8:00 - 17:00 / Full day Reliability Workshop
Full day Reliability Workshop
Tom Carr, CMRP, CRL, CMRT, Director of Growth Strategies
Maintenance and Reliability Instructor, Reliability Solutions
Achieving Reliable Manufacturing Through Precision Maintenance
During a recent conversation, a high-level manager asked; “Why is it that with all the investments in technology that we’ve made, we still have the same types of failures in the same or nearly same cycles?” How is it that we fail to recognize the value of further asset improvements to gain reliability, production enhancement, manufacturing cost and energy conservation with correct application of on-the-floor skill sets? We need to consider how “mechanical” failures can be much more than just mechanical craft issues and how these failures also include electrical, instrumentation, production, engineering, purchasing and other groups. This overview and introduction session takes a brief glimpse into how we as maintenance and reliability professionals continue to concentrate on reducing failures with an emphasis on real and measureable asset improvement.
This one day session will clearly build an awareness to include “improvement and precision based” activities with historical “failure based” efforts. The session features live dynamic machine sets that plainly demonstrate how to move to and achieve “best-in-class” running performance utilizing precision techniques in the elimination of failure sources. An important focus of the session is the introduction of successful implementation processes to quickly advance facility reliability efforts with hard and measurable results. Attendees will receive a field checklist to record observations at their facilities. Completed and returned observation sheets will receive a review of complied data “pareto” results. Finally, attendees will realize the need to place high importance on improving on- the-floor skill sets to further reduce costs, improve reliability, and positively impact business competitiveness in achieving “Reliable Manufacturing”.
This workshop is aimed towards participants with responsibilities for reliability improvement. Everyone from senior managers, superintendents, engineers to craft technicians is encouraged to attend and increase their understanding for machinery assembly and installation essentials. The workshop is a full day in duration.
Introduction to Reliable Manufacturing Maintenance Philosophies How and why machines fail The “Practical” Application of Precision The Mechanical Failure Pie
Determining Asset Health Vibration Terminology Overview of Asset Health Tools In Class Measurement of Machinery
Beginning Improvement Understanding Pipe Strain Rough Alignment Understanding Bearings Correct Fits and Tolerances
Assembly Errors Common Assembly Errors Proper Keys, Positioning, Setscrew Position Torque, pulled threads Rolling Resistance
Understanding Precision Alignment Soft Foot; Short, Angular, False, Resonant Understanding Alignment Tolerances Offset and Angularity; where do they affect Benefits of graphing; understanding relative shaft position
Unbalance What is it … what is it not? Effects of minor assembly errors Balance Tolerances The Need for Field Trim
Belt Drive Systems Effects of minor assembly errors System assembly errors and field checks Rough Alignment; the effects of scissoring Calibrated force deflection
Thermal Growth Introduction The effects of pinning, jack-bolts and radiant heat A simple three-part formula to correctly calculate
Final Subjects for Consideration General Implementation Strategies Roles, Responsibilities and Expectations Typical Work Flow Example Risk/Best-In-Class Observations
After a 27 year career in the pulp and paper industry, Tom joined Reliability Solutions in 2011 to return to his passion for building people. During his career in pulp and paper, Tom worked as a craftsman, a maintenance instructor, a training coordinator, a reliability specialist and a maintenance supervisor. The different roles prepared Tom well to serve as a mentor and instructor for technicians and leadership teams in manufacturing that desire a step change in reliable manufacturing®. Tom’s experience leads him to understand the different roles and responsibilities associated with this step change.
Expertise & Client Contributions
• Mentoring and instructing corporate and site leadership teams, maintenance leaders, technicians and engineers on all aspects of Reliable Manufacturing®
• Serving as a consultant and advisor for client leadership teams regarding the implementation of the process, principles and techniques of Precision Maintenance®
• Developing and improving Precision Maintenance® course content and manuals
• Building individual skills and confidence of maintenance teams as viewed in classrooms, acknowledged on class evaluations and confirmed through post training communication
• Helping clients achieve profitable results through excellence in Reliable Manufacturing® that he has witnessed in numerous industries and corporations
Credentials & Professional Development
• Certified Maintenance and Reliability Professional (CMRP)
• Certified Maintenance and Reliability Technician (CMRT)
• Certified Reliability Leader (CRL)
• Wallace State Community College, honor graduate – 2 year maintenance program
• John Patterson Technical College, honor graduate – Certified Industrial Maintenance Technician
• Extensive leadership training over 15 years in various manufacturing leadership roles