improvement ideas. Our improvement initiatives have to be quantitatively
convincing. TABLE 10 TOP 10 EQUIPMENT OF
BOTH SAG MILLS COSTING OTML IN
POOLING TOGETHER SOLUTIONS MILL AVAILABILITY

The plan was to hold mini shop floor sessions of the same presentation as given SAG1 Mill SAG2 Mill
to management and highlight the dominant breakdown causes of equipment to 0231ML01 0341ML01
the work teams responsible for maintaining these problem equipments. The
0231SC10 0341CV01
intent was also to seek what solutions they thing should solve the problem or
how they think these problems should be addressed. 0231CV01 0341FE01
By rolling this down to the shop floor teams we hope to be bipartisan in our Unknown 0341PP01
approach and develop cooperative solutions to our problems. The aim is to get
0231CV03 0341CV02
the shop floor personnel to buy into our initiative as it gives them a sense of
ownership and value in their job. 0231CV04 Unknown
This step, pooling together of solutions, was a challenging one especially TPS/Ok Menga 0341SC01
with the concern plant personnel reverting to the ‘fire fighting’ mode. In such
IPC/TARA 0341CV03
a reactive situation it was a struggle to book a time to have all of the shop floor
personnel present and often the sessions were deferred. As a way forward and 0231FE02 0341ML015D
instead of holding a group session the author have resorted to booking a time 0231ML01B TPS/Ok Menga
with those key personnel (i.e. leading hands and team coordinators) to pool
together their ideas.

COMMUNICATING SOLUTIONS TO MANAGEMENT

Communicating the solutions to management for their approval was a step factored in incase we do come up with
improvement ideas that will require large capital investment and that may require management to sign off on. However,
as we pooled together our solutions we also drew up guidelines to ensure that solutions identified are both practical
and within our control and that we can implement them as normal part of our duties with the resources available to us
immediately rather than having to all the time seeking to get management approval for every solution presented. This
has cut down on the bureaucracy that would otherwise be involved. Of course every effort is made now and then to
keep the upper management in the loop.
This does not, however, mean that solutions involving large capital investment have not been identified and will not
be presented to management. These will be pursued outside the requirements of this unit.

TRACK AND FOLLOW SOLUTIONS AND MEASURE OUTCOMES: AN EXAMPLE

At the end of a given period of time after implementing of the solutions, we should be able to measure against set
performance indicators in Availability, Cost, Breakdown Frequency and Downtime Durations.
As an example, one of the problems identified was excessive mill leakage due to broken liner bolts. This has cost
OTML a lot of downtimes. One of the solutions that we have implemented was for the CM crew to do random
Ultrasonic Testing (UT) of the liner bolts. After six months of doing UT on liner bolts to eliminate broken bolts whilst in
service, the outcome was tracked and measured. This resulted in a revenue loss savings of US $3 million. This was
highlighted in the presentation [3] given during the residential school in September 2008.
This will be eventually presented to our maintenance people as way of trumpeting the wins of our combined efforts.

CONCLUSION
From this paper and as presented during the residential school, this analysis of the MDTDB has:
• Identified plant equipment costing OTML in Mill Availability,
• Quantified the performance indicators in Cost, Frequency and Downtime Duration,
• Drilled down to the Dominant Causes,
• Pooled together some Solutions to address the dominant issues,
• Implemented and tracked some viable solutions,
• Determined after six months the wins of a particular solution
Overall, a systematic approach to follow the Plan-Do-Check-Act (PDCA) cycle is now customized from the MDTDB
for continuous improvement and sustaining of the Mill Uptime at Ok Tedi.

REFERENCES
[1] Latino Robert J and Latino Kenneth C, Root Cause Analysis: Improving Performance for
Bottom-Line Results. 2nd Edition, CRC Press LLC, Florida, USA.
[2] P. Willmoth, and D. McCarthy, TPM – A Route to World-Class Performance. Butterworth-Heinemann,
Great Britain, 2001.
[3] G. Hamambi, “Mill Downtime Tracking Database Analysis” Presentation at AMCON, Monash Residential
School, Gippsland Campus, September 2008.
Vol 24 No 1
 Maintenance News
Honda engine factory in China benefits from SKF on-line
machine monitoring
Sales of Honda cars in China increased by over 50% year on
year during 2009. And with another joint venture factory being
built in 2010 the company is very optimistic about delivering
more of their fashionable and high quality cars to the Chinese
market.
Contributing to this success are the modern and reliable engines
manufactured by Dongfeng Honda, a joint venture factory located
right next to the Honda car assembly plant, in Guangzhou.
Equipped with advanced manufacturing machinery the engine
factory produces engines in the range 1.3 to 2.4 litres for Honda
cars in China. And a central machine in each production line,
critical for high productivity and quality, is the multifunction
machining centre.
These machining centres must operate for very long times in
a range of speeds and loads, which often change very quickly,
as they drill, cut and turn away the metal to form the finished
products of engine block and engine head. So it is absolutely
essential that the machining centre spindle operates within
very tight tolerances to deliver the accuracy required of Honda
engines. Key to spindle performance are the bearings that
support and rotate the spindle across its tough work cycles.
And bearing performance and reliability are therefore critical
to keeping the very high cost spindles delivering high quality
machining output at cost effective levels demanded of all modern
manufacturing plants. This in turn means it is very important, to
detect early indications of any bearing wear that could take the
spindle outside its required tolerances or lead to bearing failure
that would damage the spindle assembly and require very heavy
costs to repair, as well as a long period of loss of production.
Depending on a number of factors a typical machining centre
spindle would have an operational life of 1- 2 years before
replacement of bearings was needed. The actual life is difficult
to determine and a lot of off-line measuring, requiring stopping
production, is needed before taking the decision for a full spindle
bearing replacement action.
Dongfeng Honda maintenance manager, Mr. Chen Shi, was
using off-line monitoring in this way for some years and was
concerned about the amount of lost time needed to carry out
this necessary maintenance. So, in the Honda tradition of
challenging and trying new technology, he had the desire to
upgrade to on-line monitoring. With on-line monitoring, sensors
would track the spindle bearing’s condition 24 hours a day, and
give a signal at any signs of bearing wear or drop in performance
outside specified limits. But on-line monitoring of this sort had
not been applied before by Honda in China, so he had no in-
house experience to draw on.
So, looking for a partner in this challenge he invited SKF to
propose a solution for his machining centres. An SKF inspection
report led to a 5 months test and evaluation program of the TMU
together with Honda engineers. In this period a number of factors
needed to be determined;
• best location of vibration sensors on the spindle
• arranging cabling for good data transmission yet allowing
spindle full uninhibited movement for all functional machining
operations
• getting accurate control points from Honda’s PLC for all
machining operations
• determining the spindle’s vibration spectrum and trend pattern
for its machining operations for both the spindle head and
the bearing, across a range of typical application speeds and
forces.
At the end of the test period the Honda engineers, now fully
trained on the TMU, were enthusiastic about the potential and
so Chen had 3 TMU’s installed on 3 different machining centres.
Success was almost instant with one TMU detecting a condition
later diagnosed as poor lubrication and immediately rectified, and
a second TMU detecting a bearing defect that could be allowed
to continue until an optimum time for replacing at a scheduled
machine maintenance stop.
A further 19 TMUs have since been installed at the Guangzhou
engine plant and 3 more have been ordered for the Honda plant
in Wuhan. Commenting on this Chen says; “I have been very
satisfied with the performance of the TMU and its ease of use
by our maintenance personnel. And I am also very impressed
with the professionalism of SKF’s engineers who gave fast and
knowledgeable support whenever we needed it. Dongfeng Honda
is safe in the knowledge that the spindles will not fail unexpectedly,
with the corresponding catastrophic effect on production and
costs. Furthermore we can optimize our production, as far as
machining centre availability is concerned, by replacing any
necessary bearings during planned maintenance stops”
Features of the SKF Multilog Online System TMU:
The TMU is a 3 channel 24 hour/day surveillance device designed
to protect critical rotating assets in rugged manufacturing
environments. It can warn of developing machine problems such
as bearing damage, spindle or shaft imbalance, poor lubrication
etc and provide diagnostic information for improving reliability
and quality. Monitoring is done according to user-defined
conditions, making it applicable in a wide number of industries.
In addition it has a special feature which rapidly detects shocks,
such as would occur with a spindle crash, and instantly shuts
down the machine helping to prevent severe damage to machine
components. It has a distributed architecture allowing easy and
flexible expansion to cover small, medium or large machine or
manufacturing systems. www.skf.com
SEW delivers unmatched maintenance support
When shut-down periods approach, and scheduled maintenance
and repairs are carried out, it is important that Australia’s mines
and industrial facilities have access to premium levels of motor
and drive service and support—especially those in remote
areas of the country. With an Australia-wide network of technical
support, assembly and service facilities staffed by teams of
engineers and technical experts, SEW-Eurodrive leads the way
in this regard.
According to SEW-Eurodrive Mechanical Service Team Leader,
Frank Fedele, it’s the company’s extensive support infrastructure
that allows the motor and drives expert to deliver such high
levels of service. “Australia’s industrial and mining motor and
gear-unit users are able to send repair and maintenance jobs
to SEW’s strategically located service and assembly facilities in
Brisbane, Sydney, Melbourne, Adelaide and Perth,” he said. “We
provide the fastest turnaround possible to ensure end-users can
Vol 24 No 1
 Maintenance News
get back into production as quickly as possible, after scheduled
maintenance or emergency breakdowns.”
By assembling locally, stocking a comprehensive range of spare-
parts and providing 24-hour around-the-clock technical support,
SEW-Eurodrive has gained a reputation as Australia’s most
dependable drive solutions provider. “SEW’s ability to supply
total project lifecycle support throughout Australia sets us apart,”
said Fedele.
Importantly, SEW-Eurodrive recently expanded its Perth sales
and service centre. The new facility is four times the size of the
company’s previous premises and has been purpose-designed
to accommodate the assembly and repair of larger-sized
complete drive packages.
Industry can also access a wide range of technical literature and
product information via SEW-Eurodrive’s DriveGate online portal.
Here, parts lists, CAD drawings and installation and operating
manuals, along with online support, can all be accessed to aid
product selection, installation, maintenance and commissioning.
SEW-Eurodrive also offers motor and drive technology training
courses via the company’s new DriveAcademy training program.
www.sew-eurodrive.com.au
Fiber Bragg Grating – new technology in optical fiber
and semiconductor lasers
Optical fibers provide a fundamental improvement over traditional
methods offering lower loss, higher bandwidth, immunity to
electromagnetic interference, lighter weight, lower cost, and
lower maintenance. By applying a UV laser to “burn” or write
a diffraction grating (a Fiber Bragg Grating – FBG) in the fiber
it became possible to reflect certain wavelength of light, which
used together with an interrogation analyzer precise sensing
measurements could be taken. This technology is widely used for
Dense Wavelength Division Multiplexing DWDM) applications,
for real time fault detection and imbedded monitoring of
smartstructures (stress measurement).
Applied Infrared Sensing launches new Fiber Bragg Grating
Analyzers (FBGA) from BaySpec (USA). These FBGA employ
a highly efficient Volume Phase Grating VPG® as the spectral
dispersion element and an ultra sensitive InGaAs array detector
as the detection element, thereby providing high-speed parallel
processing and continuous spectrum measurements. As an input,
the device uses a tapped signal from the main data transmission
link through a single mode fiber, then collimating it with a micro
lens. The signal is spectrally dispersed with the VPG®, and the
diffracted field is focused onto an InGaAs array detector.
The control electronics read
out the processed digital signal
to extract required information.
Both the raw data and the
processed data are available to
the host.
www.applied-infrared.com.au
Shaft Alignment and Geometric Measurements in New
Package Solutions
Elos Fixturlaser is launching two successors to its best-seller
Fixturlaser XA; the Fixturlaser XA Pro – a complete shaft
alignment tool, and the Fixturlaser XA Ultimate – shaft alignment
and geometric measurements in an ultimate package solution.
Fixturlaser XA Pro
Fixturlaser XA Pro comes with an increased software and
hardware package. The software package contains all you
need for performing shaft alignment of rotating machinery, e.g.
horizontal and vertical shaft alignment, alignment of machine
trains, Hot Check, and Softfoot. A new function is the “Machine
43
Defined Data”, which makes it possible for the user to save
machine configurations as templates. All machine data for each
specific machine, such as machine dimensions, measurement
distances, tolerances, and target values, are readily available
in the Fixturlaser XA Pro alignment tool. The hardware package
contains e.g. thin magnet brackets and an extension fixture,
which are useful when working in narrow spaces. A magnetic
base is also included which will facilitate the mounting of the
measurement units on shafts with a big diameter.
Fixturlaser XA Ultimate
Fixturlaser XA Ultimate is a measurement tool with a complete
software package for both shaft alignment and geometric
measurements, such as flatness and straightness. Having
a properly aligned machine starts already at the time of its
installation, e.g. with checking if the machine foundation is skewed
or warped in any way, which would influence the machine’s
capability to work under optimal conditions. The Fixturlaser
XA Ultimate tool gives the user access to all the software and
hardware that is required for a successful machine installation
and consequently ensuring optimal running conditions for the
machine. www.fixturlaser.com
PartsSource Releases ePartsFinder™ 4.10
PartsSource, the nation’s only multi-manufacturer, multi-modality,
alternative supplier of medical replacement parts has released
the latest version of its e-commerce platform, ePartsFinder.
Based on user feedback, ePartsFinder 4.10 advances the
procurement and management of medical replacement parts
with the following features and benefits:
• Consolidated Shopping Cart - One screen/one click parts order
process reduces cycle time
• Display Part Image - Digital imaging improves order accuracy
and reduces wrong parts delivered and returns
• Customer Notes/Enhanced Quoting - Dynamic text dialogue
improves order accuracy
• Printing Quotes - Instant quote documentation and printing
from Part Detail screen speeds approval process
• Duplicate Part/Frequently Ordered Parts - Past purchases via
History tab can be easily researched avoiding duplicating
orders and reducing time required to enter and submit parts
orders.
“ePartsFinder is used in over 600 hospitals by over 3,000
technicians.
In addition to releasing ePartsFinder 4.10, we recently
completed customer-driven integrations with leading ERP
and CMMS software companies improving the utility of our
asset management and parts procurement applications by our
customers.” www.partssource.com
Coatings and Automatic Lubricators Cut
Maintenance Costs at Pequiven
Based in Venezuela, Pequiven is a Government-owned
company founded 30 years ago. The company produces
petrochemical products, mainly for the domestic market.
The company specialises in the production of fertilisers
and chemical products, as well as olefins and other
synthetic resins.
At its phosphoric acid plant, which has a production
capacity of around 250 tonnes of P2O5 per day, Pequiven
wanted to improve the running time of a critical conveyor
system that separates the solids from the phosphoric acid
mixture.
Vol 24 No 1
 Maintenance News
The bearings on the conveyor system were regularly failing
after just 15 days. As the plant was planning to increase its
production capacity, it needed a bearing supplier that was
able to provide an integral solution to the bearing problem,
including maintenance advice and guidance.
Schaeffler Venezuela recommended that Pequiven use a
coating material for the bearings, to improve the quality of
the housing material. Also, Schaeffler engineers noticed
that manual grease lubrication of the bearings was not
always being carried out correctly at the plant. Therefore,
along with new coating materials for the bearings,
Schaeffler recommended that the plant use automatic
lubrication systems to ensure that relubrication of the
bearings is controlled and that sufficient quantities of fresh
grease is constantly supplied to the contact points inside
the rolling bearings.
Schaeffler replaced the existing bearings with its RASE40-
N-FA125 housed bearing units, with the housings coated
with Corrotect®. Corrotect® is a relatively low cost, 0.5 to
5µm thick zinc alloy coating with cathodic protection, which
is effective against condensation, rainwater, contaminated
water and weak alkaline and weak acidic cleaning agents.
Under load, the coating is compacted into the surface
roughness profile and is partly worn away. The chromate
coating and the passivation increase anti-corrosion
protection and contribute to the optical appearance of the
component.
Corrotect® is ideal for small bearings and bearing mating
parts that need to have a greater resistance to corrosion,
for example drawn cup needle roller bearings with open
ends and thin-walled components in large numbers.
Schaeffler also supplied its
‘FAG Motion Guard Champion’
automatic lubrication system.
FAG Motion Guard CHAMPION
is a robust, electromechanically
driven unit that operates on
replaceable batteries.
The device is electronically controlled and has a back-
geared motor that enables the unit to discharge lubricant
at adjustable intervals of one, three, six or 12 months.
A lubricant canister is screwed to the drive unit, holding
60, 120 or 250cm3 of lubricating grease. Automatic
pressure control at 5 bar is provided and the unit operates
in temperatures from –10°C up to 50°C. The device
is also protected against dust and splash water and is
immune to electromagnetic interference from surrounding
equipment.
By using Motion Guard Select Manager software, the
user can select the discharge interval for the application,
determine replenishment quantities and select preferred
lubricating greases.
FAG Motion Guard Champion and Compact lubricators
can be used on all types of plant, including pumps,
compressors, fans, conveyors and vehicles.
After supplying the Corrotect® coated bearings and
automatic lubricators, the running time of the conveyor
system was improved as the bearings were now lasting
more than twice the time of the original bearings – but this
still wasn’t long enough for Pequiven. Because of the very
harsh corrosive environment in which the bearings had
to operate, Schaeffler then recommended using stainless
steel bearings and a thermoplastic housing.
44
After installing the new bearings, Pequiven is now
satisfied with the running times of the conveyor system
and maintenance cost has been reduced significantly.
Schaeffler now takes full responsibility of bearing
maintenance and has helped the customer develop a
special maintenance programme.
email info.uk@schaeffler.com .
SPM®HD cuts maintenance costs at paper mill
Since the summer of 2010, Ortviken paper mill outside
Sundsvall, Sweden, uses the SPM HD measuring technique
from SPM Instrument to measure bearing condition on four twin
wire presses.
SCA Ortviken has been measuring bearing condition with SPM
HD, since summer 2010.
Ortviken paper mill, owned by SCA and located on the Gulf of
Bothnia coast in Sweden, produ-ces coated publication papers,
LWC and newsprint on four paper machines. The raw material
is fresh spruce pulpwood, mainly from SCA’s own forests in
northern Sweden. The production ca-pacity is 850.000 tons of
paper.
For Ortviken, SPM HD is the solution to years of problems with
bearing related breakdowns on low RPM machinery like the
twin wire presses, which are used for dewatering of the pulp.
None of the monitoring systems installed in the mill provided
a dependable method for detection of bearing wear and
damage, and bearing replacements therefore were carried out
in conjunction with timebased maintenance. The lack of reliable
bearing condition information often lead to the dismounting of the
wrong bearings, in turn causing breakdowns on other bearings
in worse con-dition. The relatively expansive bearing damages
made dismounting difficult and in some cases the shaft would
also be damaged. Lengthy and unplanned production stops and
consequential damages requiring repair all induced significant
additional costs.
Then in the summer of 2010, the Intellinova online system with
SPM HD was installed on Ortvi-ken’s four Andritz twin wire
presses. Following a short period of system calibration, six
bearing damages have been successfully identified to date.
Four bearings have been replaced during planned stops and
two more will be replaced in the near future. Examination of the
replaced bearings have verified that SPM HD does indicate the
correct type of bearing damage, and bea-ring replacement costs
are now significantly reduced.
Urban Lander, maintenance manager at SCA Ortviken, comments:
”After a few months of bea-ring condition measurement with
SPM HD, we conclude that it works completely and to our full
satisfaction. We are now planning for the application of SPM HD
on more low RPM machinery, and we can recommend SPM HD
to other users with bearing problems on such machinery.”
www.spminstrument.com
Maintenance Software Supports Facilities, Utilities, and
Industrial Plants
SMGlobal has released FastMaint CMMS v. 5.3, a powerful
software application that makes it easy to manage plant
maintenance, facility and building maintenance, resort and
restaurant maintenance, and fleet maintenance.
Solutions are available for use on a single Windows computer
and on a LAN, as well as a web edition that need not be installed
on each computer in the company because it can be accessed
using a standard web browser. For a web demo or to download
a fully-functional 30-day trial, www.smglobal.com.
Vol 24 No 1
 AMMJ Subscription Form
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 AMMJ - Maintenance Books
Asset Management and Maintenance Journal’s Book List
Prices are valid until 30th April 2011. All prices are Australian Dollars. Prices for Australia Include Postage and GST.
Prices for the rest of the World add the following shipping charges: One book add Aus$40; Each additional book add Aus$25.

1. MAINTENANCE and RELIABILITY BEST PRACTICES

Ramesh Gulati and Ricky Smith 420pp $140
Many years experience packed into one book. Useful to both the novice and seasoned professionals. Topics include Best Practices;
Culture and Leadership; Understanding Maintenance; Work Management, Planning and Scheduling; Inventory Management;
Measuring and Design for Reliability and Maintainability; Role of Operations; PM Optimization; Managing Performance; Workforce
Management; M & R Analysis Tools; etc.
2. FAILURE MAPPING
Daniel T Daley 165pp $115
A new powerful tool for improving reliability and maintenance. Failure Maps help describe past failures accurately and succinctly.
Recording failure histories in a manner that will make the records useful in the future. Using failure Maps to improve reliability
by identifying failure mechanisms. Improving the effectiveness of diagnostic and troubleshooting processes. Improving the
effectiveness of “triage” as part of failure response.
3. THE 15 MOST COMMON OBSTACLES TO WORLD-CLASS RELIABILITY
Don Nyman 150pp $85
This book is intended as a wake up call to those wishing to implement World-Class Reliability. The main obstacles that must be
addressed by middle managers, engineers and functional specialists in the pursuit of Maintenance and Reliability excellence. It
focuses on the managerial leadership, cultural change, organization-wide commitment, and perseverance required to transform
from a reactive to proactive system.
4. MAINTENANCE ENGINEERING HANDBOOK 7th Edition
L.R. Higgins, K. Mobley and D.J. Wikoff 1200pp $290
This handbook is a one stop source of answers on all maintenance engineering functions, from managing, planning, and budgeting
to solving environmental problems. The Seventh Edition has been thoroughly revised with eleven all new chapters along with
complete updates of key sections. A valuable source of information for Maintenance Engineers, Managers, Plant Engineers,
Supervisors and Maintenance technicians.

5. MAINTENANCE STRATEGY SERIES (5 Volumes)

Terry Wireman
5.1 Preventive Maintenance (Vol 1) 220pp $125
Details the importance of preventive maintenance to an overall maintenance strategy. The text illustrates how the components of
any maintenance strategy are interlinked with dependencies and the performance measures necessary to properly manage the
preventive maintenance program.
5.2 MRO Inventory and Purchasing (Vol 2) 150pp $125
Shows how to develop an inventory and purchasing program for MRO spares and supplies as part of an overall strategy.
Specifically, the text focuses on the importance of a well organized storage location and part inventory numbering system detailing
to the reader the most effective ways to accomplish this goal. The receiving and parts issues disciplines are discussed in detail.
5.3 Maintenance Work Management Processes (Vol 3) 200pp $125
Focuses on developing a work management process that will support the maintenance strategy components. It outlines a
financially cost effective process that collects the data to use advanced strategies such as RCM and TPM. The text extensively
details the maintenance organizational development process and then outlines nine basic work management flows. The nine flows
are then discussed in detail.
5.4 Successfully Utilizing CMMS/EAM Systems (Vol 4) 200pp $125
Shows how CMMS/EAM systems are necessary to support a maintenance and reliability organization in companies today. The
proper methodologies for selecting and implementing a CMMS/EAM system. How to properly utilize the system to gain a maximum
return on the system investment.The organization and methodology to truly achieve Enterprise Asset Management - an elusive goal
for most organizations.
5.5 Training Programs for Maintenance Organizations (Vol 5) 200pp $125
Highlights the need for increased skills proficiency in maintenance and reliability organizations today. Skills shortages. Developing
cost-effective and efficient skills training programs. Modern tools for duty, task, and needs analysis - creating a complete skills
development initiative. The reader will be able to use information in this text to develop or enhance a skills training program in their
company

6. FACILITY MANAGER’S MAINTENANCE HANDBOOK 2ND Edition

B. Lewis and R Payant 560pp $240
This essential on-the-job resource presents step-by-step coverage of the planning, design, and execution of operations and
maintenance procedures for structures, equipment, and systems in any type of facility. Now with 40% new information, this Second
Edition includes brand-new chapters on emergency response procedures, maintenance operations benchmarking and more. This
book covers both operations & maintenance.
7. IMPROVING RELIABILITY & MAINTENANCE FROM WITHIN
Stephen J. Thomas 350pp $125
This unique book is perfect for those who are internal consultants…and may not know it. This practical resource does more
than start internal consultants on the road to improvement, it accompanies them on the journey! Upper management looking to
understand internal consulting, middle tier reliability and maintenance management, and those who hold “special projects” positions
will find this reference extremely useful.
Vol 24 No 1
 47
8. PLANT MAINTENANCE MANAGEMENT ( 3 Volumes)
Anthony Kelly 3 Volume Set $295
8.1 Strategic Maintenance Planning Individual Book Price $140
Imparts an understanding of the concepts, principles and techniques of preventive maintenance and shows
how complexity can be resolved by a systematic ‘Top-Down Bottom-Up’ approach.
8.2 Managing Maintenance Resources Individual Book Price $140
Shows how to reduce the complexity of organizational design through a unique way of modeling the
maintenance-production organization along with organizational guidelines to provide solutions to identified problems.
8.3 Maintenance Systems and Documentation Individual Book Price $140
Addresses the main systems necessary for the successful operation of a maintenance organization, such as performance control,
work control and documentation, and shows how they can be modelled, their function and operating principles.
9. MAINTENANCE BENCHMARKING & BEST PRACTICES
Ralph W Peters 566pp $165
This guide provides benchmarking tools for the successful design and implementation of a customer-centered strategy for
maintenance. Included in this guide is the author-devised “Maintenance Operations Scoreboard”. This has been used to perform
over 200 maintenance evaluations in over 5,000 profit centered maintenance organizations.
10. COMPUTERISED MAINTENANCE MANAGEMENT SYSTEMS MADE EASY
Kishan Bagadia 267pp $180
Written by a world-renowned CMMS expert, Computerized Maintenance Management Systems Made Easy presents a clear, step-
by-step approach for evaluating a company’s maintenance, then selecting the right CMMS and implementing the system for optimal
efficiency and cost-effectiveness.
11. PLANT AND MACHINERY FAILURE PREVENTION
A A Hattangadi 458pp $230
Plant and Machinery Failure Prevention is based on the premis of “Zero-Failure Performance”. The book introduces the general
features and investigative methods at the design phase for determining failures in mechanical components such as: Flat Belt
Failures, Vee-belt Failures, Pulley Failures, Gear Failures, Steel Wire Rope Failures, Spring Failures, and Gasket Failures. Includes
numerous case studies.
12. MAINTENANCE PLANNING & SCHEDULING HANDBOOK 2nd edition
Richard D Palmer 544pp $185
Written by an author with over two decades of experience, this classic handbook provides proven planning and scheduling
strategies and techniques that will take any maintenance organization to the next level of performance. This book is regarded
as the chief authority for establishing effective maintenance planning and scheduling in the real world. The second edition has
important new sections.
13. TOTAL PRODUCTIVE MAINTENANCE - Reduce or Eliminate Costly Downtime
Steven Borris 448pp $180
With equipment downtime costing companies thousands of dollars per hour, many turn to Total Productive Maintenance as a
solution. Short on theory and long on practice, this book provides examples and case studies, designed to provide maintenance
engineers and supervisors with a framework for strategies, day-to-day management and training techniques that keep their
equipment running at top efficiency.
14. PRODUCTION SPARE PARTS – Optimizing the MRO Inventory Assets
Eugene C Moncrief 307pp $125
Spare parts stocking theory and practice. Uses the Pareto Principal to achieve superior results with a minimum of investment
of time. Includes the following topics: the risks inherent in setting inventory stocking levels, setting the reorder point, setting the
reorder quantity, determining excess inventory, how to avoid unnecessary purchases of spares, and how to set and monitor goals
for inventory improvement.
15. MANAGING FACTORY MAINTENANCE 2nd Ed
Joel Levitt 320pp $125
This second edition tells the story of maintenance management in factory settings. . World Class Maintenance Management
revisited and revised, evaluating current maintenance practices, quality improvement, maintenance processes, maintenance
process aids, maintenance strategies, maintenance interfaces, and personal development and personnel development.
16. THE MAINTENANCE SCORECARD – Creating Strategic Advantage
Daryl Mather 257pp $125
Provides the RCM Scorecard, which is unique to this book and has not been done previously to this level of detail. Includes
information and hints on each phase of the Maintenance Scorecard approach. Focuses at length on the creation of strategy for
asset management and details the differences between various industry types, sectors and markets.
17. IMPROVING MAINTENANCE & RELIABILITY THROUGH CULTURAL CHANGE
Stephen J Thomas 356pp $125
This unique and innovative book explains how to improve maintenance and reliability performance at the plant level by changing
the organization’s culture. This book demystifies the concept of organizational culture and links it with the eight elements of change:
leadership, work process, structure, group learning, technology, communication, interrelationships, and rewards.
18. PRACTICAL MACHINERY VIBRATION ANALYSIS & PREDICTIVE MAINTENANCE
Scheffer & Girdhar 272pp $150
Develop and apply a predictive maintenance regime for machinery based on the latest vibration analysis and fault rectification
techniques. Build a working knowledge of the detection, location and diagnosis of faults in rotating and reciprocating machinery
using vibration analysis. Gain an understanding of the latest techniques of predictive maintenance..
19. LEAN MAINTENANCE - Reduce Costs, Improve Quality, & Increase Market Share
R Smith & B Hawkins 304pp $160
Detailed, step-by-step, fully explained processes for each phase of Lean Maintenance implementation providing examples,
checklists and methodologies of a quantity, detail and practicality that no previous publication has even approached. a required
reference, for every plant and facility that is planning, or even thinking of adopting ‘Lean’ as their mode of operation.
Vol 24 No 1
 48
20. MANAGING MAINTENANCE SHUTDOWNS & OUTAGES
Joel Levitt 208pp $125
Brings together the issues of maintenance planning, project management, logistics, contracting, and accounting for shutdowns.
Includes hundreds of shutdown ideas gleaned from experts worldwide. Procedures and strategies that will improve your current
shutdown planning and xecution.
21. EFFECTIVE MAINTENANCE MANAGEMENT - Risk and Reliability Strategies for Optimizing Performance
V Narayan 288pp $130
Providing readers with a clear rationale for implementing maintenance programs. This book examines the role of maintenance in
minimizing the risks relating to safety or environmental incidents, adverse publicity, and loss of profitability. Bridge the gap between
designers/maintainers and reliability engineers, this guide is sure to help businesses utilize their assets effectively, profitably.
22. MACHINERY COMPONENT MAINTENANCE & REPAIR 3rd Ed
Bloch & Geitner 650pp $255
The names Bloch and Geitner are synonymous with machinery maintenance and reliability for process plants. They have saved
companies millions of dollars a year by extending the life of rotating machinery in their plants. Extending the life of existing
machinery is the name of the game in the process industries, not designing new machinery. This book was the first and is still the
best in its field.
23. DEVELOPING PERFORMANCE INDICATORS FOR MANAGING MAINTENANCE 2nd Edition
Terry Wireman 288pp $120
While the previous edition concentrated on the basic indicators for managing maintenance and how to link them to a company’s
financials, the second edition addresses further advancements in the management of maintenance. One of only a few
comprehensive collections of performance indicators for managing maintenance in print today.
24. RELIABILITY DATA HANDBOOK
Robert Moss 320pp $315
Focusing on the complete process of data collection, analysis and quality control, the subject of reliability data is covered in great
depth, reflecting the author’s considerable experience and expertise in this field. Analysis methods are not presented in a clinical
way – they are put into context, considering the difficulties that can arise when performing assessments of actual systems.

25. HANDBOOK OF MECHANICAL IN-SERVICE INSPECTIONS – Pressure Vessels & Mechanical Plant
Clifford Matthews 690pp $495
This comprehensive volume gives detailed coverage of pressure equipment and other mechanical plant such as cranes and
rotating equipment. There is a good deal of emphasis on the compliance [UK standards] aspects and the duty of care requirements
placed on plant owners, operators, and inspectors.
26. BENCHMARK BEST PRACTICES IN MAINTENANCE MANAGEMENT
Terry Wireman 228pp $130
This book will provide users with all the necessary tools to be successful in benchmarking maintenance management. It presents a
logical step-by-step methodology that will enable a company to conduct cost-effective benchmarking. It presents an overview of the
benchmarking process, a self analysis, and a database of the results of more than 100 companies that have used the analysis.
27. RCM - GATEWAY TO WORLD CLASS MAINTENANCE
A Smith & G Hinchcliffe 337pp $145
Includes detailed instructions for implementing and sustaining an effective RCM program; Presents seven real-world successful
case studies from different industries that have profited from RCM; Provides essential information on how RCM focuses your
maintenance organization to become a recognized ‘center for profit’. It provides valuable insights into preventive maintenance
practices and issues.
28. INDUSTRIAL MACHINERY REPAIR - Best Maintenance Practices Pocket Guide
R Smith, R K Mobley 537pp $105
The new standard reference book for industrial and mechanical trades. Industrial Machinery Repair provides a practical reference
for practicing plant engineers, maintenance supervisors, physical plant supervisors and mechanical maintenance technicians. It
focuses on the skills needed to select, install and maintain electro-mechanical equipment in a typical industrial plant or facility.
29. AN INTRODUCTION TO PREDICTIVE MAINTENANCE 2nd Edition
Keith Mobley 337pp $195
This second edition of An Introduction to Predictive Maintenance helps plant, process, maintenance and reliability managers
and engineers to develop and implement a comprehensive maintenance management program, providing proven strategies for
regularly monitoring critical process equipment and systems, predicting machine failures, and scheduling maintenance accordingly.
30. MAINTENANCE PLANNING, SCHEDULING & COORDINATION
Dan Nyman and Joel Levitt 228pp $115
Planning, parts acquisition, work measurement, coordination, and scheduling. It also addresses maintenance management,
performance, and control; and it clarifies the scope, responsibilities, and contributions of the Planner/Scheduler function and the
support of other functions to Job Preparation, Execution, and Completion. This book tells the whole story of maintenance planning
from beginning to end.

31. RELIABILITY, MAINTAINABILITY AND RISK 7th Ed

David Smith 368pp $170
Reliability, Maintainability and Risk has been updated to ensure that it remains the leading reliability textbook - cementing the
book’s reputation for staying one step ahead of the competition. Includes material on the accuracy of reliability prediction and
common cause failure . This book deals with all aspects of reliability, maintainability and safety-related failures in a simple and
straightforward style.
32. ASSET MANAGEMENT AND MAINTENANCE - THE CD
Nicholas A Hastings 820 slides $150
Asset Management and Asset Management Overview; Life Cycle Costing; Maintenance Organisation & Control; Spares &
Consumables Management; Failure Mode and Effects Analysis; Risk Analysis and Risk Management; Reliability Data Analysis; Age
Based Replacement Policy Analysis; Availability and Maintainability; Measuring Maintenance Effectiveness; Reliability of Systems.
Vol 24 No 1
 MAINTENANCE BOOKS – ORDER FORM
Prices are valid until 30 April 2011. All prices are Australian Dollars. Prices for Australia Include Postage and GST.
Prices for the rest of the World add the following shipping charges: One book add Aus$40; Each additional book add Aus$25
Engineering Information Transfer P/L, 7 Drake Street, Mornington, Vic 3931 Australia Ph: 03 5975 0083 Fax: 03 5975 5735 Email: mail@maintenancejournal.com
Please indicate
Item Title quantity required. Aus$
1. MAINTENANCE AND RELIABILITY BEST PRACTICES $140
2. FAILURE MAPPING $115
3. THE 15 MOST COMMON OBSTACLES TO WORLD-CLASS RELIABILITY $85
4. MAINTENANCE ENGINEERING HANDBOOK 7th Edition $290
5.1 PREVENTIVE MAINTENANCE - MAINTENANCE STRATEGY SERIES (Volume 1) $125
5.2 MRO INVENTORY AND PURCHASING - MAINTENANCE STRATEGY SERIES (Volume 2) $125
5.3 MAINTENANCE WORK MANAGEMENT PROCESSES - MAINTENANCE STRATEGY SERIES (Vol 3) $125
5.4 SUCCESSFULLY UTILIZING CMMS/EAM SYSTEMS - MAINTENANCE STRATEGY SERIES (Vol 4) $125
5.5 TRAINING PROGRAMS FOR MAINTENANCE ORGANIZATIONS - MAINT. STRATEGY SERIES (Vol 5) $125
6. FACILITY MANAGER’S MAINTENANCE HANDBOOK 2nd Ed $240
7. IMPROVING RELIABILITY AND MAINTENANCE FROM WITHIN $125
8. PLANT MAINTENANCE MANAGEMENT - Kelly’s 3 Volume Set $295
8.1 STRATEGIC MAINTENANCE PLANNING - Individual Book $140
8.2 MANAGING MAINTENANCE RESOURCES - Individual Book $140
8.3 MAINTENANCE SYSTEMS & DOCUMENTATION - Individual Book $140
9. MAINTENANCE BENCHMARKING & BEST PRACTICES $165
10. COMPUTERISED MAINTENANCE MANAGEMENT SYSTEMS MADE EASY $180
11. PLANT AND MACHINERY FAILURE PREVENTION $230
12. MAINTENANCE PLANNING & SCHEDULING HANDBOOK 2ND EDITION R D Palmer $185
13. TOTAL PRODUCTIVE MAINTENANCE - Reduce or Eliminate Costly Downtime $180
14. PRODUCTION SPARE PARTS – Optimizing the MRO Inventory Assets $125
15. MANAGING FACTORY MAINTENANCE 2nd Ed $125
16. THE MAINTENANCE SCORECARD – Creating Strategic Advantage $125
17. IMPROVING MAINTENANCE & RELIABILITY THROUGH CULTURAL CHANGE $125
18. PRACTICAL MACHINERY VIBRATION ANALYSIS & PREDICTIVE MAINTENANCE $150
19. LEAN MAINTENANCE - Reduce Costs, Improve Quality, & Increase Market Share $160
20. MANAGING MAINTENANCE SHUTDOWNS & OUTAGES $125
21. EFFECTIVE MAINTENANCE MANAGEMENT - Risk and Reliability Strategies $130
22. MACHINERY COMPONENT MAINTENANCE & REPAIR 3rd Ed $255
23. DEVELOPING PERFORMANCE INDICATORS FOR MANAGING MAINTENANCE 2nd Ed $120
24. RELIABILITY DATA HANDBOOK $315
25. HANDBOOK OF MECHANICAL IN-SERVICE INSPECTIONS – Mechanical Plant $495
26. BENCHMARK BEST PRACTICES IN MAINTENANCE MANAGEMENT $130
27. RCM - GATEWAY TO WORLD CLASS MAINTENANCE $145
28. INDUSTRIAL MACHINERY REPAIR - Best Maintenance Practices Pocket Guide $105
29. AN INTRODUCTION TO PREDICTIVE MAINTENANCE 2nd Ed $195
30. MAINTENANCE PLANNING, SCHEDULING & COORDINATION $115
31. RELIABILITY, MAINTAINABILITY AND RISK 7th Ed $170
32. ASSET MANAGEMENT AND MAINTENANCE - THE CD $150

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Vol 24 No 1
And you thought
we just made bearings
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Combining over 100 years of experience to
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3 MON VA1
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20 BTM ESA VA2 BTM
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SUN 31 25 13 PME FMC Reliability
18 6 BTM PMS
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11 28 Bearing Centered Maintenance
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26 Australia Day 14 OA1 WESTERN Failure Analysis
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Newcastle 10-12 May
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8 30 Canberra 16-18 February 9 February 22 September Maintenance Strategy 25-26 May (WI320)
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13-15 April
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14 MON 2 Picnic Day (NT) 24
DB MIC
28-29 January 23-27 August
Orange Fax: (06) 359 9145
12 October
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SUN LB1 VA1 17 23-25 February 1555 QUEENSLAND NEW ZEALAND VA1 Vibration
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15 TUE 3 BTM FMC
14-16 September Archerfield Hamilton level 1 (WI202)
25 7-9 July Oakleigh 2-3 February NEW SOUTH WALES
OAM
8 PSF
BTM BTM ML1
RCF BTM Ph: (09) 238 10-11 August
MON 1
PSF VA1
CR CR LB1 VA1 18 Smithfield Lautoka 25 February 9079 23-25 February Toowoomba
23 OAM 11 BTM Fax: (09)
SOUTH AUSTRALIA Smithfield
BTM ML1 RCF 23-25 March 1 September238 9779
BTM FMC
OA1 BTM CAF
ESA 16 WED 4 BTM
26 13-15 July Maintenance 12-13 July
9 BTM ML1
OAM
BTM
25-27 May AUSTRALIA Wingfield PME Predictive 23-25 February
TUE 2
CAF RCF VA1
CR BTM ESA PT VA1 19 CR
NEW ZEALAND WESTERN
Ph: (03) 338 for Electric Motors SOUTH AUSTRALIA
BTM ML1 RCF
24 OAM
BTM 12 19-21 October 14-15 July QUEENSLAND
17 THU 5 BTM Whangarei Fax: (03) 338 1917
Kalgoorlie level 1 Wingfield
Systems

10 OA1 BTM 27 OAM

VICTORIA Archerfield
LB1 RCF VA1 20 CR Wollongong 9-11 February 4 May 1334
NEW SOUTH WALES 23-24 November
WED 3 25 OAM ESA
13
PT
22-24 June Oakleigh 22-24 June
BTM Auckland Karatha TASMANIA
18 BTM ML1
FRI 6 Ph: (07) 349 Smithfield QUEENSLAND
11 OA1 BTM CAF 28 NORTHERN TERRITORY 2-4 March Fax:October
26 2451 3-4 February
Hobart
THU 4 LB1 CAF 21 (07) 349 3451 WESTERN AUSTRALIA 7-8 September Mt Isa
26 14 Darwin Hamilton Perth 12-13 October
19 SAT 7 23-25 February Perth QUEENSLAND 13-15 July
23-25 March

2010 SKF Trai

12 OA1 ESA PSF 13 May VICTORIA
FRI 5 PSF
QUEENSLAND
Ph: (07) 377 19-20 April Archerfield SOUTH AUSTRALIA
27 Rotorua/Kawerau 5 November8416 13-14 July Gipssland
20 Fax: (07) 377 8486 Mt Gambier
13 Archerfield 20-22 April NEW ZEALAND Lubrication SOUTH AUSTRALIA 16-17 March 10-12 August
SAT 6 September 26 11-13 May
ML1 Machinery 1

ning
19 Napier Hamilton Technician level Wingfield Oakleigh
12 12-14 October Ph: (03) 687 VICTORIA
11-13 May March

Handbook
5 Family & Community Fax:24(03) 688 4444 (WE265) 15-16 June 17-18 August Oakleigh
SUN 20
27 Day (ACT) Blackwater Palmerston North Christchurch 2640 NEW SOUTH WALES WESTERN AUSTRALIA
PMS VICTORIA 5-7 October
March 28 13 PMS IR1 7-9 December 15-17 June 20 July Smithfield Oakleigh Kalgoorlie WESTERN AUSTRALIA
Reliability and
21 6 UT
FMC
28 Bundaberg New Plymouth Ph: (06) 344
14 MON 21
MAR RCF
Fax: 4804
Crusher 21-23 September 19-20 October 1-2 September Perth
CR Improving
PMS
7 PMS OA1 ML1 1-3 June 20-22 July (06) 344 4112
WESTERN AUSTRALIA
IR1
29 14 1 Perth
Reliability level
maintenance
SUN 7 BTM PME BTM QUEENSLAND 9-11 March
22 Lower Hutt
OAM UT
Labour Day (VIC) PMS SPM
FMC
29 Cairns Archerfield 15-16 June
15 TUE MIC RCF
13-15 April (WI270) Perth NEW ZEALAND
22 17-19 August
training from
8 Adelaide Cup (SA) PMS PMS ML1
OA1 ESA
9-11 March 23-24 March 8-9 December
15 NEW SOUTH WALES
IR1
MON 1 Labour Day (WA) Canberra Day (ACT)
OAM BTM ML1
PME 30 BTM PME Hamilton
8 Emerald Nelson
The developm
BTM
SPM 23 UT
NEW ZEALAND
13-15 October
RCF ESA
30 Gladstone
SKF
CR ML1 RCF MSR FMC
FMC 16 PMS
WED 1 22-24 June 7-9 September Newcastle Maintenance
BTM ML1 VA1 23 PMS Proactive
ent and knowledg
BTM PMS
9 13-15 July
PMS
PME OA1 ML1 Hamilton
TUE 2 31 16 IR1
16-17 March Skills level 1 (WE241)
promote a
BTM RCF
24 OAM BTM ML1 ESA 9 UT BTM BTM Gladstone Christchurch 13-14 April VA2 Vibration
Analysis
10 BTM ML1 VA1
FMC 17 PMS BTM CR
MSR THU 2 ML1 RCF SPM
UT
24 PMS 23-25 March 13-15 October Smithfield Townsville
1-3 June NEW SOUTH WALES productive, e path for your
Christchurch level 2 (WI203)
WED 3 BTM DB
MSR 25 OAM BTM ML1
SPM UT 10 UT
17 PMS IR1 OA1
19-21 October Timaru 10-11 August
QUEENSLAND SOUTH AUSTRALIA Smithfield safe and innovative
9-10 November staff to VICTORIA
Mackay 2-4 November 21-25 June
work environm
PMS BTM
BTM ML1 VA1
FMC 18 FRI 3 25 Wingfield & Maintaining Oakleigh
11 27-29 July Dunedin Archerfield PT Selecting
18 QUEENSLAND 8-12 November
THU 4 4-6 May level
ent
BTM
26 OAM 11 23-25 November 28-29 January Power Transmission WESTERN AUSTRALIA
MSR
19 PMS
SAT 4 Moronbah TASMANIA Archerfield
12 23-25 February Invercargill Mt Isa 26-30 July 1 (WE290)
FRI 5 Hobart Perth
27 Mt Isa 14-16 December 23-24 June SOUTH AUSTRALIA NEW SOUTH WALES 26-30 July
20 SOUTH AUSTRALIA 16-19 February
2010 SKF Training

13 2-4 March Smithfield NEW ZEALAND

SAT 6 October 10
17
24
7-9 September CAF Compressed
Air
and
Wingfield VICTORIA
Gipssland
Whyalla
15-19 March 9-10 November Hamilton
Toowoomba Fundamentals 19-20 August QUEENSLAND
3 17-19 August Wingfield 18-22 October
SUN 31 18 VA2
25 19-21 April Energy Efficiency WESTERN AUSTRALIA 13-17 September Archerfield
NEW SOUTH WALES Oakleigh
April 18
25
4
Labour Day
OA1 (NSW, ACT & SA)
11
26 OA1 BTM ESA
Townsville
Smithfield
Kalgoorlie
23-24 February 18-20 May VICTORIA 12-13 August
SOUTH AUSTRALIA
VA3 Vibration Analysis
level 3 (WI204)
11 MON 19 VA2 BTM PME
PT 16-18 March WESTERN AUSTRALIA Oakleigh
4 BTM ESA ML1
RCF
23-25 November 9 February VICTORIA
SUN LB1 IR1 26 ANZAC Day
5
12
IR Infrared Thermography Perth 20-24 September Wingfield
19 BTM OA1 VA1
SOUTH AUSTRALIA QUEENSLAND 12-13 July
12 IR1
TUE RCF
BTM
PME PT 27 OA1 BTM
Analysis level 1
(WI230)
12-14 October WESTERN AUSTRALIA Oakleigh
20 29 Nov-3 Dec
VA2
5 Easter Monday Mt Gambier Archerfield VICTORIA
BTM BTM ML1 VA1
NEW SOUTH WALES
FMC
MON
BTM
BTM LB1 IR1 27 13 NEW ZEALAND Kalgoorlie
20 6 OA1 VA1
OA1 BTM RCF
DB
25-27 May 4 February 17-21 May Oakleigh NEW ZEALAND
13 BTM IR1 RCF OA1
WED
BTM
MAR 28 Smithfield Christchurch
6 VA1 21 VA2
Whyalla VICTORIA Perth 24-25 June Hamilton
12-16 April
IR1
23-25 March
BTM BTM ML1 FMC
BTM 28 BTM 14
TUE 21 BTM BTM PT 7 OA1 VA1 RCF 12-14 October Oakleigh 22-26 November WESTERN AUSTRALIA 15-20 November
14 BTM IR1 RCF OA1
THU 29 OA1
11 February QUEENSLAND Auckland
Handbook

7 22 VA2 FMC Wingfield September Perth of

IR1
29 BTM DB 15 BTM VA1
WESTERN AUSTRALIA Archerfield 31 August-2 PSF Pump Systems FMC Fundamentals
WED OA1 BTM BTM 8 28-30 April 21-22 April
22 PT
30 Perth 19-23 April Strategy Fundamentals
and Machine Condition
15 BTM IR1
FRI 1 16-18 August NEW ZEALAND
8 30 BTM 16
23
2 February WESTERN AUSTRALIA MSR Maintenance
Energy Efficiency NEW ZEALAND
THU 1 BTM IR1 7-9 December Review (MS230) Christchurch
23 9 Perth NEW SOUTH WALES Hamilton
OA1
16 IR1
SAT 2 TASMANIA DB Dynamic Balancing 13-17 September NEW SOUTH WALES 18-19 May
9-11 March
9 Hobart Smithfield Auckland
FRI 2 Good Friday (WE250) Smithfield Rotorua
24 10-12 August to SKF 8 February 19-20 October
17 NEW SOUTH WALES MAR Introduction 17-19 March 18-20 May
| Reliability and

10 Marlin System QUEENSLAND

SAT 3 November 21
28 VICTORIA
Albury
Smithfield
QUEENSLAND
QUEENSLAND
Archerfield Archerfield SPM Spare parts
Management Palmerston North
14 28 October and Inventory Control 27-29 July
7 29 VA3 11-13 May QUEENSLAND Archerfield 30 August-1 September 5 February
SUN 22
SRM
VICTORIA level 1 (WC230) New Plymouth
PMS
Ballarat 25 May level 1
May 23 15 VA3 Archerfield
OA1 Oil Analysis Oakleigh NEW SOUTH WALES 24-26 August
16 8 VA2 ESA VA3 BTM 20-22 April 24 August 21 October
9 MON 1 30 12 February Smithfield Christchurch
2 23 PMS BTM SRM RCF Bendigo SOUTH AUSTRALIA WESTERN AUSTRALIA (WI240)
24 16 VA3 BTM NEW SOUTH WALES WESTERN AUSTRALIA 15-16 March 21-23 September
SUN 30 17 PMS 9 VA2 RCF PT MIC
12-14 October Wingfield Perth
SRM BTM Melb Cup (VIC) Smithfield Perth QUEENSLAND Invercargill
May Day (NT) SPM 10 TUE 2 24 PMS BTM SRM
RCF
Gippsland 3 March 29 June
3 Labour Day (QLD) 25 BTM MAR RCF
17 VA3 BTM RCM 20-23 April 1 February Archerfield 20-22 October
MON 31 PMS ML1 FMC
PT PT 7-9 September VICTORIA 21 September
18 10 VA2 RCF
QUEENSLAND 2-3 September
maintenance

ML1 ESA RCF

SPM 11 BTM SRM
WED 3 BTM
PMS BTM SPM Oakleigh Oakleigh to SKF Reliability Centered AUSTRALIA
4 25 MIC Introduction Archerfield RCM SOUTH
TUE PT 26 BTM MIC RCF
18 VA3 BTM RCM 23-25 March 29 April Maintenance (MS332)
19 PMS ML1 FMC 11 VA2
21-23 June Microlog 14-17 September Wingfield
ML1 RCM RCF
12 BTM SRM
THU 4 BTM
26 SPM WESTERN AUSTRALIA NEW SOUTH WALES SOUTH AUSTRALIA QUEENSLAND 13-14 May
16-18 November
PMS
5 27 BTM 19 RCM
WED
VA3 Perth Smithfield Archerfield VICTORIA
BTM ESA SPM
20 PMS ML1 FMC 12 VA2
WESTERN AUSTRALIA 21 July
Wingfield
17-19 November
ML1 RCM
13 FRI 5 ESA
27 Albany 24 August 26-29 October Oakleigh
6 WESTERN AUSTRALIA
28 20 25-26 November
THU 21 13 14-16 September ESA Easylaser Shaft QUEENSLAND VICTORIA
WESTERN AUSTRALIA
PMS
SPM
Archerfield Perth
14 SAT 6 Bunbury Alignment Oakleigh
7 RCM
26 May 27-30 July 5-7 May Perth
FRI 29 21-23 April NEW SOUTH WALES
training from

22 3-4 May
15 Geraldton Smithfield
8
SAT 1 December 12
19
26 20-22 July 9 June
1 December
5 27 Christmas Day
SUN 20
June 27 13
on
For further information courses:
20 6
13 28 Boxing Day
Engineering
The Power of Knowledge
6 MON 21
26 14 BTM

future
Public, On site or
SUN 21 PMS BTM 7 BTM
Queens Birthday 29
SKF

14 TUE
E rs.marketing@skf.com
7 Foundation Day (WA) 22
MON
VA1 29 MAR 15 BTM

P 03 9269 0763
22 PMS BTM 8 BTM RCF
BTM PME RCF VA3 BTM ESA 30
15 WED 1
BTM
8 BTM 23
30 16 BTM

.au/training
BTM ML1 VA1
TUE 1 23 PMS BTM
CR
9 BTM RCF

W www.skf.com
BTM PME RCF BTM VA3 BTM 31
9 BTM ESA
16 THU 2 24
WED 2 BTM ML1
PMS PT
VA1 CR 17
24 BTM 10
17 BTM
FRI 3 VA3
25
BTM ML1
10 BTM 18
THU 3 25 PMS PT 11
18 SAT 4
11
FRI 4 26 The Power
12
19
of Knowledge
SAT 5
Engineering

For further information contact SKF Reliability Systems on 03 9269 0763 or email rs.marketing@skf.com