NEWS | FEATURES | PRODUCTS | CASE STUDIES April/May 2023 | Issue 474 www.pwemag.co.uk @PWEmagazine1 The power of CMMS Inside this issue: 36 > Ceramic vs hybrid bearings 38 > Decarbonising petrochemical refining 42 > Where the IoT meets sustainability page 16 @plant-&-works-engineering PWE Plant & Works Engineering Since 1981
Home of the UK Maintenance Community This event is dedicated to the maintenance, reliability and asset management industry 7-8 June 2023 | NEC Birmingham INCORPORATING Secure your pass here: www.mandeweek.co.uk/ register-now Find out more at www.maintec.com @mandeweek2023 PART OF
Investment in future technologies is crucial. However, we also need to focus on and use the technologies of today to begin the journey of decarbonisation. The beginning of the decarbonisation journey The Government’s recent energy security statement has rightly put investment in the technologies of the future that are necessary to secure energy supply and keep the UK’s transition to net zero on track. However, although the statement has been welcomed from many within industry, including Make UK, there are warnings that the focus on carbon capture and storage, port infrastructure for floating offshored wind and advanced modular nuclear technology Editor’s Comment ‘ ’ are just a part of a complex puzzle. Yes, it is right that these technologies have been put front and centre and this will be welcomed by manufacturing, but as Verity Davidge, Director of Policy at Make UK said when commenting on the statement, we need to maximise use of the technologies we have today to help industry itself decarbonise and which revolve, for the majority of businesses, around energy efficiency. Her comments rightly highlight the importance of keeping our domestic manufacturing capability afloat in all areas, including the many smaller players in the supply chain, there remains a huge risk that if we do not support manufacturers to overcome the current cost of energy crisis their hands will be tied behind their backs when it comes to investing in the future. I also strongly agree with her view that industry needs a stable policy environment that is long-term and coherent across the board if we are to truly meet our net zero ambitions. Investment in future technologies is crucial. However, we also need to focus on and use the technologies of today to begin the journey of decarbonisation. April/May 2023 www.pwemag.co.uk Plant & Works Engineering | 03
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April/May 2023 www.pwemag.co.uk Plant & Works Engineering | 05 Editor: Aaron Blutstein t| 01732 370340 e| firstname.lastname@example.org Content Sub Editor: Leslah Garland t| 01732 370340 e| email@example.com Sales Director: Damien Oxlee t| 01732 370342 e| firstname.lastname@example.org Sales Manager: Andrew Jell t| 01732 370347 e| email@example.com DFA Direct: Ian Atkinson t| 01732 370340 e| firstname.lastname@example.org Production Manager & Designer: Chris Davis e| email@example.com Marketing Executive: Hope Jepson e| firstname.lastname@example.org Operations Manager: Emma Floyd t| 01732 370340 e| email@example.com Reader/Circulation Enquiries: Perception t| +44 (0) 1825 701520 e| firstname.lastname@example.org Financial: Finance Department e| email@example.com Managing Director: Ryan Fuller e| firstname.lastname@example.org Chief Executive Officer: Ian Atkinson e| email@example.com Published by: DFA Media Group 192 The High Street, Tonbridge, Kent TN9 1BE t| 01732 370340 e| firstname.lastname@example.org w| www.pwemag.co.uk Official Supporters: Printer: Warners, UK © Copyright 2023, DFA Manufacturing Media Ltd ISSN 0262-0227 PWE is a controlled circulation magazine, published 11 times a year. Please contact DFA Media with any subscription enquiries. Paid subscriptions are also available on an annual basis at £100.00 (UK) or £170.00 (Overseas) P+P included. The content of this magazine, website and newsletters do not necessarily express the views of the Editor or publishers. The publishers accept no legal responsibility for loss arising from information in this publication. All rights reserved. No part of this publication may be produced or stored in a retrieval system without the written consent of the publishers. COMMENT 3 NEWS 6 A round-up of what’s happening in industry. INSIGHT 12 MAINTENANCE MATTERS - INCORPORATING PROBLEM SOLVER 16 Focus on: CMMS/ Plant & Asset Management/ Preventative Maintenance/ Remote Maintenance Monitoring Donal Bourke, Sales Director, PEMAC explains how CMMS software can support preventive maintenance strategies within manufacturing organisations. MAINTEC 2023 PREVIEW 26 PROCESS, CONTROLS, & PLANT 30 Focus on: Compressed Air/ Seals, Bearings & Lubrication The British Compressed Air Society (BCAS) has launched a new compressed air installation best practice guide (BPG 101). PWE reports. ENERGY & ENVIRONMENTAL MANAGEMENT 38 Focus on: Boilers, Burners, & Controls/ Net Zero Petrochemical processes have traditionally been heated with fossil fuels, but pressure is building to mitigate carbon dioxide emissions and advance long-term decarbonisation goals. HANDLING & SAFETY MATTERS 46 Focus on: Health & Safety As well as dealing with increasing scrutiny regarding their impact on the environment, the nature of the Oil & Gas sector means that employee welfare is something that must be at the forefront of an organisations’ thoughts. SPECIAL FOCUS HIRE EQUIPMENT 48 PRODUCTS & SERVICES DIRECTORY 50 Contents 12 48 26 38 BCAS official media partner
News 6 | Plant & Works Engineering www.pwemag.co.uk April/May 2023 Talking Industry LIVE in partnership with the Manufacturing Technology Centre (MTC) has finalised its speaker and seminar programme, which is set to feature some of industry’s most renown and upcoming figures to offer visitors a unique professional learning experience. The event which takes place at the MTC, Coventry on April 25, 2023, will provide an environment for delegates to learn about cutting edge technologies and best practice through unscripted panel discussions, presentations, live demos, and workshops. Limited to 400 delegates, this unique oneday event will be broken in to five distinctive elements allowing visitors to tailor their own experience learning new skills, meet new suppliers and gain knowledge whilst networking with peers. The inaugural Talking Industry LIVE keynote address will set the tone for the event with an interactive, engaging and informal podcast style discussion by Mike Hague-Morgan, Executive Director of Autocraft Solutions Group, and Dr Megan Ronayne, Head of Industrial Technologies & Manufacturing at Innovate UK KTN. Together they will explore how one of Europe’s leading OEM partners for the manufacture, remanufacture and assembly of IC engines and EV batteries transitioned from being a very traditional manufacturer using hand tools and a paper system, to a hightechnology company with world-class quality, repeatability and digital traceability which has been the catalyst for such rapid growth from £7m to £70m turnover. Following this highly unique keynote, the day’s proceedings will feature three 45minute interactive panel discussion spread throughout the day. Audience participation will be encouraged, and questions will be taken throughout the discussions. Topics include, Robotics and Automation, Increasing Overall Equipment Effectiveness (OEE) and Digital Manufacturing, Industrial Data and Artificial Intelligence. The first panel discussion will look at Robotics and Automation and how these technologies will form a critical part of the future of UK Manufacturing. Panelists Mike Wilson, Chief Engineer, Automation, High Value Manufacturing (HVM) Catapult and Chief Automation Officer, Manufacturing Technology Centre (MTC); David Dearden, Managing Director, Euchner UK; and Alan Sheppard, Managing Director, LCA Group, will discuss how key challenges such as labour shortages, and supply chains weaknesses could be addressed, in part, by faster adoption of robotics and automation, and how can we accelerate this adoption and develop a competitive UK manufacturing sector. Increasing OEE through Digital Manufacturing will be the focus of the second panel discussion where Sam Kirby, Industrial IT Specialist, Novotek, Steve Cartwright, Chief Engineer for Technology – Digital Engineering, MTC, Duncan Stanton, Lamonde Managing Director, Lamonde Automation, and Luke Walsh, Managing Director, Brainboxes, will look at how OEE can be easily improved through straightforward measures. The panel will also look at hidden downtime, that mounts up and causes cycle times to drift, and how to interpret and visualise existing data and unlock new data. The final panel discussion will focus on Industrial Data and Artificial intelligence. Eric Topham, CEO & Data Science Director, TDab, Mostafizur Rahman, Technical Specialist, AI & Data Science Informatics, MTC, and Stuart McLeod, Technology Manager, Digital Engineering, MTC will discuss why AI and machine learning offer opportunities for increasing business performance, agility, and growth, focusing on what is the current state of artificial intelligence in manufacturing, the challenges and barriers to adoption? What opportunities are offered for manufacturing, to the national net-zero goal? Running alongside the three panel discussions throughout the day will be a series of six 45-minute exciting and highly topical seminars including presentations on Why condition monitoring? Why not? Vincent Burson - IFM; Mobile Robotics: Mobile, flexible & resilient - The factory of the future, Mike Payne - KUKA; Additive Manufacturing: Automated 3D Printing, Luke Rogers - AI Build; Collaborative Automation: Solving the UK Productivity Puzzle, Barry Graham - OMRON; Prepare for the Future Today, Nikesh Mistery - GAMBICA; and What is Made Smarter? The benefits of adopting digital technology within your business, Jim Vithanage - Made Smarter. In addition, there will be two in-depth workshops provided by the event’s content partners. Euchner UK’s session will be on managing equipment safety and cyber security in the modern factory. The second is provided by Rittal/Eplan and will cover smarter panel building. Workshop places are limited to 40 per session so pre-registration is advised. Full details of each of the panel discussions, seminars, and workshops are available by visiting the official Talking Industry LIVE website at: www.talkingindustry.org/talking-industry-live There will also be the opportunity for delegates to see ground-breaking products and innovations from KUKA, Werma, Motor Technology, Novotek, Euchner, Rittal, Eplan, Weidmuller, Omron, BCAS, Charter Controls, Made Smarter and many more, thanks to a micro exhibition that is running during the event. There are only 400 spaces available for the event. To register your interest in attending, visit the event’s Eventbrite page at: https://www.eventbrite.co.uk/e/talkingindustry-live-tickets-474610170797?aff=SJPR Leading manufacturing and engineering figures set to appear at Talking Industry LIVE
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News 08 | Plant & Works Engineering www.pwemag.co.uk April/May 2023 Our country is at a crossroads. We have a proud legacy of being an industrial nation, the first country to industrialise, the country who invented many of the technologies we use every day to live in an advanced 21st century economy. We are now in grave danger of being left behind in the global race to decarbonise and transform to a more sustainable future. It is clear that there is now a global race to transform. Huge new industries are emerging in the race to net zero from electric transportation to a green hydrogen-based economy and the UK is being left behind. The government has shown courage and foresight in the past. We have created one of the largest wind generation programmes in the world through this foresight however this momentum is stalling, and we need to reset our vision for the future. The core problem in the UK is the lack of an industrial strategy. The current government has relied heavily on the free market creating supply chains and that is exactly what is happening. Passing legislation to create a massive market for electric vehicles is one thing but without a comprehensive industrial strategy progress on battery production which represents 50% of the cost of these vehicles or the UK automotive supply chain moving from making internal combustion engines to parts for electric vehicles has been painfully slow. The result is that many manufacturers are now sourcing batteries from European gigafactories. The free market does work. As the US and EU governments race to create massive financial programmes to attract investment in these new sustainable industries these markets will attract the investment, skills and technology required and the UK will lose out. The UK cannot compete with such huge financial packages however we do have a key advantage, our innovation in technology is world leading. What we need to do is to recognise that the world is not a free market it is skewed by initiatives such as the inflation reduction act but we can and must compete with this by setting out a comprehensive industrial strategy which clearly lays out our priorities and supports these with policy, regulation, education and incentives for investors to be confident in the long term, converting our key advantage in innovation to products services and jobs. Of course, the problem here is that it must be longer term than our political system currently accepts. The government needs to act now to ensure we are not left making the horse drawn carriages of the 21st century. By MAKE UK chief executive, Stephen Phipson MAKE uk - the manufacturers’ organisation monthly news comment Leading engineering and apprentice training centre Oxfordshire Advanced Skills (OAS) has hosted double Paralympic Champion Emma Wiggs, to launch the new Emma Wiggs Challenge aimed at using design engineering to improve life for people with disabilities. Emma Wiggs MBE is a 10-time world champion para-canoeist and double Paralympic champion, having won gold medals at the Rio and Tokyo Paralympics. Since a mystery virus impaired mobility in her legs at age 18, Emma has dedicated herself to sport, inspiring people as she shows what is possible with determination and a positive mindset. Having previously tasked OAS’s training provider, the Manufacturing Technology Centre, to design a bespoke canoe paddle which helped her achieve gold at the 2020 Tokyo Olympics, Emma Wiggs has presented a fresh challenge to OAS apprentices. The Emma Wiggs Challenge is an exclusive competition, designed by OAS in partnership with Emma, and tasks first year engineering apprentices at OAS to find solutions through design and manufacture for challenges that people with disabilities might face in everyday life. It could be something wheelchair-based or relate to an everyday task which someone with a disability might find more challenging. Apprentices are forming small teams to work on their design concepts, with Emma hosting virtual workshops over the course of the challenge, enabling each team to ask questions and refine their design concepts. Teams will present their concepts and ideas to Emma and a panel of judges in June, as they near the end of the first year of their apprenticeship with OAS. The winners will spend a day with Emma Wiggs at the National Water Sports Centre in Nottingham where they will get a behind-the-scenes tour of the facility and try some water-based activities as part of their prize. Emma Wiggs said: “I’m so proud to be supporting apprentices at this crucial early stage of their career. I’ve always thrived on inspiring people to be the best version of themselves that they can be, and through this challenge I hope to help inspire the apprentices at OAS to create new design concepts to help people with disabilities in their everyday lives.” After the launch event, Emma Johnstone, operations manager at OAS, commented: “It was great to have Emma Wiggs here to meet the apprentices, share her experiences and help inspire them to achieve their maximum potential as well as look at how their new engineering skills could support others, in this case, putting a focus on the real challenges people with disabilities face in their daily lives. We want OAS to be as inclusive and accessible as possible for all our future apprentices. “I can’t wait to see the ideas and designs that the apprentices come up with and look forward to welcoming Emma back in the summer to help us pick a winning team.” OAS apprentices take on the Emma Wiggs challenge
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News 10 | Plant & Works Engineering www.pwemag.co.uk April/May 2023 ABB has launched its new film series: Unstoppable. This series aims to promote diversity and profile three remarkable female leaders in the mining, pulp and paper, and metals industries. Unstoppable highlights the inspiring stories of three women who have broken down barriers and made significant contributions to their respective industries. Through this series, ABB aims to raise awareness of the importance of diversity and inclusion; and encourage more women to pursue careers in STEM fields. The first film in the series features Marjorie Boles, Chief Information Officer at Sappi, a visionary in the pulp and paper industry who has transformed her company with her passion for digitalisation. The second film profiles Tove Thelin Täckdal, Concentrating Plant Manager at Copperstone Resources, a trailblazer in the mining industry who has dedicated her career to promoting sustainability and innovation in the sector. The final film highlights Chithra Sharma, Chief Commercial, Engineering and Projects for Capital Procurement at Tata Steel, a pioneering leader in the metals industry who has pushed boundaries and challenged the status quo to drive growth and competitiveness. By shining a spotlight on strong female role models in industries where the greatest disparities exist, ABB aims to influence others to come forward and play a part in Unstoppable. The directors of the series hope to make a positive difference and bridge known gender gaps. According to the World Economic Forum, women make up only 22 percent of the global mining and metals workforce, underscoring the urgency to foster diversity and inclusion in this and many other traditionally male-dominated sectors. “We’re not doing well enough to ensure diversity in our industries and know there are many dynamic career paths open to women,” said Joanne Woo, Global Head of Communications, Process Industries, ABB. “This is why we’re proud to launch the Unstoppable film series, which showcases the incredible achievements of women in industry.” “The adage holds true: if you can see it, you can be it. Raising the visibility of women in industry is vital in breaking down gender stereotypes and showcasing role models. Through our series we aim to ignite a spark that will encourage others to join the movement towards a more diverse and inclusive workplace.” “At ABB, we believe that diversity is a key driver of innovation and progress, and we are committed to promoting equal opportunities for all,” said Joachim Braun, President of Process Industries, ABB. “Our target is to double the representation of women in senior management positions at ABB by 2030.” “Leadership must take responsibility for driving change in diversity and inclusion. It is not only a moral imperative but a business necessity. Leaders must actively work to hire, advance and support women in the workplace, and create a culture that empowers them to succeed.” “I am honoured to be part of the Unstoppable film series and to share my story. It is my hope that through this series, we can inspire and empower more women to pursue careers in the mining industry and drive sustainable innovation. I believe that diversity is key to unlocking the potential of any industry, and I am proud to be part of a company that values and promotes inclusion,” said Tove Thelin Täckdal, Concentrating Plant Manager at Copperstone Resources. For more information on the Unstoppable film series, visit: https://campaign.abb.com/unstoppable. Film series to underline the lives of women in industry and advocate for diversity The Manufacturing Technology Centre (MTC) is hosting a free two-day conference – Robotics and Automation – A New Perspective 2023 on 10-11 May which will explore the future of automation in UK industry and demonstrate the opportunities available to UK industry. The adoption of robotics and automation in UK manufacturing result in higher productivity, efficiency and quality as well as more sustainable operations, according to experts at the Manufacturing Technology Centre. Delegates from a wide range of industries from construction to agriculture and food production will get the chance to share insights into the transformational benefits of cutting edge robotic technologies and learn how automation can improve productivity and drive global competitiveness for UK businesses. Topics to be covered by the conference include examining barriers to adoption and how to meet the challenges presented by automation. Other sessions will look at the solutions that automation presents to meet industry’s sustainability goals, and the opportunities for robotics in education and skills development. The conference will also look at recent advances in collaborative and mobile robotics, computer vision, artificial intelligence and sensing, together with the decreasing costs of robotics and automation hardware which can create new opportunities for the deployment of novel applications. The event, which builds on a successful conference in 2022, will build on the recommendations of a report by MTC robotics experts and the Industrial Policy Research Centre at Loughborough University. The report called for more knowledge-sharing across the robotics community, the need for support for developers and early stage adopters, an emphasis on skills, as well as a greater understanding among the investor and finance community of the business benefits of automation. Mike Wilson, chief automation officer at the MTC and author of the report, said: “This isn’t just a typical manufacturing conference. It’s an opportunity to meet, discuss and address the challenges with the adoption of automation and robotics. Delegates can listen to inspiring talks by industry experts, join educational workshops, discover innovative technologies or simply network with likeminded individuals. “The event aims to instil confidence in our companies to transform their future. It will enable SMEs and supply chain companies to explore ground-breaking and innovative industrial robotic solutions so they can understand how their manufacturing operations would benefit. The conference will bring together high-level speakers from industry, government and academia to emphasise the transformational benefits of automation, as well as the skills and system integration solutions needed to enable adoption. The MTC is offering sponsorship packages to industrial manufacturers, robotics manufacturers and system integrators who want to showcase their products and services to a high-powered audience of manufacturing leaders and decision makers. Details of sponsorship packages are available from: firstname.lastname@example.org. MTC to showcase automation and robotics capabilities
Innovation, insight and future inspiration Celebrating the advancements in manufacturing & engineering excellence and innovation 7-8 June 2023 | NEC Birmingham INCORPORATING There has never been a more important time for our sector to pull together and to work together, to create a shared agenda and Manufacturing and Engineering Week will do exactly that. I am delighted to be part of the Advisory Board and that MAKE UK are a partner of this groundbreaking event.” Stephen Phipson CBE, Chief Executive, MAKE UK and M&E Advisory Council Chairman Register your interest here: www.mandeweek.co.uk/ register-interest Find out more at www.mandeweek.co.uk @mandeweek2023
12 | Plant & Works Engineering www.pwemag.co.uk April/May 2023 Insight – Talking Industry Review According to a poll conducted amongst the audience during the event, which asked, “do the green shoots emerging on the foliage outside the studio match those of IIoT in UK manufacturing?”, the answer is: yes and no. Only 10% judge themselves to be at an advanced level, while the remaining 90% were approximately equally divided amongst “Not sure where to start”, “At the start”, and “Midway on the journey”. On the panel on this occasion were: Jean-Paul Verheylewegen, Global Sales Manager, MB Connect Line (the IT security company acquired by Red Lion Controls in 2022) Chris Barlow, Sales & Marketing Director, Novotek Alejandra Matamoros, Technology Manager, Manufacturing Technology Centre Luke Walsh, Managing Director, Brainboxes Digitalisation is a journey, so to start with, keep it simple, start small, then scale up. We look at the how to get people and technology on the right road. Leading off, Jean-Paul highlighted the maxim of starting with small pilot projects, whilst having an holistic vision in mind Talking Industry: IIOT, digitalisation & Industrial Communications - smart steps to an AI future? Talking Industry Digitalisation and the Industrial Internet of Things (IIoT) represents the next level of industrial automation. Consultant editor at DFA and chair Andy Pye summarises some of the discussions from the recent Talking Industry episode.
Insight – Talking Industry Review April/May 2023 www.pwemag.co.uk Plant & Works Engineering | 13 of the overall benefits of digitalising the whole enterprise. Not so much “start small”, but “start smart” as he put it, a concept which all the panelists agreed. Jean-Paul explained that there are two parts to an IIoT project: the first part is collecting data in the field from a variety of IoT devices, scale it, process it and then push it to a higher system, as an MES. The second part is generating value out of that data and distributing it. Two different sets of skills are required: people with an IT knowledge may have difficulties with data acquisition from the field, people with a more OT profile may have difficulties with cloud systems, value creation or distribution, because the tools that are used there require more specific IT competencies. The theme continued with Chris, who focused on how to manage the data flow issues, all the way from acquisition to usage and thence to storage. Like Jean-Paul, he acknowledged the importance of getting people on board the journey, citing potential conflicts for budgets and even personnel themselves. He explained the differences by comparing a SCADA system, used for real-time visualisation and the control of a manufacturing system, with an MES, which is about bridging business systems and control systems, and managing people and processes and all of the data involved in transforming raw materials into finished goods. Luke interjected that before you can choose between a holistic approach or a piecemeal approach to digitlisation, you need to convert the workforce from being (possibly) Digital Sceptics towards being Digital Champions - in his view, you cannot do this overnight, but in a slow measured approach. Alejandra spoke at our Talking Industry Live programme in 2022 at the Drives and Controls Exhibition in 2022. She remains not only the first person hailing from Venezuela to take part, but also the first from the continent of South America. With the exception of Antarctica, we now have featured at least one person from every continent. Here, she discussed the differences between the traditional hierarchical ways of integrating production systems and the IIoT methods. What are the potential and challenges of networked production systems? She said that at the MTC, the emphasis is to take the that holistic view, to discover and understand that long term vision. That doesn’t come with only bringing the seniors to that meeting, but involving all key stakeholders from those processes. Then, and only then, you can start delivering the project in smaller chunks. So start small, but to plan for that with a proper technology roadmap that takes you through the whole transformation journey. Unusually, we concluded the formal part of the discussion with a demonstration, in this case of the Brainbox smart energy monitoring system, which utilises IIoT connectivity to efficiently capture, aggregate and analyse plant-wide energy data. This is a great example of a small step which delivers an immediate return to the bottom line. Luke cited an example where one company discovered that they had been operating on their backup compressed air system for months without even knowing! With current energy prices, it is no surprise that the machine elicited great interest from several attendees in the chat. We could not let our panelists go without asking them about the future of AI in manufacturing, as part of the digitalisation process. Luke jumped in to say that in his view digitalisation must come first. “AI has gone from being peddled as snake oil to actually having a legitimate place within the environment of manufacturing. And its legitimacy is only just starting to kind of show itself to us. AI depends on digital data and can manipulate digital things exceptionally well.” Chris added that predictive maintenance is an area which benefit greatly from elements of machine learning. There may be other areas to find that will probably be going to be where the greatest proliferation will occur, at least in the beginning. Alejandra expressed reservations about the safety and ethical aspects associated with using artificial intelligence algorithms. “We need still to evolve warranty policies that will actually define the concerns and the boundaries of how far AI can actually be taken,” she suggested. Jean-Paul concluded that AI works on data and (as a comment in the chat pointed out) regardless of the potential capabilities of AI in the future, companies need to digitally transform first. As was shown in the poll, we are still in the process of digitising industry. The methodology is still being built. He sees AI as a new tool that will evolve to be helpful in interpreting data. There are many ways to catch up if you missed it: Talking Industry episodes are available on demand, and as Podcasts at: https://talkingindustry.org/
The inaugural Talking Industry LIVE keynote address will be an interactive, engaging and informal podcast style discussion by Mike Hague-Morgan, Executive Director of Autocraft Solutions Group, and Dr Megan Ronayne, Head of Industrial Technologies & Manufacturing at Innovate UK KTN. Robotics and automated systems will form a critical part of the future UK manufacturing economy. As the ninth largest manufacturing economy in the world, the UK languishes as the 27th largest adopter of robotics. Brexit and COVID-19 have exposed weaknesses in our supply chains. Industry is facing the tightest labour market we have seen in modern times. These challenges could be addressed, in part, by faster adoption of robotics and automation. How can we accelerate this adoption and develop a competitive UK manufacturing sector? OEE (Overall Equipment Effectiveness) is the gold standard for measuring manufacturing productivity. Simply put, it identifies the percentage of manufacturing time that is truly productive. But worryingly, most UK manufacturers are running below a score of 60% and almost half are scoring under 40%.Everyone is busy, and the problem with being too busy is a complacency towards everyday issues. Focus becomes directed only to visible issues causing downtime to plant and machinery. But what about hidden downtime, that mounts up and causes cycle times to drift? Artificial intelligence and machine learning offer opportunities for increasing business performance, agility, and growth. Business leaders are determining how these techniques can integrate successfully with human intelligence and what they will deliver as they evolve. Despite this, there are questions regarding the ease of implementation, adoption, operation, and trust associated with these types of technologies. What is the current state of artificial intelligence in manufacturing, the challenges and barriers to adoption? What opportunities are offered for manufacturing, to the national net-zero goal?
Completely FREE to attend event including parking, breakfast, refreshments and a two-course luncheon Breakfast from - 8.30 Lunch from - 12.30 Nikesh Mistry- Sector Head of Industrial Automation Vincent Burson - Condition Monitoring Sales & Support Specialist Michael Payne - Logistics Sector Manager Luke Rogers - Commercial Director Jim Vithanage - Digital Transformation Specialist Dave Roddis - Senior Advisor Digital Transformation Charlotte Horobin - Region Director Midlands & East of England Stuart Coulton - Marketing Manager Although the number of machinery-led workplace accidents has fallen over the past few years many experts are expecting this figure to rise as advanced technology is introduced onto the factory floor. With some of the most advanced machinerysafety technology available - Euchner is in a great place to explain the emerging trends in safety-related control standards and what this means for your business. Additionally, each of the workshop sessions will include a Q&A discussion with practical contributions from industry leading experts in the field of industrial cyber-security and machinery safety integration. This informative and interactive legislation-led plant-safety & cyber security focused workshop gives everyday advice and promises to be insightful for those organisations starting their journey or already well on their way. Skills shortages are apparent at all levels, however, after listening to our customers this is particularly an issue in highly skilled areas such as panel design, manufacturing and wiring. With this in mind, companies are turning to technology to help them work smarter and close the skills gap within industry. Join engineers from EPLAN and Rittal for the ‘Smarter Working’ workshop to discover new solutions and applications to make your electrical design, component mounting, and wiring easier and faster! The purpose of the workshop is to highlight how the continuity of data from a single source of truth streamlines panel building. Data can seamlessly flow from electrical engineering design, through to panel modification and wire fabrication, and finally to the technicians constructing and wiring the panel using digital applications.
16 | Plant & Works Engineering www.pwemag.co.uk April/May 2023 Maintenance Matters Focus on: CMMS Preventive maintenance is a critical aspect of any manufacturing organisation. By keeping equipment and machinery in top condition, organisations can avoid costly breakdowns, increase productivity, and reduce downtime. Preventive maintenance is a strategy designed to extend the life of an asset by identifying potential issues before they become major problems. This involves conducting regular inspections, performing routine maintenance, and making repairs, as necessary. In addition to reducing downtime and increasing productivity, a well-executed preventive maintenance program can also contribute to the safety of the workplace. When equipment is not properly maintained, it can create hazardous conditions for employees, resulting in accidents and injuries. Preventive maintenance ensures that equipment is regularly inspected and maintained, minimising the risk of workplace accidents, and keeping employees safe. Implementing a preventive maintenance program can also improve the overall efficiency of the manufacturing process. When machines are functioning optimally, production can run smoothly and at a faster pace. This can lead to increased output and profitability for the organisation. One of the most effective ways to implement a preventive maintenance program is by using computerised maintenance management system (CMMS) software. Implementing a Preventive maintenance programme with the help of CMMS software can provide numerous benefits to manufacturing organisations, ranging The power of CMMS from increased safety to improved efficiency and profitability. In this article, we will discuss how CMMS software supports manufacturing organisations with their Preventive maintenance strategies. What is CMMS Software? CMMS software is a computerised system that assists maintenance teams in managing and tracking maintenance activities, equipment inventory, and work orders. It provides an easyto-use interface for maintenance personnel to track equipment history, schedule maintenance tasks, and create work orders. Additionally, it can integrate with other business systems, such as Enterprise Resource Planning (ERP) and manufacturing execution systems (MES), to ensure a seamless flow of information across the organisation. How CMMS software supports preventive maintenance strategies Equipment Maintenance Tracking: Real-time tracking of equipment maintenance history is critical for effective Preventive maintenance strategies. CMMS software allows maintenance teams to track equipment usage, monitor maintenance task frequency, and identify failure patterns. By analysing this information, maintenance teams can determine the optimal time for preventive maintenance tasks and avoid unexpected equipment breakdowns. Work order management: CMMS software streamlines the work order management process by automating creating, scheduling, and tracking of work orders. It allows maintenance teams to schedule and assign tasks to the appropriate personnel. Additionally, it provides real-time visibility of work orders, allowing teams to prioritise tasks and allocate resources effectively. Asset management: CMMS software provides a centralised location to manage all assets, including equipment, inventory, and spare parts. It allows maintenance teams to track the usage of equipment and identify the need for replacement or repair. Additionally, it provides real-time visibility of inventory levels, ensuring that spare parts are available when needed, reducing downtime, and increasing productivity. Predictive maintenance: By analysing equipment data, such as vibration and temperature readings CMMS software can provide predictive maintenance capabilities. The software can detect early warning signs of equipment failure and generate alerts, allowing maintenance teams to take proactive measures to prevent equipment breakdowns. Reporting and analytics: CMMS software provides advanced reporting and analytics capabilities that enable maintenance teams to identify trends and make informed decisions. It allows teams to track KPIs, such as equipment downtime, maintenance costs, and asset utilisation, and generate reports that provide actionable insights. By implementing an effective preventive maintenance program using a CMMS, organisations can extend the life of their assets, reducing the need for deferred capital replacement. Benefits of CMMS software for preventive maintenance CMMS software can also provide several advantages and benefits for manufacturing organisations looking to improve their preventive maintenance strategies. The following are some of the key benefits which can be realised by organisations when using CMMS software in conjunction with their preventive maintenance strategies: Increased equipment availability: Real-time visibility of equipment maintenance history, allowing maintenance teams to schedule preventive maintenance tasks at the optimal time. This ensures that equipment is available when needed, reducing downtime and increasing productivity. Reduced maintenance costs: CMMS software enables maintenance teams to track Donal Bourke, Sales Director, PEMAC explains how CMMS software can support preventive maintenance strategies within manufacturing organisations.
Focus on: CMMS Maintenance Matters equipment usage and identify the need for replacement or repair. This ensures that maintenance tasks are performed only when necessary, reducing maintenance costs and increasing the lifespan of the equipment. Improved safety: Real-time tracking of equipment maintenance history, enabling maintenance teams to identify potential safety hazards. By addressing these hazards proactively, organisations can reduce the risk of accidents and improve workplace safety. Improved communication and collaboration: Communication and collaboration can be improved between maintenance teams and other departments within the organisation. By integrating with other business systems, such as ERP and MES, CMMS software can provide a single source of truth for equipment maintenance and work orders. This can help to reduce miscommunications and ensure that all stakeholders have access to up-to-date information. Streamline processes and real-time visibility: The procurement process for spare parts and equipment can be streamlined by CMMS software. By providing real-time visibility of inventory levels and usage, maintenance teams can make informed decisions about when to order replacement parts and equipment. This can help to reduce lead times and ensure that spare parts are available when needed, reducing downtime, and improving productivity. Accuracy and completeness of records supporting enhanced regulatory compliance: CMMS software enables organisations to track equipment maintenance history, ensuring compliance with regulatory requirements. It can help to improve the accuracy and completeness of equipment maintenance records. By automating the tracking of maintenance tasks and equipment usage, maintenance teams can ensure that all maintenance activities are recorded accurately and consistently. This can help to provide a comprehensive audit trail of equipment maintenance history, which can be useful for regulatory compliance, warranty claims and insurance purposes. It allows organisations to generate reports that provide evidence of compliance, reducing the risk of regulatory fines and penalties. Conclusion Preventive maintenance is critical for any manufacturing organisation to avoid costly breakdowns, increase productivity, and reduce downtime. In today’s highly competitive manufacturing landscape, implementing a successful preventive maintenance program is more crucial than ever. By leveraging the capabilities of CMMS software, organisations can gain a competitive advantage by increasing their equipment uptime and reliability, minimising the risk of equipment failure while reducing maintenance costs improving safety and enhancing compliance. Overall, CMMS software provides a powerful tool for manufacturing organisations looking to improve their preventive maintenance strategies. CMMS software provides a comprehensive solution for managing and tracking preventive maintenance tasks, enabling organisations to implement an effective preventive maintenance programme. With these benefits in mind, it’s clear that preventive maintenance is not just a “nice to have” for manufacturing organisations - it’s a must-have. By investing in CMMS software and implementing a robust preventive maintenance programme, manufacturing organisations can position themselves for long-term success and growth. Visit our stand A48 at Maintec and get a personal demo. meetings.hubspot.com/tom-reames email@example.com +44 7493 328466 www.maintmaster.com WANT TO BECOME A MAINTMASTER? The most flexible CMMS Graphical Navigation QR Scanning Maintenance Standard IoT Sensors Integrated Quick Fixed Deployment
LEFT: From the initial stoppage of the pump to recommissioning, the whole project was completed in nine and a half weeks 18 | Plant & Works Engineering www.pwemag.co.uk April/May 2023 Maintenance Matters Focus on: Plant & Asset Management At a time when national electrical grids are under extreme pressure, unexpected outages can prove to be a considerable challenge. When a power plant in Germany experienced the sudden failure of a boiler feed pump, output dropped by more than 40%, which affected both the local grid and company profits. Needing to resolve this situation urgently, Sulzer was called in to repair the asset and conduct an investigation to secure the reliability of the power station. Rapid boiler feed pump repair ensures power generation reliability station was covered by other sites, the profit loss ran into multi-millions of Euros for every week the pump was out for repair. Considering the current demand for energy across Europe, time was most certainly of the essence. “The first task was to explain to the plant management how the project would be delivered and the timeframe involved”, explains Claudia Calies, Service Centre Manager for Sulzer. “Clearly, the pump was required back in service in the shortest time possible and we have to manage this expectation and provide an accurate timeline for the work to be completed.” Double shifts From the first field service personnel on site to the last commissioning engineer leaving, Sulzer’s global network of technicians, engineers, designers, logistics specialists and project managers combined their OEM knowledge and service expertise to resolve this issue. Due to the highwater pressures involved, the pipe connections to the pump are welded, requiring a specialist to disconnect the 10-tonne pump. Once this was complete, the pump was removed and transported to Sulzer’s service centre in Jänschwalde to enable the necessary repairs to be completed. The initial investigation found that the balance piston and sleeve were welded together, and this would require the shaft to be cut off and drilled out to separate the parts. The piston was replaced while a boring machine was used to bore out the sleeve to its original dimensions and complete the repair. The Jänschwalde service centre staff worked two shifts per day to minimise the time required to get the pump back up and running. Spare parts The plant operator had a stock of spare parts, including a new pump rotor, which had been ordered at the time of the pump’s installation. Considering the age of the rotor, it was sent to Sulzer to be inspected and to confirm its suitability for installation after 10 years in storage. The repaired balance piston was then fitted together with the spare rotor, which had passed its Thermal power plants rely on boiler feed pumps to supply large volumes of pressurised water to create the steam that drives the turbines. Keeping these vital assets in good order requires personnel to follow detailed operating procedures and planned maintenance programmes. Following on from the failure of the first pump in this particular power station, the worry of a second pump suffering from the same problem and ensuring overall reliability meant root cause analysis was as important as getting the facility back to full capacity. Fast repairs The power plant in question has two boiler feed pumps that have been in service for approximately 10 years without any issue. However, recently, the operator noticed a problem with the mechanical seals and called in Sulzer. The company responded immediately with specialist field service personnel on site the next day. Further investigation revealed that the pump was seized because of not following the correct start-up and maintenance procedures. While the boiler feed pump was out of action, productivity from the plant was significantly reduced. Although the lost output from the power
RIGHT: The pump was removed and transported to Sulzer’s service centre in Jänschwalde to enable the necessary repairs to be completed Focus on: Plant & Asset Management Maintenance Matters April/May 2023 www.pwemag.co.uk Plant & Works Engineering | 19 The project in numbers: 10-tonne pump Up to 12 personnel involved Time to complete repair: 9.5 weeks Profit lost during downtime: Multi-million euro per week during the project. Although the operator had initially suspected that the pump might be at fault, it was concluded that the incorrect start-up procedure was responsible. The additional training and the checks that were carried out on the second pump have ensured that the scenario will not be repeated and that both pumps will continue to deliver reliable service. Claudia concluded: “We regularly support the plant with annual shutdowns and communication between us is open and transparent, which is essential for a rewarding relationship.” Following the successful completion of the project, the original rotor will be refurbished by Sulzer with a new balance piston being fitted along with refurbished impellers. This will enable the power plant to restock the spare part in case it should be needed in the future. For more informa琀on call 0121 601 6691 scan code for the training guide or email: firstname.lastname@example.org Can You Join the Elite? Do you have a strong knowledge of pumps, their di昀erences, uses and a good understanding of Pump Systems. This is an NOCN Level 4 course with a comple琀on 琀me of 90 hours. Essentials of Pumping Technology inspection. All the additional spare parts required for the repair were also on-hand having been ordered for urgent delivery. “Due to the important role of the pump, the power plant needed to have extensive documentation completed detailing all of the work carried out. This included independent checks and x-ray inspection of the new welds when the pump was reinstalled. The complex details involved in the repair of key pieces of equipment go far beyond the physical repair work, but Sulzer’s experience in maintaining all rotating equipment means that every aspect is covered in a turnkey project.” The root cause With the power plant running two of these pumps, the operator was very keen to identify the root cause of the initial problem to enable any additional preventative measures to be taken. During the inspection, there was evidence that a steam bubble was present in the area around the balance piston, indicating a lack of cooling and lubrication, which led to a massive rise in temperature. Some information that was missing during the initial investigation was that the plant suffered an unexpected shutdown two or three days before the pump failure took place. Once the reason for the shut-down was resolved, the pump was restarted, however, during this process a procedural issue was determined as the root cause of the subsequent pump failure, confirming the operational reliability of the pump. As a result, having reinstated the pump and recommissioned it, Sulzer offered additional training for the plant personnel to try and prevent any reoccurrence in the future. Stopping pump failure In total, from the initial stoppage of the pump to recommissioning, the whole project was completed in nine and a half weeks. In contrast, the alternative would have been to order a new pump, but typically such a highly engineered asset would have considerably longer lead time. Once the pump was reinstalled and operational, a review meeting was held to assess the performance of Sulzer’s team and the results achieved